Linkbelt Operator's Manual 240X2-MH Hydraulic Excavator - PDF DOWNLOAD

Model 240X2-MH

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 PERSONAL INJURY OR DEATH. Safety Decals on this machine use the words Danger, Warning or Caution, which are defined as follows: • DANGER: Indicates an immediate hazardous situation which, if not avoided, will result in death or serious injury. The color associated with Danger is RED. • WARNING: Indicates a potentially hazardous situation which, if not avoided, will result in 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.

WARNING IMPROPER OPERATION OF THIS MACHINE CAN CAUSE INJURY OR DEATH. 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 instructions on machine operation and maintenance.

E2480

To the Owner Your machine has been designed and built to the highest standards of quality. It conforms to all current safety regulations. However, the risk of accidents can never be completely excluded. That is why it is essential to observe elementary safety rules and precautions. Hazard control and accident prevention are dependent upon the awareness, concern and prudence of the operator. Personnel involved in the operation, transport, maintenance and storage of equipment must be suitably trained.

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.

Use this manual as a guide. Your machine will remain a reliable working tool provided it is kept in good working condition and serviced properly.

The standard attachments and equipment available for use with this machine are intended for general earthmoving purposes, material rehandling, ditch cleaning, etc. If the machine is to be used for handling loads, (concrete pipe sections, shoring material, etc.), make sure the machine is suitably equipped for this type of work.

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 authorized LBX Link-Belt distributor 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 LBX Link-Belt distributor.

Before permitting a new operator on this machine, make sure: 1. That the operator has received the necessary training on how to operate the machine correctly and safely or from an approved organization.

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

Always keep this manual in the operator’s compartment (in the seat back, behind the operator’s seat). Make sure it is always complete and in good condition. If you wish to obtain additional manuals, or manuals in another language, consult your authorized LBX Link-Belt distributor.

Your authorized LBX Link-Belt distributor is at your disposal for any further information. He will also provide any after-sales service you may require, and genuine authorized LBX Link-Belt parts, and service, your guarantee of quality and performance.

0-1

E0010

Safety Labels RIGHT, LEFT, FRONT AND REAR OF THE MACHINE The terms “Right”, “Left”, “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.

The illustration 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 upperstructure.

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1 FRONT 2 REAR 3 RIGHT-HAND SIDE

0-0001E

4 LEFT-HAND SIDE 5 TRAVEL REDUCTION GEARS 6 IDLER WHEELS

Break-in This product is shipped after full inspections and conditioning, however, extremely overloaded usage at the initial stage could lead the reduction in performance and life. Therefore, approx. initial 100 hours (indicated hours on the service meter) break-in is neccessary.

Break-in should be conducted paying attention to the following points: • Try to keep idling and warming for 5 minutes after starting the engine.

• Avoid operation under heavy load or at high speeds.

• Avoid any sudden start, acceleration or unnecessary sudden stop and quick turn.

Specified Work This product is designed to use mainly in the following work: • Excavation • Land granding work • Trenching work • Loading work • Demolition (Demolition specification vehicle only)

E0020

0-2

For Safe Driving IMPORTANT: Remove the protective (rust preventative) aluminum cover wrapped around the cylinder rods immediately after receiving the machine. If the machine is left with the covers on, water can collect on the inside of the cover, which will be the cause for rust to develop on the cylinder rod.

In the case of transportation by sea, sea water salt adheres to the machine making rust easier to develop. Immediately follow the measures below after receiving a machine that has been transported by sea. If the measures are not taken, the machine will develop rust easily.

1. Confirm that there are no salt deposits on the machine exterior. When salt deposits are suspected, wash the entire machine with water.

3. If Storage Is To Be Continued [Storage procedures for rust prevention.]

1 Grease up each part of the attachment.

CAUTION Do not use high pressure cleaning water directly on the alternator, battery and other electrical parts or wiring.

0-0003E

Storage for up to one month (1) Once a week operate each motion (attachment, swing, travel) with no load which performs rust prevention operation.

1 Put the engine in low~medium rpm and perform the warming up operation.

0-0002E

2 Slowly operate each cylinder of the front attachment five strokes each.

2. Performing Rust Prevention Operation.

Storage for more than one month

CAUTION

(1) Place each cylinder in the most retracted position and apply anti-rust oil to the exposed cylinder rod.

Start the engine after you understand the operation methods.

1 Set the engine at low~medium rpm and go through the warming up operation.

2 Slowly operate each cylinder of the front attachment five strokes each.

0-0004E

(2) Perform rust-prevention operation once a month.

1 Before performing the rust-prevention operation, remove the anti-rust oil (wipe off with kerosene, etc.).

2 After finishing the rust prevention operation, fully retract each cylinder and apply anti-rust oil to the exposed cylinder rod.

0-3

E0040

For Safe Driving Safety Rules

IMPORTANT

Most accidents involving machine operation and maintenance can be avoided by following basic rules and precautions. Read and understand all the safety massage in this manual, the Safety Manual, and the safety decals on the machine before you operate or service the machine. See your Authorized LBX Link-Belt dealer if you have questions.

The safety messages in this section point out situations which can happen during the normal operation and maintenance of your machine.

These safety messages also give possible ways of dealing with these conditions.

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 personal injury or death.

Pocket

0-0005

Safety messages in this section point out situations which can be encountered during the normal operation and maintenance of your machine. These safety messages also give possible ways of dealing with these conditions.

Additional safety messages appear in the manual to indicate specific safety hazards.

READ THIS MANUAL COMPLETELY and make sure you understand the characteristics of speed, stability, steering, and operation of this machine.

Do not remove this manual or the safety manual from this machine. See your LBX Link-Belt dealer for additional manuals. Also see the inside of the rear cover of this manual for detailed information for ordering manuals.

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

E0050

0-4

For Safe Driving Warranty In case faults occur to the machine, the warranty is valid within the range described in the warranty document.

Model and Serial number of manufacture When ordering parts, obtaining information or assistance, always supply your LBX distributor with the type and serial number of your machine or accessories.

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

Machine

TM

LBX COMPANY LLC LEXINGTON, KENTUCKY, U.S.A. Model No. Serial No. Manufacturer No.

/#&' +0 ,#2#0 $;

0#)#07/#*#4#%*1 +0#)' -7 %*+$# ,#2#0

0-0006E

KHP11160-00

0-0007E

Excavator Identification ___________________________________________________________________ Model Number _________________________________________________________________________ Serial Number __________________________________________________________________________

Engine Make and type _________________________________________________________________________ Serial number __________________________________________________________________________

Component serial numbers Hydrauric pump _________________________________________________________________________ Swing reduction gear ____________________________________________________________________ Travel reduction gears ___________________________________________________________________ Travel control valve ______________________________________________________________________ Attachment control valve __________________________________________________________________ Swing control valve ______________________________________________________________________

0-5

E2450

Table of Contents To the Owner ..................................................... 0-1 Safety Labels ..................................................... 0-2 For Safe Driving ................................................. 0-3

Regarding machines shipped as the machine intended for commonly use both in the magnet and the other end-attachment ....................................................2-8

Emergency Lowering Device ............................. 2-9 Inspection of emergency lowering device before starting operation ........................................................2-9 Emergency lowering device KHP14510.................2-10 Points to notice when operating emergency lowering device.................................................................2-11 In case where operation of the emergency lowering device is in trouble .................................................2-12

Safety Section .....................................0-7 Precaution Identification Plates (DECALS)........ 0-8 Identification Plates inside the Cabin ...................... 0-8 Outside Identification Plate ................................... 0-13 Precaution Identification Plates on Parts (Examples) .......................................................................... 0-18

Prior to Operation............................................. 0-19 Confirmation of Safety items............................ 0-21 During Operation.............................................. 0-24 While Traveling ................................................ 0-27 After Operating................................................. 0-29 While Transporting........................................... 0-30 Before Regular Inspection & Maintenance ...... 0-31 Inspection and Maintenance ............................ 0-32

Starting and Stopping the Engine .................... 2-13 Inspections before Starting the Engine ..................2-13 Starting the Engine ................................................2-14 Inspections after Starting the Engine .....................2-15 Stopping the Engine (Normal Operation) ...............2-16

Warm-up Operation.......................................... 2-17 Warm-up Operation ...............................................2-17

Operations (Traveling) ..................................... 2-19 Operations (Swing) .......................................... 2-26

Instruments and Controls ..................1-0

Swing Operation ....................................................2-26

Location of Components .................................... 1-1

Operations (Attachment) .................................. 2-27 Operations........................................................ 2-28

Overall View ............................................................ 1-1 Operator’s Cab........................................................ 1-2 Seat and Console.................................................... 1-3 Right Panel.............................................................. 1-4 Console right side front ........................................... 1-4

Characteristics of Hydraulic Excavator ..................2-28 Cautions for operations..........................................2-28 Cautions for Interference .......................................2-29

Special Attachment .......................................... 2-30 Operating Instructions (Cautions) .................... 2-31 Operating Instructions (Procedures) ................ 2-33 Operation of magnet ........................................ 2-35

Explanation of device......................................... 1-5 Console right side front ........................................... 1-5 Right Console.......................................................... 1-6 Right Control lever .................................................. 1-8 Left Console ............................................................ 1-9 Left Control lever................................................... 1-10 Right Panel............................................................ 1-12 Control Levers....................................................... 1-19 Operator’s Seat ..................................................... 1-22 Operator’s Cab...................................................... 1-23 Radio..................................................................... 1-28 Air Conditioner ...................................................... 1-30 Fuses .................................................................... 1-37 Battery................................................................... 1-38 Starting the Engine by Using Booster Cables ....... 1-39

Operation of magnet ..............................................2-35 Operation control ...................................................2-36

Monitor operation in detail................................ 2-39 Monitor operation in detail......................................2-39 On engine speed in magnet mode.........................2-43

Bucket: Turning Over and Replacement .......... 2-44 Bucket: Turning Over and Replacement ................2-44

On Completion of Daily Operations.................. 2-46 On Completion of Daily Operations .......................2-46

Operating in Cold Climates .............................. 2-48 Operating under Extreme Conditions............... 2-49 Transportation .................................................. 2-50

Anti-theft Protection ......................................... 1-41

Loading and Unloading ..........................................2-50 Switch settings during loading and unloading ........2-50 Transportation........................................................2-50

Anti-theft Protection............................................... 1-41 Using the Anti-theft Protection Function................ 1-42

Storing.............................................................. 2-55

Operating Instructions........................2-0 Operation of New Machine ................................ 2-1

Inspections and Maintenance............ 3-0

Using a New Machine ............................................. 2-1

General Cautions ............................................... 3-1 Periodic Maintenance Check List....................... 3-3

Daily Inspections................................................ 2-2 Daily Inspections ..................................................... 2-2

Daily Inspections (Prior to Operation) ......................3-3 Periodic Maintenance Check List.............................3-4 Fuel / Lubricants for Different Ambient Temperature Settings ................................................................3-5 Genuine LBX Company LLC Parts and Elements ...3-6 Disposable Items .....................................................3-7

Interference prevention system.......................... 2-4 Function of interference prevention system ............ 2-4 Inspection of interference prevention system before starting operation ................................................ 2-5 Instructions of anti-interference device KHP14520 . 2-6 Precautions in handling interference prevention system ................................................................................ 2-7

Grease / Oil and Elements ................................. 3-8 Inspection Prior to Operation ............................. 3-9 Inspections Prior to Operation .................................3-9

0-6-1

Table of Contents Greasing Attachments...................................... 3-13

Inspecting Upper/Lower Take-up Roller (Idler Wheel) .......................................................................... 3-50 Inspection and Tightening of Shoe Plate............... 3-50 Cleaning Crawler................................................... 3-50 Inspection and Adjustment of Track Shoe Tension .......................................................................... 3-51

Greasing Front Attachment Pins ........................... 3-13

Greasing Elevator Cab..................................... 3-15 Greasing Elevator Cab .......................................... 3-15

Fuel System ..................................................... 3-16 Fuel........................................................................ 3-16 Fuel Refilling and Fuel Level Checking ................. 3-19 Drainage of Water and Sediments in the Fuel Tank ........................................................................... 3-19 Draining Water from the Pre Fuel Filter................. 3-20 Pre Fuel Filter Replacement.................................. 3-21 Draining Water from the Fuel Filter (Main) ............ 3-22 Fuel Filter (Main) Replacement ............................. 3-22

Magnet ............................................................. 3-52 Adjustment of Magnet Backlash............................ 3-52

Air Conditioner.................................................. 3-53 Inspection and Care of Air Conditioner ................. 3-53

Routine Replacement Safety Parts .................. 3-57 Troubleshooting................................................ 3-58 Contacting Us................................................... 3-63

Engine .............................................................. 3-24

Specifications......................................4-0

Engine Oil Replacement........................................ 3-24 Engine Oil Filter Replacement............................... 3-24 Cooling System ..................................................... 3-26 Inspecting and Refilling Coolant ............................ 3-26 Replacing the Coolant ........................................... 3-27 Cleaning and Inspecting the Radiator Net and Fin ........................................................................... 3-28 Cleaning and Replacing the Air Cleaner (double elements)................................................................ 3-29 Inspection and Adjustment of Fan Belt.................. 3-31

CONVERSION FACTORS ................................. 4-1 CONVERSION FACTORS ...................................... 4-1

Specifications ..................................................... 4-2

Optional Components.........................5-0 Selector Valve .................................................... 5-1 Selector valve (2-way)............................................. 5-1

Bolt Torque....................................................... 3-32 Bolt and Nut Torque .............................................. 3-32

Hydraulic Oil..................................................... 3-36 Hydraulic Oil Level Inspection ............................... 3-36 Refilling Hydraulic Oil ............................................ 3-36 Draining Water and Sediment from the Hydraulic Oil Tank................................................................... 3-37 Hydraulic Oil Management .................................... 3-38 Hydraulic Oil Replacement .................................... 3-38 Bleeding Air from the Hydraulic Components........ 3-39 Air Bleeding Procedures........................................ 3-39 Air Bleeding from Hydraulic Pump......................... 3-39 Air Bleeding from Cylinder..................................... 3-40 Air Bleeding from Swing Motor .............................. 3-40 Cleaning and Replacing Suction Filter .................. 3-41 Replacing Return Filter.......................................... 3-41 Replacing Air Breather Element ............................ 3-42 Replacing Pilot Oil Filter Element .......................... 3-42 Checking Hoses and Lines.................................... 3-43

Battery.............................................................. 3-44 Battery Inspection and Charge .............................. 3-44

Inspection of accessories................................. 3-46 Inspection of accessories ...................................... 3-46

Upper Frame .................................................... 3-47 Turntable Bearing Greasing .................................. 3-47 Greasing Swing Ring Gear.................................... 3-47

Swing Unit ........................................................ 3-48 Oil Level Inspection and Refilling of Swing Reduction Gear................................................................... 3-48 Oil Replacement for Swing Reduction Gear.......... 3-48

Travel Unit........................................................ 3-49 Travel Reduction Gear .......................................... 3-49 Oil Level Inspection and Refilling of Travel Reduction Gear................................................................... 3-49 Oil Replacement for Travel Reduction Gear.......... 3-49

0-6-2

Safety Section SAFETY

WARNING

You must read this safety section carefully.

This section contains important safety information.

The symbols on precaution film labels are attached to machines in order to prevent personal injury. Before starting operations, read carefully the indications on film labels with symbols.

It is a very difficult task to cover and handle all possible dangers in this manual. For this reason, the descriptions on precaution film labels do not always cover everything. Try to understand fully this manual and drive and operate properly, paying special attention to prevent damage to the machine or personal injury.

Contents of the manual • Precaution Identification Plates (DECALS) • Prior to Operation • Confirmation of Safety items • During Operation • While Traveling • After Operating • While Transporting • Before Regular Inspection & Maintenance • Inspection and Maintenance

0-7

E0080

Safety

Precaution Identification Plates (DECALS)

Always keep the precaution ID label clear and readable.

When the plate gets dirty: Clean the plate with water or washing agent. Don’t use any gasoline or organic solvent.

If a precaution identification plate is extremely dirty and the dirt is difficult to remove, replace it with a new one.

Before changing it, make sure it is the same type.

In case Precaution Identification Plates are lost or damaged: Ask for a new precaution identification plate at the nearest approved sales shop.

Before changing it, make sure it is the same type.

Identification Plates inside the Cabin

3 2

1

5 6 4

7

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-*2

'/'4)'0%; .19'4+0) &'8+%'

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LM-0021E

0-8

Safety

Precaution Identification Plates (DECALS)

1WARNING Label KHP12142 A

D

C

E

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%10641. (70%6+105 10 6*+5 /#%*+0' #4' +06'4%*#0)#$.'㧚 10.; #0 #76*14+<'& &'#.'4 4'24'5'06#6+8' +5 #..19'& 61 /1&+(; 6*' %10641. 2#66'40㧚 9*'0 # /1&+(+%#6+10 *#5 $''0 /#&' 6*' 4'24'5'06#6+8' /756 %*#0)' 6*' &'%#. 61 /#6%* 6*' 0'9 %10641. 2#66'40㧚 (#+.74' 61 %*#0)' 6*' &'%#. %17.& 4'57.6 +0 &'#6* 14 5'4+175 +0,74; -*2

B

0-0009E

A Raise gatelock lever

B Exchange of control function

Raise lever completely to shut off controls before leaving the cab to avoid accidental control engagement and possible injury.

%10641. (70%6+105 10 6*+5 /#%*+0' #4' +06'4%*#0)#$.'㧚 10.; #0 #76*14+<'& &'#.'4 4'24'5'06#6+8' +5 #..19'& 61 /1&+(; 6*' %10641. 2#66'40㧚 9*'0 # /1&+(+%#6+10 *#5 $''0 /#&' 6*' 4'24'5'06#6+8' /756 %*#0)' 6*' &'%#. 61 /#6%* 6*' 0'9 %10641. 2#66'40㧚 (#+.74' 61 %*#0)' 6*' &'%#. %17.& 4'57.6 +0 &'#6* 14 5'4+175 +0,74;

4#+5' .'8'4 %1/2.'6'.; 61 5*76 1(( %10641.5 $'(14' .'#8+0) 6*' %#$ 61 #81+& #%%+&'06#. %10641.

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0-0046E

0-0010E

0-9

E0100

Safety

Precaution Identification Plates (DECALS)

C Electric shocks

D Read manual before driving and maintemance

If you let the machine go too close to electric wires, you could get an electric shock.

Keep a safe distance and away from electric wires.

Guidelines for Safe Distances.

Voltage

Safe Distance

6,600 V or less 22,000 V or less 66,000 V or less 154,000 V or less 187,000 V or less 275,000 V or less 500,000 V or less

6.6 ft (2 m) or more 9.8 ft (3 m) or more 13.1 ft (4 m) or more 16.4 ft (5 m) or more 19.7 ft (6 m) or more 23.0 ft (7 m) or more 36.1 ft (11 m) or more

This is very important. You must read this carefully.

You must read the manual before driving, maintaining, disassembling/assembling or transporting your machne.

0-0013E

E Attachment interferece with cab The bucket teeth may hit the cab, depending on the type of attachment.

Exercise care when operating a bucket near the cab.

0-0012E

0-0014E

E0110

0-10

Safety

Precaution Identification Plates (DECALS)

2Emergency exit KHP 11600

5Instruction of anti-interference device KHP14520

In an emergency, pull the pull-ring on the rear window to allow the window to be detached so that you can escape through the opening rear window out of the machine.

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KHP11600-00

㧞㧚㧭㧾㧹‫ޓ‬㧻㧼㧱㧾㧭㨀㧱

㧟㧚㧱㧸㧱㨂㧭㨀㧻㧾‫ޓ‬㧻㧼㧱㧾㧭㨀㧱

㧞㧚㨀㧱㧹㧼㧻㧾㧭㧾㨅‫ޓ‬㧯㧭㧺㧯㧱㧸‫ޓ‬㧭㧺㧰‫ޓ‬㧱㧹㧱㧾㧳㧱㧺㧯㨅‫ޓ‬㧯㧭㧺㧯㧱㧸‫ޓ‬㧻㧲‫ޓ‬㧭㧺㨀㧵㧙㧵㧺㨀㧱㧾㧲㧱㧾㧱㧺㧯㧱‫ޓ‬㧰㧱㨂㧵㧯㧱 㧨㨀㧱㧹㧼㧻㧾㧭㧾㨅‫ޓ‬㧯㧭㧺㧯㧱㧸㧪 ‫ޓ‬㧶㧻㨅㧿㨀㧵㧯㧷‫ޓ‬㧯㧻㧺㨀㧾㧻㧸‫ޓ‬㨃㧵㧸㧸‫ޓ‬㧮㧱‫ޓ‬㧭㧮㧸㧱‫ޓ‬㨀㧻‫ޓ‬㧻㧼㧱㧾㧭㨀㧱‫ޓ‬㨃㧴㧵㧸㧱‫ޓ‬㧿㨃㧵㨀㧯㧴‫ޓ‬㧻㧺‫ޓ‬㧸㧱㧲㨀‫ޓ‬㧿㧵㧰㧱 ‫ޓ‬㧶㧻㨅㧿㨀㧵㧯㧷‫ޓ‬㧵㧿‫ޓ‬㧼㨁㧿㧴㧱㧰‫ޓ‬㧱㨂㧱㧺‫ޓ‬㧭㧺㨀㧵㧙㧵㧺㨀㧱㧾㧲㧱㧾㧱㧺㧯㧱‫ޓ‬㧰㧱㨂㧵㧯㧱‫ޓ‬㧵㧿‫ޓ‬㧭㧯㨀㧵㨂㧭㨀㧱㧰㧚 ‫ޓ‬㧭㨀㨀㧭㧯㧴㧹㧱㧺㨀‫ޓ‬㧹㧭㨅‫ޓ‬㧴㧵㨀‫ޓ‬㧯㧭㧮‫ޓ‬㨃㧴㧵㧸㧱‫ޓ‬㧭㧺㨀㧵㧙㧵㧺㨀㧱㧾㧲㧱㧾㧱㧺㧯㧱‫ޓ‬㧰㧱㨂㧵㧯㧱‫ޓ‬㧵㧿 ‫ޓ‬㨀㧱㧹㧼㧻㧾㧭㧸㧸㨅‫ޓ‬㧯㧭㧺㧯㧱㧸㧱㧰㧚

0-0011

㧻㧼㧱㧾㧭㨀㧱‫ޓ‬㨃㧴㧵㧸㧱‫ޓ‬㧿㨃㧵㨀㧯㧴 㧔㧾㧵㧳㧴㨀‫ޓ‬㧿㧵㧰㧱‫ޓ‬㧶㧻㨅㧿㨀㧵㧯㧷㧕

㧨㧱㧹㧱㧾㧳㧱㧺㧯㨅‫ޓ‬㧯㧭㧺㧯㧱㧸㧪 ‫ޓ‬㧿㨀㧻㧼‫ޓ‬㧻㧼㧱㧾㧭㨀㧵㧻㧺‫ޓ‬㧭㧺㧰‫ޓ‬㧯㧻㧺㨀㧭㧯㨀‫ޓ‬㧻㨁㧾‫ޓ‬㧸㧻㧯㧭㧸‫ޓ‬㧰㧱㧭㧸㧱㧾‫ޓ‬㧵㧹㧹㧱㧰㧵㧭㨀㧱㧸㨅㧘‫ޓ‬㧵㧲 ‫ޓ‬㨃㧭㧾㧺㧵㧺㧳‫ޓ‬㧮㨁㨆㨆㧱㧾‫ޓ‬㧰㧻㧱㧿‫ޓ‬㧺㧻㨀‫ޓ‬㧿㨀㧻㧼‫ޓ‬㧻㧾‫ޓ‬㧻㧼㧱㧾㧭㨀㧵㧻㧺‫ޓ‬㧹㧭㧸㧲㨁㧺㧯㨀㧵㧻㧺㧿㧚㧭㧯㨀㧵㨂㧭㨀㧱 ‫ޓ‬㧱㧹㧱㧾㧳㧱㧺㧯㨅‫ޓ‬㧯㧭㧺㧯㧱㧸‫ޓ‬㧿㨃㧵㧯㨀㧴㧘‫ޓ‬㨃㧴㧱㧺‫ޓ‬㧹㧭㧯㧴㧵㧺㧱‫ޓ‬㧺㧱㧱㧰‫ޓ‬㨀㧻‫ޓ‬㧮㧱‫ޓ‬㧹㧻㨂㧱㧰‫ޓ‬㨀㧻‫ޓ‬㧿㧭㧲㧱㨀㨅 ‫ޓ‬㧯㧻㧺㧰㧵㨀㧵㧻㧺㧚 ‫ޓ‬㧭㧯㨀㧵㨂㧭㨀㧱‫ޓ‬㧱㧹㧱㧾㧳㧱㧺㧯㨅‫ޓ‬㧯㧭㧺㧯㧱㧸‫ޓ‬㧿㨃㧵㨀㧯㧴 ‫ޓ‬㧭㨀㨀㧭㧯㧴㧹㧱㧺㨀‫ޓ‬㧹㧭㨅‫ޓ‬㧴㧵㨀‫ޓ‬㧯㧭㧮㧚 㧔㧯㧻㨂㧱㧾‫ޓ‬㧵㧺㧺㧱㧾㧕

3Caution against the fall of front window KHP12170 There is a danger of an injury due to possible sliding fall of the stored front window.

Be sure to lock the front window securely at the position to be stored.

㧝㧚㨃㧭㧾㧺㧵㧺㧳‫ޓ‬㨁㧼‫ޓ‬㧹㧭㧯㧴㧵㧺㧱‫ޓ‬㧮㧱㧲㧻㧾㧱‫ޓ‬㧻㧼㧱㧾㧭㨀㧵㧻㧺㧚 㧞㧚㧰㧻‫ޓ‬㧺㧻㨀‫ޓ‬㧰㧵㧿㧭㧿㧿㧱㧹㧮㧸㧱‫ޓ‬㧿㧱㧺㧿㧻㧾㧿‫ޓ‬㧭㧺㧰‫ޓ‬㨃㧭㨀㧯㧴‫ޓ‬㧻㨁㨀‫ޓ‬㧲㧻㧾‫ޓ‬㧿㧱㧺㧿㧻㧾‫ޓ‬㧰㧭㧹㧭㧳㧱㧚 㧟㧚㧭㧺㨀㧵㧙㧵㧺㨀㧱㧾㧲㧱㧾㧱㧺㧯㧱‫ޓ‬㧰㧱㨂㧵㧯㧱‫ޓ‬㧰㧻㧱㧿‫ޓ‬㧺㧻㨀‫ޓ‬㧭㧯㨀㧵㨂㧭㨀㧱‫ޓ‬㧼㧾㧻㧼㧱㧾㧸㨅㧘 ‫ޓޓ‬㧵㧲‫ޓ‬㨁㧺㧿㧼㧱㧯㧻㧲㧵㧱㧰‫ޓ‬㧭㨀㨀㧭㧯㧴㧹㧱㧺㨀‫ޓ‬㧵㧿‫ޓ‬㧵㧺㧿㨀㧭㧸㧸㧱㧰㧚 㧠㧚㧭㨀㨀㧭㧯㧴㧹㧱㧺㨀‫ޓ‬㧹㧭㨅‫ޓ‬㧴㧵㨀‫ޓ‬㧯㧭㧮㧘‫ޓ‬㧵㧲‫ޓ‬㨀㧱㧹㧼㧻㧾㧭㧸㧸㨅‫ޓ‬㧯㧭㧺㧯㧱㧸‫ޓ‬㧿㨃㧵㧯㨀㧴 ‫ޓޓ‬㧻㧾‫ޓ‬㧱㧹㧱㧾㧳㧱㧺㧯㨅‫ޓ‬㧯㧭㧺㧯㧱㧸‫ޓ‬㧿㨃㧵㨀㧯㧴‫ޓ‬㧵㧿‫ޓ‬㧭㧯㨀㧵㨂㧭㨀㧱㧰㧚 -*2

LM-0022E

(#..+0) 9+0&19 /#; %#75' $1&+.; +0,74;㧚 #(6'4 4'/18+0) 14 4'2.#%+0) (4106 9+0&19㧘 '0574' 6*#6 #761.1%- +5 '0)#)'& #0& .1%- 9+0&19 +0 2.#%'㧚

6Caution elevator cab KHP14500

-*2

0-0015E

4For use of cigarette lighter socket

STAYING IN THE DANGER ZONE FORBIDDEN

KHP11590 The cigarette lighter located in the front-right console is of DC24V rating.

It is strictly prohibited to connect any of the equipment of 12V rating as this causes it to be damaged.

24V

KHP14500-00

LM-0023E

KHP11590-00

0-0013

0-11

Safety

Precaution Identification Plates (DECALS)

7How to deal with emergency lowering device KHP14510 Operate the switch only when the lifting device of elevator cab fails to be actuated.

Control of the switch allows the elevator cab to be lowered.

● The emergency lowering device provides function in an emergency.

If the lifting device of elevator cab is out of order, contact a service shop immediately for repair.

'/'4)'0%;

EMERGENCY LOWERING DEVICE

CONSOLE (RIGHT)

SWITCH OPERATE KHP14510-00

LM-0024E

0-12

Safety

Precaution Identification Plates (DECALS)

Outside Identification Plate

LM-0025E

0-13

Safety

Precaution Identification Plates (DECALS)

8Shoe (crawler belt) tension

0Battery explosion KHP1536

KHP1014

The wrong handling of battery causes explosion itself.

You must read the manual before maintaining battery.

Plug could pop out from the shoe (crawler belt) tension adjustment device.

When releasing the shoe, read the manual and handle shoes properly.

GREASE UNDER HEAVY SPRING PRESSURE. DISASSEMBLY WITHOUT RELEASING PRESSURE MAY RESULT IN SERIOUS INJURY OR DEATH. DO NOT DISASSEMBLE TRACK CHECK COMPENSATING SYSTEM VALVE BEFORE COMPLETELY RELEASING GREASE PRESSURE. RELEASE RETAINING GREASE PRESSURE BY BRACKET LOOSENING CHECK VALVE. DO NOT REMOVE CHECK VALVE OR RETAINING BRACKET. KHP1014-00

0-0019E

9Keep out of the range of turns KHP1532 When the machine makes a turn, you may be caught in the upper part of the turning body.

Do not attempt to enter within the range of the turns.

0-0032E

AElectric shocks KHP0210 If you let the machine go too close to electric wires, you could get an electric shock.

Keep a safe distance and away from electric wires.

Guidelines for Safe Distances.

KHP1532-00

0-0086E

Voltage

Safe Distance

6,600 V or less 22,000 V or less 66,000 V or less 154,000 V or less 187,000 V or less 275,000 V or less 500,000 V or less

6.6 ft (2 m) or more 9.8 ft (3 m) or more 13.1 ft (4 m) or more 16.4 ft (5 m) or more 19.7 ft (6 m) or more 23.0 ft (7 m) or more 36.1 ft (11 m) or more

Stay away from machine if close to power lines.

Machine, load, and ground can become electrified and deadly.

1P2240

0-0020E

0-14

Safety

Precaution Identification Plates (DECALS)

BEntanglement KHP1533

DRelieving pressure KHP1542

Entanglement in rotaing parts of the fun could cause injury.

Always stop the rotaing engine when conducting inspection and maintenance.

You can relieving the pressure from the reservoir before removing tank cap.

HOT HYDRAULIC FLUIDS MAY CAUSE SEVERE BURNS AND BODILY INJURY. BEFORE REMOVING HYDRAULIC TANK CAP, SHUT OFF ENGINE AND COMPLETELY RELEASE TANK PRESSURE BY OPENING AIR TANK DRAIN VALVE AND AIR RELIEF PLUG. SEE OPERATOR'S MANUAL FOR INSTRUCTIONS. KHP1542-00

0-0023E

EDiesel Fuel KHP11681 The location of the fuel tank.

ROTATING FAN AND BELTS CAN SEVER FINGERS AND HANDS. STAY CLEAR. KHP1533-00

0-0021E

CRelieving pressure KHP1534 You can relieving the pressure from the reservoir by removing cap.

&+'5'. (7'. 10.; 75' 10.; 6*' 4'%1//'0&'& &+'5'. (7'. )4#&' 14 '0)+0' &#/#)' /#; 1%%74 5'' 6*' 12'4#614 5 /#07#. (14 6*' 4'%1//'0&'& &+'5'. (7'. )4#&' -*2

0-0024E

FHot surfaces KHP1535 The exhaust system must never be touched while the engine is running or immediately after the engine has stopped.

HOT FLUID UNDER PRESSURE CAN CAUSE SEVERE BURNS. RELIEVE PRESSURE BEFORE REMOVING CAP. SEE OPERATOR'S MANUAL FOR INSTRUCTIONS.

HOT SURFACES CAN BURN HANDS AND FINGERS. STAY CLEAR.

KHP1535-00

0-0025E

KHP1534-00

0-0022E

0-15

Safety

Precaution Identification Plates (DECALS)

GDo not walk on Engine cover

IFall attention KHP12210

KHP1011 -''2 1(( 61 24'8'06 5'4+175 $1&+.; +0,74; -*2

0-0028E

JPart number: KHP12191 This decal shows where to attach slings when handling the excavator. Use these points and these points only.

SLIPPERY AND UNSTABLE SURFACE. DO NOT WALK ON ENGINE COVER.

KHP12191-00

KHP1011-00

0-0026E

HEngine Hood handling KHP1010

0-0229E

KDo not open high pressure fuel

FALLING ENGINE HOOD CAN CAUSE SERIOUS INJURY. ENGAGE HOOD LOCK IN OPEN POSITION.

system KHP13150

DO NOT OPEN HIGH PRESSURE FUEL SYSTEM WITH ENGINE RUNNING ENGINE

KHP1010-00

OPERATION CAUSES HIGH FUEL PRESSURE. HIGH PRESSURE FUEL SPRAY

0-0027E

CAN CAUSE SERIOUS INJURY DEATH.

0-0114E

0-16

Safety

Precaution Identification Plates (DECALS)

LCaution, elevator lock KHP13100 If it is unavoidable to enter under the elevator cab such as in case of carrying out inspection and maintenance, be sure to set the lock pin.

Otherwise, there is a risk that the elevator cab may be lowered accidentally inviting serious injury such as by being caught in.

LM-0094

MHow to deal with emergency lowering device (outside cab) KHP13460 Operate the switch only when the lifting device of elevator cab fails to be actuated.

Control of the switch allows the elevator cab to be lowered.

● The emergency lowering device provides function in an emergency.

If the lifting device of elevator cab is out of order, contact a service shop immediately for repair.

KHP13460-00 LM-002E

0-17

Safety

Precaution Identification Plates (DECALS)

Precaution Identification Plates on Parts (Examples) Battery

Accumulator Filled with high pressure gas Flame throwing-in, welding and pre-arcing are prohibited.

0-0029E

(Accumulator)

This decal is on the batteries and draws attention to the risks and precautions to be taken when handling batteries. See “Batteries” in the “Electrical System” Section.

0-0030E

Radiator Cap

DENGER. NEVER OPEN WHEN HOT CHECK & FULL COOLANT IN RESERVE TANK.

CAUTION

0

E0171

0-18

Safety

Prior to Operation

Wear proper clothing, and always keep your qualification certificates with you!

Hold a meeting to coordinate operations: Operation procedures should be full discussed. If a signal man is arranged, you should make sure who is the signalman and what kind of signals are used.

● Wearing necessary protective devices is a basic safety rule.

While driving: ● Helmets ● Safety shoes ● Properly fitted clothing Use the following items, according to operations: ● Protective goggles ● Dust mask ● Earplugs ● Protective devices

0-0033

Always perform checking prior to the start of work ● Before starting operation, conduct start of work inspections (check prior to start of operation) without fail. ● Make sure that working lamps and wipers properly operate. In addition, clean the windows, working lamps, mirrors and inside the cabin. ● If any performance problems are found, immediately repair them.

0-0031

For safety operation, do not operate the machine when you are not in a good health

Follow the start of work inspections described in the “Inspection and Maintenance” section.

An operator should not operate a machine when he or she may not be able to operate it in a normal way because of fatigue, illness, drug influence, etc.

LM-0001

0-0032

0-19

Safety

Prior to Operation

Be sure no danger is near the machine

Taking Care of Machine ● Clean the windows for good visibility. Replace if damaged.

● If there is a risk of falling stones, a head guard

● Clean dirt off the work lights to gain good lighting

device should be worn. ● Check the strength of the shoulder and ground. ● Use lighting when it is dark.

when it is dark. Check the lighting system.

● Clean the rear view mirrors and adjust their locations to gain good visibility. Replace if damaged.

Take necessary safety measures where it is in a dangerous condition.

● Clean inside the cabin, put away and organize things that are not necessary to operate the machine. ● The inside of the engine room becomes very hot.

Remove dead leaves or combustibles which may cause a fire.

Recheck and make sure ● Do you fully understand all the operations? ● Do you fully understand all the signals? ● Is it all right and safe around the work area? ● Was anything overlooked while checking the ma-

LM-0002

chine?

● Is your health condition and working wear appro-

Keep out of the work area (Keep others away from the work area)

priate?

● Make sure no people or obstacles are within the work area before starting operations.

● To keep away people from the work area, post “Keep Out” signs.

● In view of securing safe operation, secure the area of further 6.6 feet (2 m) around the machine working range of 360° as no admittance.

1 Working area 2 Safety area

LM-0003

Ԙ

ԙ 0-0036

0-20

Safety

Confirmation of Safety items

Do not let anyone ride on the machine except for the driver

Pay attention to signals and signs ● Set up signs on the locations where there is possible danger, like soft shoulders, slopes, etc.

● Do not let anyone ride on the machine except for

● Place a guide at places where danger is foresee-

the driver.

able. The driver should pay attention to signs and follow signals by a guide.

Sit on operator’s seat to drive the vehicle ● To drive the vehicle, the driver always should sit on the operator’s seat.

● Be sure to sit on the operator’s seat and fasten the seat belt to operate the machine.

LM-0006

LM-0004

Do not use machine for other uses than the specified main usage ● Hydraulic excavators are designed for use in excavation and loading.

It is very dangerous to use machine for other than main purposes such as lifting/lowering people.

Usage other than main purposes may lead to personal injury, and damage to the machine.

Never attempt any of them.

LM-0005

0-21

Safety

Confirmation of Safety items

Step and access handles

Starting and Operating the Machine ● When you start, drive and turn the machine, always push the horn switch and give signals.

Then, after checking around machine to make sure no one is near, and move the machine.

In addition, if the visibility is limited or as necessary, arrange a guide to make sure it is safe.

Ԙ

ԙ

Ԙ

Ԙ LM-0008

ԙ

Installing safety devices LM-0007

● Attached guards or covers according to the operation types.

To get on or off of the machine use the step 2 and access handles 1.

● Misuse of safety devices may cause personal injury or serious accident. ● Be familiar with the usage of gate lock levers and seat belts, and use in a proper manner. ● Never attempt to detach safety devices. In addition, always keep them in a normal operating condition.

Always maintain three point support getting on and off the machine.

Always maintain three point support while getting on and off the machine and entering or exiting the operators cab. A three point support system has been provided that enables a person to us simultaneously two hands and one foot or two feet and one hand while ascending, descending or moving about the machine.

Do not try to modify them ● Modification sometimes may cause safety problems. ● Whenever modification is necessary, contact and consult our sales shops or service shops. ● We shall not be responsible for machine’s faults and accidents which are caused by unapproved modification.

When getting in or out of the cab, it is imperative that the upper structure frame is in line with the undercarriage.

Never jump down from the machine. When leaving the machine or the upper structure, always face the machine and use the steps and access handles.

To get in or out of the cab, never use to the left-hand control lever, the left-hand control arm or the door handle.

Clean the steps and access handles and remove all traces of grease, oil, mud and (in winter) ice.

0-22

Safety

Confirmation of Safety items

Be careful of asbestos dust ● Inhalation of asbestos dust may cause lung cancer. No asbestos is used in this machine; however, be careful when handing materials which possibly contains asbestos. ● Do not clean the machine using compressed air. ● Do not use grinders when you polish parts. ● If necessary, use dust musk or other respiratory equipment.

0-0043

Installing optional parts ● When you install optional attachments and use the parts, read the manuals for the attachments.

● Installation of attachments may cause safety problems or machine faults and reduced life; always contact and consult our sales shops or service shops. ● Depending on types of attachments to be installed, the stability of machine will change. Special attention should be paid during driving and operating the machine. ● We shall not be responsible for machine’s faults and accidents which are caused by using attachments. ● Installing and uninstalling attachments should be performed on the hard level ground.

Accumulator mounted machine ● Because an accumulator is attached, the attachment can be lowered by means of its own weight by operating the control lever even for a certain time after the engine stops. ● After stopping the engine, place the starter switch to ACC or OFF position, and the gate lock lever to lock position. ● The accumulator is filled with high pressure gas.

To handle the accumulator, follow the instructions described on the attached precaution identification plate.

0-23

E0220

Safety

During Operation

Use agreed signals to perform work needed for collaboration

Electric shocks In case your machine touches an electric wire,

● If 2 or more vehicles work together at the site, decide the signalman and signs.

● Warn workers around the machine “Do not touch the excavator”.

● When escaping from the excavator, do not use the steps, just jump off the machine

LM-0009

LM-0011

Working in urban areas ● To keep people away from the work area, post

Operate the excavator on a level ground

“Keep Out” signs. If the work is performed in a heavy traffic area, a signalman should be placed to prevent accidents.

● (There is the possibility of overturn if it is operated on a slope.)

If operated on an inclined ground, start the work after a level hoot-hold has been secured.

LM-0010

Use special care around electric wires

LM-0012

● Take safety measures such as holding meetings and consulting with the electric companies, or placing signalman.

0-0046

0-24

Safety

During Operation

Engine warm-up

If you detect an abnormality in the machine, immediately stop operation

● Warm up the engine and the hydraulic oil sufficiently before starting operations.

● When you find something is wrong with the ma-

● Check that the measuring instruments are in nor-

chine during operation, immediately stop the operation, check and fix the problem. ● Do not use the machine until repairs have been finished.

mal operating condition.

LM-0013 LM-0016

Do not leave the excavator with loads being attracted such as while waiting for dump trucks

Proceed to the next operation after objects (such as iron scrap) being attracted have clearly been released

● The load being attracted may fall off because attracting capacity of a magnet is getting weak gradually as its property.

● When carrying out swinging with pieces of attracted object (such as iron scrap) remained, the object may be fallen off and scattered which is dangerous.

LM-0014

Do not allow anyone (such as a worker) to be under lifted loads being attracted and/or at a risky place

LM-0017

● Forbid anyone to enter into the working range and into the area where attracted objects can be scattered away, and also take measures that people cannot go in and come out of the work site. ● Do not allow a load being attracted to pass over the operator's seat or over worker's head.

LM-0015

0-25

Safety

During Operation

Do not lift up a weight of loads more than that specified ● If a load weighing more than that specified has been attracted, the machine becomes unstable which in turn may allow it to be overturned.

Never try it as the objects being attracted may also be fallen off.

LM-0018

Ventilation ● Engine exhaust fumes are dangerous. ● Take ventilation measures to prevent gas poisoning when starting the engine in the locations where ventilation is poor such as indoors, in tunnels, or underground.

0-0043

Make sure the ground is safe ● Be sure that the ground or passage is strong enough and there is no risk of collapsing from the machine’s weight and vibrations. ● Be careful of operating during the snow seasons since the ground is covered and not visible. ● Just after a rain fall, cliffs, grooves and road shoulders are dangerous since they tend to be softened. Keep away from them as much as possible. Landslides may occur due to the machine’s vibration or weight. ● If there are rises and falls in the ground, the machine’s operating conditions become unstable.

Try to travel the machine on flat places if possible.

0-26

Safety

While Traveling

Check your route

traveling up and down hills

● You should investigate your route in advance. ● When you have to move a machine in a location

● While traveling up and down hills, travel in parallel with the line of the maximum inclination. traveling diagonally up or down a slope is dangerous.

where your vision is limited, arrange a guide who can give signals as needed. ● And also, before crossing a bridge, pay attention to allowable weight of the bridge.

LM-0022 LM-0019

Starting an operation

Be careful when you change direction on a slope

● When running the machine, first check the direc-

● Changing direction on a slope may cause the machine to slide sideways or overturn. When changing directions is absolutely necessary, do it only on a slope with hard ground and a low incline.

tions of the travel reduction gears and operator’s cab; then, start the operation.

LM-0020 LM-0023

While traveling ● When traveling the machine, choose level

Traveling uphill and downhill (slopes)

ground as much as possible. ● Avoid obstacles, electric poles, and buildings while traveling. ● While traveling on frozen, snow covered ground, pay attention to the ground strength and slippery conditions.

● While traveling on hills, travel slowly and keep the magnet 20-30 cm above the ground level.

● When the machine becomes unstable, stop the machine by touching the magnet to the ground.

LM-0024 LM-0021

0-27

Safety

While Traveling

It is dangerous to travel with an iron scrap being stuck to the magnet ● This may allow the iron scrap stuck to be fallen by the shock of traveling. ● There may be a risk of overturn as stability of the machine will change while traveling.

LM-0025

Do not travel the machine with the elevator cab lifted up ● Vibration of elevator mechanism may increase which in turn will damage the machine.

LM-0026

0-28

Safety

After Operating

Parking

Before leaving the machine

● Park the machine on hard, level and safe

1.

2.

3.

4.

5.

6.

ground.

● Lower the magnet to the ground and stop the engine.

Lower the magnet to the ground.

Put the operating lever in neutral.

Shut off the engine.

Remove the engine key.

Raise the gate lock lever.

Lock the doors.

LM-0027 LM-0030

Parking the machine on a slope ● Lower the magnet to the ground, put the lever in

Inspection after operation

neutral, and place the braking blocks behind the crawlers (both right and left) on the downhill side. ● Engage turn locks also.

Check each part of the machine after operations (in addition to washing the machine).

● If any faults are detected, repair them immediately; do not postpone it until the following day.

● Fill the fuel tank to full after the daily operations are finished.

Especially in the following situations, perform inspection and repair procedures earlier than usual: after operations at very dusty locations in freezing or very hot weather after operations in swamps or soft ground locations.

LM-0028

Parking on roads ● When parking the machine on road, put up signals or/and fences which can be seen at night from other cars. ● Lower the magnet to the ground and lock the doors to prevent some one from operating or tampering with the machine.

LM-0031

LM-0029

0-29

Safety

While Transporting

Loading and unloading

Removing front attachments

● When you load on or unload the machine from

● When front attachments are removed, the center

trailers or trucks, use ramps.

of gravity moves significantly towards the rear.

● Do not load and unload the machine by jacking it

● Pay special attention when travel the machine.

up. ● Do not carry out loading and unloading the trailer, and transportation with the elevator cab lifted up.

There may be a risk of overturn as stability of the machine will change while traveling.

● When traveling on ramps, apply a counterweight to the side facing the upward slope.

0-0069

Towing methods

LM-0032

● When towing the machine, use wire ropes strong enough for the traction load.

● Do not use wire ropes which have kinks, twists,

Transporting the machine

or damage for towing.

● Fix the machine firmly to prevent the body from

● Do not allow anyone between the towing vehicle

moving while transporting.

and the excavator.

● Check the carrying capacity. ● If a permission provided for by the Road Traffic

● Do not tow the machine on slopes because there

Control or Road Transportation Vehicle laws is necessary, apply for and obtain it.

● Take measures to prevent damage to ropes and

is a risk of the machine sliding sideways. the excavator by placing wood protectors between the towing wire ropes and the excavator. ● Tow the machine slowly in order to lessen the impact on the machine. ● Connect the excavator and towing vehicle to form a straight line.

LM-0033

0-30

Safety

Before Regular Inspection & Maintenance

Maintenance and inspection methods

Important safety parts

● Before performing inspection and maintenance,

● Parts related to safety and fire prevention are

read the “Inspection and Maintenance Section” thoroughly.

specifically referred to as “Important Safety Parts”. Replace these parts regularly. ● “Important Safety Parts” include parts which are difficult to determine the part life by their exterior appearance. Replace these parts regularly even if there are no apparent abnormalities. ● If any abnormality is found before the replacement interval, change and repair the part.

Maintenance/ Inspection Section

0-0038E

Inspect and maintain the machine on level ground 1.

2.

3.

4.

Choose a safe place with level and hard ground.

Lower the magnet to the ground, Stop engine and remove key.

Apply brakes to the shoes.

LM-0034

Display a sign “Inspection Under Way” ● Hang a plate indicating “Inspection/Maintenance Under Way” on the door or operating lever.

LM-0035

0-31

Safety

Inspection and Maintenance

Do not attempt to maintain moving parts

Opening hoods and covers ● Do not open the engine hood while the engine is running.

● Avoiding adjustments during driving if possible. ● Repair or adjustments are inevitable, two or

● Engage hood locks whenever you open the en-

more technicians should work jointly. ● Pay special attention and avoid entanglement of clothing in rotating parts.

● Do not open the engine hood when the wind is

gine hood or covers. strong.

Locked!

OK!

LM-0026E

LM-0036

Fire prevention

The machine is very hot right after the engine stops!

● Use incombustible oils for cleaning parts. ● Extinguish flames which may cause fire hazards. ● Prepare fire extinguishing appliances such as

● All parts of the machine are very hot just after the

extinguishers.

engine stops. Touching anything may result in skin burns. ● Start inspection/maintenance after all parts have cooled down.

● Do not smoke while inspecting and maintaining the machine.

FUEL

LM-0037E LM-0037

0-32

Safety

Inspection and Maintenance

Use protective appliances

Holding attachments

● When carrying out maintenance, wear protective

● It is very dangerous to replace or repair joints/

goggles, helmet, safety shoes, gloves, and in accordance with the work, wear protective items such as dust mask and earplugs. ● Always wear protective appliances when doing grinding and hammering work since metal debris flies out.

hoses while holding attachment in the air.

● Always lower them to the ground or place it on blocks.

LM-0040

Use tools in a proper manner.

Maintaining underneath the machine

0-0042E

● When working under the machine, use safety supports or safety blocks under the crawlers to support the machine.

Conducting maintenance work in high places ● Put everything in order around the footing area. ● Do not spill oil or grease and do not leave tools lying around.

Be careful not to slip while the machine is traveling. ● Use tools or handrails when mounting up or dismounting. Also, be careful of slippery surfaces. ● DO NOT jump from higher places. ● When working together, decide on and use signals. ● When working together, follow the instructions from the leader.

LM-0041

Be prepared in case of emergency! ● Decide where to contact and how to handle the situation in case of an accident or fire. Additionally, investigate places where extinguishers and first-aid boxes are stored.

0-0078

0-0081

0-33

Safety

Inspection and Maintenance

Release oil pressure before starting maintenance ● Prior to inspection/maintenance, release air

Caution against high-pressure fuel and high-voltage charge during engine running

pressure and oil pressure in circuits after the parts have cooled down. ● When maintaining electric systems, remove the battery negative (-) terminal and start the work.

Pay attention to high-pressure fuel for the engine ● High-pressure fuel is in the fuel pipe while the engine is running or immediately after it has been stopped.

● Carry out inspection/maintenance after stopping the engine and wait for more than 2 minutes until the pressure in the pipe is dropped.

Pay attention to high-voltage charge to the engine ● High-voltage is charged to the controller and/or to the injector while the engine is running or immediately after it has been stopped.

Do not touch the controller and the injector.

If it is necessary to touch them such as in maintenance work, contact our service shops.

LM-0042

High pressure oil

Battery

● Pipes and equipment inside of the excavator are

● Batteries emit flammable gases. Always keep flames away. ● The battery electrolyte contains dilute sulfuric acid. If the fluid touches the skin, immediately wash it off with water and then wash fully with soap. If it gets in the eyes, after flushing them with plenty of water, get medical help. ● Before checking and handling the battery, turn off the power supply (by placing the starter switch to OFF). ● If you use or recharge the battery while the battery electrolyte is lower than the lower level indicated on the side of the battery, it may cause breakage (explosion). ● Check the level of the battery electrolyte, battery mounting conditions and the voltage, using testers, on a regular basis.

filled with high pressure oil. ● It is very dangerous to perform inspections/maintenance when oil pressure exits, because the oil could flow out. ● If leakage of high pressure oil from a small hole contacts skins or eyes, it may cause skin or eye injury. If you touch high pressure oils, get medical treatment immediately. ● If the oil is hot, it may cause burns. Wear protective goggles and gloves when conducting inspection/maintenance.

0-0083

0-0084

0-34

Safety

Inspection and Maintenance

Removing the battery.

Parts that have been removed

● Before maintaining the electric system, discon-

● Place removed parts in a stable condition, other-

nect the negative (-) battery terminal.

wise, they may fall down and become dangerous. ● Keep children and bystanders away from the parts storing area. ● When the ground is not hard and solid, parts may sink and fall down of their own weight. Arrange the parts storing area in a place which has level and hard ground. ● If soil or dirt gets inside the pipes, it could cause malfunction or errors. Plug or cap pipes of removed parts.

● Batteries emit flammable gases and may cause ignition and explosion. Battery electrolyte contains dilute sulfuric acid. Handle the battery with extreme care.

0-0085

Ventilation ● When conducting maintenance work in the poor ventilated locations such as indoors, keep doors and windows open and ventilate air to avoid gas poising.

0-0087

Use manufacturer’s genuine parts Always use the manufacturer’s genuine replacement parts, oils and greases. In addition, apply oils and greases compliant to temperature conditions.

Major inspections and maintenance work should be conducted in our Service Shop.

HYDRAULIC OIL

LM-0043

ENGINE OIL

GEAR OIL

COOLANT

Handling high pressure hoses ● Kinks and cracks on high pressure hoses could

0-0043E

cause breakage. Do not use any hoses with kinks and cracks. ● If fuel hoses or hydraulic oil hoses are loose or cracked, they could cause fire. Always repair them immediately.

0-35

Safety

Inspection and Maintenance

First clean the machine, then check and repair it

Draining oil and changing filters ● It is dangerous to drain water or oil and replace filters just after the engine stops. Carry out the work after each part has cooled down (approximately 68 - 104°F (20 - 40°C)).

Cleaning machines makes it easy to detect failures and faults.

Keep the oil filler and oil level gauge clean and avoid dust and dirt entry.

● When changing oil or changing filters, inspect the drained oil and old filters and check for metal debris or foreign substances.

If a large amount of metal debris is detected, contact our Service Shops for repairs.

0-0089

Washing vehicles 1. When washing the machine, be careful not to splash the electrical equipment. ● Monitors and electrical equipment in the operator cabin. ● Do not apply steam directly to battery, connectors and other electrical equipment.

0-0091

Disposal of waste fluids ● Do not pour waste fluids onto ground, rivers,

2. Do not apply high pressure washing steam directly to the radiators.

Wash the radiator carefully and gently.

lakes and marshes. It can harm the environment.

● When disposing of oil, fuel, cooling water, solutions, filters and other harmful substances, follow the local rules and regulations.

Keep fluids free of water and dirt When adding fuel/hydraulic oil/engine oil, keep them free of water, dust and other contaminants.

Do not adding fuel or oil with the strainer removed from the filler port.

water

0-0092

dust

dirt

Use clean oil ● Use clean oil and grease to avoid introducing

0-0044E

dirt.

• Use clean oil and grease.

• Also use clean containers.

● After filling grease, wipe any spilled grease or oil.

• Extra grease on operating/rotating parts.

E0350

0-36

Safety

Inspection and Maintenance

Keep lubricants at proper levels

Do not drop tools and parts

● Either too high or too low lubricant levels are bad

● When opening inspection windows or tank filler

for proper machine operation. When checking and adding oil, maintain the proper levels.

ports for inspection, be careful not to drop bolts/ nuts and tools into them. ● Take out everything from your pockets to avoid dropping things.

Correct oil level

Oil level gauge

0-0045E

Welding and repairing ● Turn off the electric supply. (Move the starter

0-0095

switch to the OFF position). ● If an electronic part (microcomputer) is attached, remove it (electronic components such as controllers). ● Set up a ground within 3.3 feet (1 m) from the area to be welded. ● Do not apply 200 V or more continuously. ● Do not put any seals or bearings between welded area and the ground. ● When welding or heating a painted area, remove the paint first. When heat is applied to a painted area, harmful fumes will be produced. ● If heat is applied near to a section where hydraulic equipment and pipes are located, flammable fumes or vapors may be produced and ignited.

Installing O-rings When removing sealing parts containing O-rings, clean the fitting faces.

Be careful not to damage O-rings and assemble them by applying oil when attaching them.

After finishing maintenance work When working together, decide on and use signals 1. After maintenance, make sure that at low idle there is no oil or water leakage from where the maintenance work was done (for approximately 5 minutes).

2. Operate each component slowly, and make sure that they work correctly.

3. Then, increase the engine revolutions and make sure there is no water or oil leakage.

4. Operate each component and make sure that there are no abnormalities.

0-0043

0-0094

0-37

E0360

Safety

Inspection and Maintenance

Inspection and maintenance during cold seasons 1. Use fuel and lubricating oils and greases appropriate for the temperature conditions.

2. Check the battery charging rates.

3. Use anti-freeze (long-life coolant).

4. Remove mud and water attached to the machine body. Wipe off water drops on the cylinder rods.

Inspection and maintenance when the machine is used under special situations When used under extremely hot conditions 1. Check/maintain cooling water and radiators.

2. Check and adjust the fan belt tension.

When used in a rocky place Pay special attention to breakage of the shoe and recoil spring, loose bolts and nuts, cracks and wears. Loose the tension of shoes by a small amount.

When used by the ocean Wash salt off especially carefully. Take special care of electronic equipment, hydraulic cylinders, shoes and recoil spring to prevent corrosion.

When used at sites full of dust and sand 1. Check the elements of air cleaners more often, and clean or change the elements and dust cups regardless of exchange intervals.

2. Tighten caps fully to prevent dust and sand from entering the hydraulic oil tank.

When used in marshes or on soft ground Lubricate and grease the parts earlier than usual.

Grease any pins which have been submerged in muddy water every day. In addition, check and clean the shoes and recoil spring.

E3430

0-38

Instruments and Controls This INSTRUMENTS AND CONTROLS section describes the functions and proper operation of the components required to operate the machine.

For safe operation, fully understand the contents of this section.

• Location of Components Overall View Operator’s Cab Seat and Console Right Panel • Explanation of device Console right side front Right Console Left Console Right Panel Control Levers Operator’s Seat Operator’s Cab Radio Air Conditioner Fuses Battery Starting the Engine by Using Booster Cables Anti-theft Protection

To operate and control the machine, refer to the OPERATING INSTRUCTIONS Section.

1-0

CONTROLS

Contents

Instruments/Controls

Location of Components

Overall View 1 Magnet 2 Bucket Link 3 Arm Link 4 Bucket Cylinder 5 Arm 6 Arm Cylinder 7 Boom 8 Boom Cylinder 9 Operator’s Cab 0 Swing Unit A Fuel Tank B Hydrauric Oil Tank C Battery D Air Cleaner E Engine and Radiator F Counterweight G Tarntable Bearing H Shoe (Track) I Travel Unit J Lower Roller K Upper Roller L Shoe Tension Unit

N Power distribution board O Generator

M Take up Roller

LM-0096

1-1

Instruments/Controls

Location of Components

Operator’s Cab

Ԙ

ԛ

Ԛ ԙ LM-0097

No.

1 2 3 4

Name Travel lever Foot rest Travel pedal Monitor

(See page) (P1-19)

1-2

Instruments/Controls

Location of Components

Seat and Console

LM-0098

No.

1 2 3 4 5 6 7 8 9 0 A B C D

Name Armrest Seat belt Seat reclining lever Operator’s seat Headrest Seat pocket Air-conditioner control panel Emergency stop switch Rocker switch (option) Ashtray Gate lock lever Left tilt lever Left-hand control lever Lock lever

(See page)

No.

E F G H I J K L M N O P Q R

(P1-22) (P1-22) (P1-30) (P1-9) (P1-18) (P1-10) (P1-11) (P1-9) (P1-10) (P1-11)

1-3

Name Seat height knob Seat & console slide lever Cup holder Right tilt lever Throttle volume Right-hand control lever Starter switch Radio Magazine rack Hot & cool box Storage box Seat slide lever Elevator cab lifting up/down switch Emergency switch for lowering elevator cab

(See page) (P1-22) (P1-22) (P1-7) (P1-6) (P1-8) (P1-6) (P1-28) (P1-36) (P1-22) (P1-7) (P1-7)

Instruments/Controls

Location of Components

Right Panel Ԙ

ԙ

Ԛ

ԛ

Ԝ

LM-0099

No.

Name

1 Monitor panel 2 Storage compartment 3 Rocker switch (4 places maximum)

No.

(See page) (P1-12)

Name

4 Storage compartment 5 12V power socket (option)

(See page) (P1-18)

(P1-18)

Console right side front No.

1 2 3

Ԙ

4

Name A/C sunlight sensor Clock Storage compartment for small articles Cigarette lighter

(See page) (P1-5)

(P1-5)

ԙ

Ԛ

ԛ

1-0005

1-4

E6700

Instruments/Controls

Explanation of device

Console right side front Clock

Cigarette lighter

H

M

1-0007

Use it when lighting a cigarette.

When the starter switch is turned ON, push the lighter in and release.

Since the lighter pops up after a few seconds, extract it for lighting.

After use, remove ashes being stuck in the ashtray to return it into the socket.

Removal of the lighter allows the lighter socket to be used as DC 24V power supply.

1-0006

Adjustment of clock

● Every time “H” button is pressed, “HOUR” indication increases with increment of 1 (1 → 12). ● Every time “M” button is pressed, “MINUTE” indication increases with increment of 1 (00 → 59). ● Pressing “M” button for a certain period allows the clock to be reset.

CAUTION ● Since the metal part is very hot while using the lighter, do not touch this area, otherwise scald may result. ● If the lighter will not be popped up in 30 seconds after it has been pushed in, the lighter may be out of order.

Pull back the lighter immediately and then ask a our authorized service shop for inspection. ● Do not hold the lighter after it has been pushed in. ● Remove the dust and ashes stuck to the heater. ● Do not use any cigarette lighter except the one being attached to the machine.

Otherwise, it fails to be returned or it is popped up. ● The cigarette lighter is of DC24V rating.

Do not connect any of the equipment of 12V rating to the socket as this may cause it to be damaged.

E0420

1-5

Instruments/Controls

Explanation of device

Right Console Throttle Volume

START

SP H A

SP

Starter Switch

ON ①

ACC OFF

1-0008

1-0009

Start Engine starting position

Regurates engine r.p.m. In addition, it is interlocked with mode selection.

When each is selected to the following modes, the monitor display changes accordingly.

ON Engine running position Electrical system energizing position

High speed SP: Super power mode H: Standard mode A: Auto mode Low speed

ACC (Accessory) Accessory power supply connection.

Engine stopping position.

OFF Key inserting/removing position.

Electrical system off position.

● SP Use this mode when carrying it out in speed priority operation.

To make it operate in this mode, turn the throttle potentiometer while the button 1 is being depressed.

The key is used both for opening/closing doors and opening/ closing the fuel tank cap.

IMPORTANT ● The machine is equipped with an antitheft func-

●H This mode is to be applied when carrying out normal operation.

tion.

When the antitheft function is to be activated, enter the assigned password with the engine key turned ON before starting the engine. ● The engine will not be started with the gate lock lever being released.

●A This mode is to be applied when carrying out fuel efficiency priority operation.

IMPORTANT If the engine speed does not change even after turning the throttle control. Push the idle switch to OFF. (see next page) If the idling switch is turned ON, the idling icon appears in the message.

1-6

Instruments/Controls

Explanation of device

Right Tilt Lever

Elevator cab lifting up/down switch

START ON ACC OFF

SP

SP H A

LM-0100

1-0010

The switch is to lift up and down the elevator cab.

The switch cannot be operated when it is operated in magnet mode.

UP : Cab moves upward DOWN : Cab moves downward

WARNING Stop the engine when adjusting the control lever.

Dangerous! An inadvertent touch on the lever causes the machine to move.

Emergency switch for lowering elevator cab

It is a lever that adjusts the position of the control lever Pull the tilt lever upward, the console will move up and down.

Push the tilt lever down and back to the original position, the console will lock.

LM-0101

The switch is to lower the elevator cab in an emergency.

Do not operate the switch unless it is in an emergency such as when the elevator cab Up/Down switch has been broken.

1-0005E

WARNING Since there is the possibility that operator's cab may interfere with implement when the emergency lowering device is actuated, keep a sufficient distance between the operator's cab and the implement.

1-7

Instruments/Controls

Explanation of device

Right Control lever

● Low Idling The engine idling icon is displayed.

Release switch

A H SP

START

n/min

ON ACC OFF

SP H A

1-0007E LM-0102

● Low idling speed varies according to operation

Pushing the switch allows the scrap attracted to the magnet to be released (dropped).

mode.

WARNING When the scrap is released, pay special attention to safety around the worksite.

Idle Switch

START ON ACC OFF

SP H A

LM-0194

By using this switch, the engine r.p.m can be adjusted to low idling.

Each time the Idle switch is pressed, the engine r.p.m. can be switched alternately between low idling and the original r.p.m.

● This will not function while performing attraction (magnet electric system)

1-8

Standard mode

1000min-1

Magnet mode

1500min-1

While attracting

It will not function.

However, attraction is possible even when the engine runs at a low idling speed.

Instruments/Controls

Explanation of device

Left Console Left Tilt Lever

Emergency Stop Switch

B

A

1-0017

LM-0104

If the engine does not stop even if the key is turned to OFF on the starter switch, press this switch to stop the engine.

WARNING Pull the gate lock lever and stop the engine when adjusting the console.

Dangerous! An inadvertent touch on the lever may cause the machine to move.

Position of A: Operation of emergency stop.

Position of B: Release of emergency stop.

It is a lever that adjusts the position of the control lever.

Pull the tilt lever upward, the console will move up and down. Push the tilt lever down and back to the original position, the console will lock.

1-0077

1-9

Instruments/Controls

Explanation of device Left Control lever

Ashtray

Attraction switch

LM-0105

Open the lid to use it.

When detaching it, pull it up with the lid being opened.

LM-0106

Pushing the switch allows the scrap to be attracted to the magnet.

CAUTION

◆ It is not necessary to keep pressing the switch to hold the scrap to be attracted.

Be sure to close the lid after use.

If the lid is remained open, cigarette fire may spread.

Temporary release switch for preventing interference

LM-0107

If bringing the attachment come close to the cab further when it is in an automatic stop condition, control the lever while depressing the temporary release switch.

This can operate the implement but the implement may interfere with the cab.

DANGER In case where the interference prevention function is released temporarily or in case of emergency, the implement may interfere with the cab.

1-10

Instruments/Controls

Explanation of device

Horn Switch

Gate Lock Lever

①

②

③

LM-0108

When the switch located on top of the left side operation lever is pressed, the horn will sound.

③

CAUTION Always press the switch and sound the horn to give signals when you start, travel or swing the machine.

①

②

1-0014E

WARNING ● When the machine will not be driven or op-

Radio muting switch

erated, shift the gate lock lever to the position at 2 or 3 to confirm that the control is locked. ● If the gate lock lever is at the position 1, touching the control lever allows the machine to start moving.

This prevents the machine from being operated incorrectly even if a control lever is touched mistakenly when the machine will not be operated or when getting on or off the machine.

Position of gate lock lever at 1 [operation position] When operating the machine, shifting the gate lock lever fully to the front side allows the lock bar to be raised upward by which releases the lock.

LM-0109

This is to muffle the sound of a radio set.

Pressing it again restores the sound.

In case where the engine has been stopped with the switch selected to muting, the muffling function is to be released when the engine is started again.

Position of gate lock lever at 2 [not operation position] When the machine will not be operated, shifting the gate lock lever to the middle position allows the lock bar to be stored in the console by which it is locked.

Position of gate lock lever at 3 [raise the control arm position] When getting on and off the machine, shifting the gate lock lever fully to the rear side allows the left console to be sprung up by which it is locked.

1-11

Instruments/Controls

Explanation of device

Right Panel Ԙ

n/min

ԙ

Ԛ

A H SP !4567

ԛ

Ԝ

TRIP

ODO

12345.6

1/10H

AUTO

TRIP

n/min

C

H

C

H

E

F

ԟ

Ԡ

Ԟ

ԝ LM-0110

No.

1 2 3 4 5 6 7 8 9

Name Horn Volume Switch Washer Switch Wiper Switch Work Lamp Switch Meter Indication Trip Switch Auto Idle Switch Travel Mode Change Switch Monitor Display

(See page) (P1-16) (P1-17) (P1-16) (P1-16) (P1-17) (P1-17) (P1-17) (P1-16) (P1-13)

1-12

E6750

Instruments/Controls

Explanation of device

Monitor display

1 Icon 2 : Engine is running at an idling speed

Ԙ

n/min

ԙ

Ԛ

ԛ

: Pressure is being increased : Auto warm-up

A H SP !4567

: Fan is rotating : Engine pre-heat

C

Ԟ

H

C

H

E

ԝ

F

Ԝ

No.

Name

1 2 3 4 5 6 7

Icon 2 Throttle & mode indication Error number indication Icon 1 Fuel meter Hydraulic oil temperature meter Coolant temperature meter

2 Throttle & mode indication LM-0111

A H SP 1-0021

Operation mode is displayed by icon.

WARNING ● The monitor is intended to indicate the ma-

SP Mode

H

H Mode

A

A Mode

3 Error number indication

chine’s condition and to quickly alert the operator of any abnormalities by means of messages or buzzers. It is not intended to be used for inspection or maintenance. ● The monitor can be damaged by water.

Take care that it does not get wet.

E6760

SP

Error number is indicated.

4 Icon 1 : The icon appears when function of the antitheft device has been set.

For details, refer to how to use the antitheft function.

1-13

Instruments/Controls

Explanation of device

6 Fuel Meter

E

F 1-0023

Indicates the amount of fuel in the tank.

F: High fuel level E: Low fuel level If 2 bar graphs are displayed, remaining fuel being is running short. Replenish the tank with fuel. If only 1 of bar graph is displayed, the message, LOW FUEL , appears. Stop the engine immediately to supply the fuel.

7 Hydraulic Oil Thermo meter 8 Coolant Water Thermo meter

C

H

C

H 1-0022

Indicates the engine coolant water temperature and hydraulic oil temperature.

C: Low temperature H: High temperature If only 1 of bar graph is shown due to low temperature, warm up the engine. Whenever all (8) bar graphs are displayed due to high temperature, the message, OVER HEAT appears. If 7 bar graphs are displayed, reduce the operating load to prevent overheat.

1-14

E0500

Instruments/Controls

Explanation of device ● The message display indicates the condition of the

Message Display

machine and indicates warnings. When a warning is indicated, the warning buzzer also sounds.

A H SP

IMPORTANT ● When the warning buzzer sounds, carry out the

LOW COOLANT

inspection and maintenance described in the message. ● Follow the instructions given in the “Inspection and Maintenance” Section. (If abnormal indication persists, consult with the authorized Service Shop and ask for service.)

1-0015E

Buzzer How to sound

Fna time

Message Display SERVICE DUE

Nothing

LOW FUEL LOW COOLANT

Continuousness

5 seconds

Meaning and Measures to be Take At the time of every 500 hour service intervals, one minute indication appears for 5 times when the engine starts.

Indicates the fuel level is very low. Add fuel.

Indicates the coolant water level is low. Add coolant water.

LOW OIL PRESS

Indicates the engine oil pressure is abnormally low. Stop the engine, check engine oil level and add oil.

If the engine is not stopped while this message is displaying it, the engine is automatically stopped.

OVER HEAT

Indicates the engine coolant temperature or hydraulic oil temperature abnormally rises. Put the engine in low idling and reduce water or oil temperatures.

Check the radiator & oil cooler.

It automatically becames a low idling if the water temperature rises further while this message is displaying it, and when the water temperature rises, the engine is stopped automatically still.

ALTERNATOR ELEC PROBLEM AIR FILTER

Indicates problems in battery charging system. Check the electric circuit.

Indicates electric problems (short circuit or disconnection) in the electric system.

Check the electric circuit.

Indicates the air filter is clogged.

Air filter are cleaned or exchanged promptly.

CHECK ENGINE

It indicates trouble (such as short-circuit and break) in electric system for engine.

Check electric circuit related engine.

BOOST TEMP. HIGH

Temperature of boost air to engine is unusually high.

Engine runs at a low idling speed automatically for protection of engine.

Stop machine operation without stopping the engine until message disappears. (Keep the engine running at a low idling speed.)

Engine stops automatically if temperature of boost air increases further while the message is being shown.

CHECK HYD. OIL FILTER

Return filter element is blocked.

Replace element.

Intermission (PIPI)

Once

SECURITY ON

It indicates if antitheft device using password is set.

Enter the password before starting engine when carrying out operation next time.

Intermission (PI-PI-)

It keeps sounds

ENGINE STOP

Emergency stop switch for engine is turned ON. Turn OFF emergency stop switch before starting the engine.

E0512

1-15

Instruments/Controls

Explanation of device

Switch Panel ● Horn Volume Switch

● Wiper Switch

1-0025

1-0027

Pressing horn volume selector switch makes a short “beep” sound allowing the sound of horn to be changed from normal to low volume and viceversa.

When the switch is pressed, the wiper function toggles in an Intermittent/Continuous/Stop cycle.

It is as follows of lighting indicator lamps.

Low volume: Indicator (green) located upper-left of the switch lights.

Intermittent: I lamp ON Continuous: II lamp ON Stop: Lamps OFF

Normal volume: Indicator (green) located upper-left of the switch goes off.

IMPORTANT

Selected horn volume is held even after the starter switch has been turned OFF. (If the starter switch has been turned OFF with the horn volume selected low, the low volume is to be maintained when the starter switch is turned ON again.)

Using the wipers when the windshield is dry or dirty and when it is covered by snow can cause damage to them. Use caution in such cases.

● Work Lamp Switch ● Travel Mode Change Switch

1-0029

When the switch is pressed, the work lamp will be turned on/off.

1-0026

Switch lamp is turned on: Work lamp will be turned on.

WARNING

Switch lamp is turned off: Work lamp will be turned off.

When the travel mode changes during traveling, travel direction can be erratic. Stop the machine and then change speed modes.

When the switch is pressed, the travel speed toggles between High Speed and Low Speed.

High speed: Indicator (red) located upper-left of the switch lights.

Low speed: Indicator (red) located upper-left of the switch goes off.

Every time the engine is started, the travel mode is selected at low speed.

1-16

E0520

Instruments/Controls

Explanation of device

● Auto idling switch

● Hour Meter

TRIP

ODO

12345.6

AUTO

n/min

1/10H 1-0029

TRIP

Pressing auto idling switch makes a “beep” sound selecting normal to/from auto idling speed.

3-0269E

Normal: Indicator (green) located lower-right of the switch goes off.

Indicates the operation time of the machine.

The last digit corresponds to 1/10 of an hour (6 minutes).

When the engine is stopped, the LCD is indicated.

Auto idling: Indicator (green) located lower-right of the switch lights.

When auto idling has been selected, the engine runs at low idling speed after approximately 5 seconds with the control lever put at neutral position.

Operation of the control lever or the throttle volume allows the engine to return to the original speed automatically.

Selected normal or auto idling is held even after the starter switch has been turned OFF. (If the starter switch has been turned OFF in the auto idling mode, this mode is to be maintained when the starter switch is turned ON again.)

● Trip Switch (TRIP) When the TRIP switch is pressed, the trip function will be indicated.

In approximately one minute, the trip indication will be turned back to the Hour meter.

When the trip switch is pressed for about 2 seconds while the trip meter is displayed, the switch will be set at “0.0”.

● Washer Switch

1-0030

When the switch is pressed, washer fluid is sprayed and the wipers are activated.

The washer fluid reservoir is located in the house behind the operator’s cab.

IMPORTANT ● Never operate the windshield washer control when the reservior is empty. This could cause damage to the electric pump. ● In cold weather, add anti-freeze to the windshield washer water.

E0531

1-17

Instruments/Controls

Explanation of device

● 12V Power Socket (Option)

● Rocker switch (Option)

2-0045

Rocker switches selecting flow rate of pump are mounted on the machines fitted with special attachment.

Machines fitted with 2-speed converging circuit can select 1st and 2nd speeds by using the switch illustrated below.

1-0032

A 12V power socket is optionally provided to supply power to electric equipment and accessories for automobile use.

10

12V

̖​̖​̖ Crushing operation (2nd speed)

̖​̖​̖ Excavating operation

KHP1803-00 1-0033

1((

(1st speed)

LM-0007E

CAUTION This socket is only for use in the equipment of 12V rating.

Do not use it to supply power to the equipment of 24V rating.

1-18

E6770

Instruments/Controls

Explanation of device

Control Levers Control Lever

WARNING Do not hang anything on the control levers. It may cause misoperation.

Travel Lever Ԙ Ԛ

ԛ

ԙ

1-0034

WARNING

1-0017E

● Before operating the travel lever, confirm the direction of the lower frame (forward or backward).

The travel unit is in the back and the travel lever is pushed, the machine moves forward and if it is pulled towards you the machine moves backward. ● When not traveling, do not place your feet on the travel pedals.

WARNING ● Even if the lever is put into neutral, the swing may continue briefly due to inertia.

Therefore, keep enough distance not to hit anything during swing operations. ● The operation method of levers varies according to the machine specification. Verify the operation procedure nameplate attached inside the cab. Master and be familiar with the operation levers before operating the machine. ● The operation of the excavator attachment is the reverse of that of the bucket. Caution should be taken when performing this operation

1 Press the right and left travel levers at the same time to move the machine forward.

2 Pull the right and left travel levers at the same time to move the machine backward.

3 Press the left travel lever to make a right turn.

4 Press the right travel pedal to make a left turn.

Boom, arm, bucket and swing operations can be controlled individually or simultaneously. The speed of the operation varies according to the control lever stroke. When the hand is released from the operation lever, the lever automatically returns to neutral.

E2430

1-19

Instruments/Controls

Explanation of device

Single Pedal Travel Push the top of the pedal for FORWARD travel.

Push the bottom of the pedal for REVERSE. Both tracks will move at the same speed.

ԙ 5-0036

2 At half-locking position, the pedal can be operated in one direction only.

1-0018E

IMPORTANT When travering the machine, always have the drive sprockets positioned to the rear. The Travel Controls are reversed if the drive sprockets are positioned to the front.

③

Pedal operation Put the pedal at locking position 1 when it will not be operated.

5-0037

3 At free position, the pedal can be operated in both directions of in front and in the rear.

When switching pedal operation, pull the lock lever A to change the operating position.

Ԙ 5-0035

KHP1486-00

When the pedal is: 1 At locking position.

1-0043E

1-20

Instruments/Controls

Explanation of device

Operation Name Plate

KHP11370-00 1-0036

WARNING

Arm out

● Before beginning operations, verify that

Swing left

the operation method described or the operation nameplate is the same as the actual movements of the machine. ● When verifying each operation, perform it slowly. ● The operation method may different depending on the specifications.

E0560

Boom down Swing right

Arm in

Bucket in

Bucket out Boom up 1-0019E

1-21

Instruments/Controls

Explanation of device

Operator’s Seat E. Suspension adjustment

WARNING

Turn the seat height knob 1 clockwise to adjust hardness of the seat.

Before adjusting the seat, lower the bucket to the ground and stop the engine or pull the gate lock lever to lock the control of the machine.

Always verify that the seat is locked after adjusting it.

F. Slide adjustment of console & seat 1. Pull the slide lever 4 to adjust the position as a whole.

2. When position as a whole has been decided, release the lever 4 to lock it.

Adjust the seat to allow the operator to easily reach the operation pedals and levers.

F

G.Seat pocket

⑤

H

The seat pocket is provided at the back side of the backrest.

Use it to for storing the operator’s manual and the like.

C G

A B I

D

H. Seatbelt

⑥

WARNING

③ E ② ④

Be sure to check the seatbelt and the buckle for condition before operating the machine.

If the belt has been damaged and/or fluffy, or the buckle has been deformed and/or broken for a long time of use, replace the seatbelt.

⑦ ①

⑧

1-0020E

A.Seat adjustment for its height 1. With no weight put on the seat, turn the seat height knob 1 for adjustment.

1. Fasten the seat belt before operating the machine.

• To raise: Turn it to the right (clockwise).

• To lower: Turn it to the left (counterclockwise).

2. Check that the seatbelt is not twisted to insert it into the buckle.

B.Seat adjustment for forward/backward

3. Check that the belt is locked securely.

1. Pull the slide lever 2 upward to adjust position of the seat back and forth.

1. Press the lock switch 5 located at the top of the backrest to adjust height of the headrest.

2. When the seat has been positioned, release the slide lever 2 to lock the seat.

J. Lumber support adjustment

I. Headrest

Press the inflation bulb 7 to fill air into the lumber support which in turn protrudes the waist support.

Press the button at the base of the inflation bulb 7 to deflate the lumber support allowing it to return to its initial position.

C.Reclining adjustment 1. Pull the reclining adjustment lever 6 to adjust angle of the backrest.

2. When angle of the backrest has been decided, release the lever 6 to lock the backrest.

D.Armrest 1. Turn the adjustment dial 3 located under the armrest to adjust its angle.

2. The armrest can be spring up to the side of backrest.

1-22

E0570

Instruments/Controls

Explanation of device

Operator’s Cab Roof Panel

CAUTION ● Be careful not to get your hand or anything

Ԙ

caught in the door or windows when closing them. ● When working with the door fully open, securely engage the door lock.

ԙ

Cab’s Door

1-0042

To open: Hold the handle 1 and push the lock 2 upward to unlock the roof panel.

Push up the roof panel to open it.

Ԙ

To close: Hold the handle 1 and pull down the roof panel slowly.

1-0041

Left Side Window

Pushing the door latch knob 1 opens the door.

Door Lock Release Lever Ԙ

Ԙ

Ԙ 1-0040

When the lock 1 is released, the window panes can be opened and closed to the left/right as required.

1-0039

This is used to keep the door open.

Fully open the cab door and push it into lock position to lock it open.

To close the door, press down the lever 1 located on the left side of the operatorís seat to release the lock.

E0590

1-23

Instruments/Controls

Explanation of device

Front Window

Opening 1. Shift the release lever 1 located upper part of the upper window in the arrow direction to unlock.

WARNING When opening and closing the front window: ● On a level site, lower the bucket to the ground and stop the engine. ● When opening and closing the window, do it slowly with care to avoid getting fingers or hands caught. ● Securely lock the window in place before starting the operation.

Ԙ

● Upper Window 1-0043

WARNING When opening and closing the upper window, be sure to lock the control of the machine with the gate lock lever.

If the machine makes an unexpected movement by touching the control lever mistakenly, an accident resulting serious injury or death may occur.

2. Hold the lower handle with the left hand and the upper handle with the right hand to pull it up slowly.

(#..+0) 9+0&19 /#; %#75' $1&+.; +0,74;㧚 #(6'4 4'/18+0) 14 4'2.#%+0) (4106 9+0&19㧘 '0574' 6*#6 #761.1%- +5 '0)#)'& #0& .1%- 9+0&19 +0 2.#%'㧚 -*2

1-0044

0-0015E

CAUTION

3. Move the upper window to press it against the auto-lock 2 located rear-left of the roof to fix it securely.

Since only the auxiliary lock 3 could be locked in some cases, hold the handles to shake the upper window to check that it has securely been locked.

Be careful! The stored front window may fall down.

You could get injured when the stored front window could slide and fall off.

Make sure the front window is locked in the stored position.

The front window (upper window) can be stored into the top of the operator’s cab.

ԙ

Ԛ

1-0045

1-24

E3390

Instruments/Controls

Explanation of device

Closing

● Opening/closing of lower window

1. Shift the release lever 1 located upper part of the upper window in the arrow direction.

Move the upper window slightly toward the front with the handles being held.

The lower window of the front window can be removed with the upper window being remained open.

1. Hold up the lower window to take it out of the window frame.

2. Hold each handle of the upper window and lower it slowly, then press the upper window hard against the window frame to fix it.

3. Check that the upper window has securely been locked.

Ԙ

1-0047

2. Store the removed lower window in the holder located at the rear part of the cab.

In order to store, insert the lower window into the brackets (2 places) 1 located at the bottom of the window frame to fix it securely with the catcher 2 mounted in upper part.

1-0046

ԙ

Ԙ 1-0048

E0610

1-25

Instruments/Controls

Explanation of device

Rear Window

Interior Light Switch

ԙ Ԙ

Ԙ

1-0049

1-0050

Put the interior light switch to “ON” to turn on the interior light.

The interior light is located at the upper left side of the operator’s cab.

Putting the interior light switch at the middle position between “ON” and “OFF” allows it to go off in 30 seconds after the door has been closed.

CAUTION ● Do not remove the rear window except for using it as an emergency exit.

● Do not put an object by which could be an obstacle against an escape.

IMPORTANT

In case where the cab door fails to be opened, use the rear window as an emergency exit.

● Turn off the interior light after it has been used.

Pull the pull ring 1 and remove the seal 2 off the window frame completely, then push the rear window hard so that it can be removed outside.

Otherwise, it may cause the battery to be run out.

Coat Hook CAUTION Do not hang clothes by which may obstruct the view or heavy clothes during machine operation.

The coat hook is provided at rear-left side in the cab.

1-0080

1-26

E0620

Instruments/Controls

Explanation of device 2. Loosen bolt 4 and attach mirror to stay 1.

Adjust the mirror angle so that the rear of the machine can be seen well from the driver’s seat.

Tighten bolt 4 and fix the mirror.

Mirror adjustment WARNING Be sure to check and adjust the mirror before operation.

Wrong adjustment of mirror provides poor visibility so that a collision of the machine or a serious accident resulting injury or death may result.

Mirror A Adjust the mirror A so that the right side of rear end of the machine can be seen on a part of the mirror.

Mirror B Adjust the mirror B so that the left side of rear end of the machine can be seen on a part of the mirror.

1-0023E

Precaution during transportation To prevent accidents during transportation, position the rear view mirror so that it is not protruding.

1. Loosen installation bolt 3 for rear view mirror and fold the mirror towards the inside.

Tighten bolt 3 and fix stay 1.

A ②

③

B

90゜

①

① 90゜

1-0081

1-0024E

The illustration may differ from that of actual machine.

2. After transporting, adjust the rear view mirror position so that the rear of the machine can be seen well from the driver’s seat.

1. Install rear view mirror stay 1 to the house right side stay 2 with bolt 3.

1-0022E

E7140

1-27

Instruments/Controls

Explanation of device

Radio

1-0051

AM/FM Radio 6 Preset buttons (1~6)

IMPORTANT

One station each in the FM and MW bands, respectively, can be preset for each of these keys, 1 to 6 Refer to the section "Preseting desired stations"

● When water gets inside the speakers or radio, it can cause unrepairable damage. Do not get it wet. Especially under rainy weather or when washing the machine, close the windows. ● Do not use benzine, thinner or other solvents for cleaning the scale plate or knobs. ● Wipe with a soft and dry cloth. ● Do not disassemble the radio.

7 SEEK button When this button is pressed, the radio automatially, searches for a receivable station, and automatically stops searching once a station is picked-up.

1 Power switch /volume control

8 Band select switch

Turn this knob clockwise. The "click" sound indicates that the power supply is turned on.

Further turning increase the sound volume.

Pressing this switch changes over between FM and MW. The display indicates the receiving band and frequency.

Note : MW only models do not have this function.

2 Tone control Turning this knob counter-clockwise decrease high frequency sound level and clockwise to increase high sound level.

9 Tuning buttons Pressing either UP or DOWN buttons shifts the receiving frequency step by step. Pressing eitllre of these buttons continuously, allows continuous shifting of the receiving frequency.

3 Display The display indicates the receiving frequency, tlme ard / or operating functions.

4 CLOCK button

Listen to the radio

Pressing this button to indicate current time.

Pressing this button again to resume freqpency display.

Note : Battery back-up models (B-type) do not have clock function and this button is disabled.

1. Turn on ACC switch to ON position and turn ON the radio switch.

2. Select desired band MW or FM by band switch.

3. Select desired frequency by pre-set button, SEEK button, or tuning button.

5 AST (Auto-store memory) button This button has two functions depending on pressing time. Pressing this button and release within two seconds, it will work as Preset-Memory-Scan and the radio will receive pre-programed stations for a few seconds and change to another stations. Pressing this button again to stop scanning. Pressing this button longer than two seconds, it will be Auto-store Memory.

4. Adjust desired volume level and tone by the controls accordingly 5. To turn off the radio, turn volume control knob to counter-clockwise until "click" sounds.

1-28

E0640

Instruments/Controls

Explanation of device

SEEK tuning

Time set

When this button is pressed, the radio automatically shift receiving frequency upward and searches for a receivable station.

And automatically stops searching once a station is picked-up.

1. Turn on ACC switch to ON position and turn ON the radio switch.

2. Press “CLOCK” button, if display is indicating frequency, and indicate time.

3. Pressing “M” button while depressing “CLOCK” button will increase MINUTES. Pressing “H” button while depressing “CLOCK” button will increase HOUR.

Manual tuning Pressing either UP or DOWN buttons shifts the receiving frequency step by step Pressing either of these buttons continuously, allows cuntinuous shifting of the receiving frequency.

4. Releasing “M” / “H” and “CLOCK” button will set the time. [depressing]

Presetting desired station into memory 1. Select desired station by manual or seek tuning.

2. Press desired number of memory button for more than two seconds.

Adjustment of minutes

3. Repeat 1-2 to preset other stations into preset memory.

Adjustment of hours

• Follow same method to change previously stored station to other station.

• In case battery back-up line is cut of due to replacing battery or any other reason, previously stored memory will be erased and the presetting procedure should be done again.

• The radio is capable to store 6 stations of MW and 6 stations of FM band.

1-0042E

Muting switch A muting switch by which the volume of the radio sound can be muted is provided on the console lever on the left.

Refer to “left-hand side console” (P1-11) for details.

Auto-store memory Pressing AST button more than two seconds, radio starts automatically to search receivable stations and store the frequency automatically into each memories.

E0650

1-29

Instruments/Controls

Explanation of device

Air Conditioner

R/ F

AUTO

MODE

A /C

AUTO TEMP

ON

DEF

OFF

1-0053

Control Panel

2 Auto Control Switch By pressing this switch when the main power supply switch is OFF, the air conditioner runs in an automatic mode.

When the switch is pressed, the vent air temperature, vent change and fan air volume are automatically controlled and the AUTO indication is lit on the LCD display.

1 Main Power Supply Switch 2 Auto Control Switch 3 Compressor Switch 4 Fan Air Volume Change Switch 5 Temperature Control Switch 6 Inside/Outside Air Change Switch 7 Vent Change Switch 8 Defroster Switch

AUTO

1 Main Power Supply Switch This switch operates (ON) and stops (OFF) the air conditioner.

When turned ON by pressing this switch, the operation starts using the setting when the last time turned off.

1-0055

3 Compressor Switch

ON

Turns ON/OFF the compressor.

When it is turned ON, is indicated on the LCD display.

Press the auto control switch, the compressor is automatically turned on.

When this switch is pressed, the AUTO on the LCD display is turned off.

OFF 1-0054

A/C 1-0056

1-30

E0661

Instruments/Controls

Explanation of device

4 Fan Air Volume Change Switch When the air conditioner is running, by pressing this switch the fan air volume will be changed.

The AUTO indication is turned off on the LCD display and the air volume set is lit.

By pressing

, the air volume increases.

By pressing

, the air volume decreases.

1-0057

LCD Display

Fan Air Volume

Low

Medium

5 Temperature Control Switch

Highest

6 Inside/Outside Air Change Switch

When the air conditioner is running, pressing this switch sets the inside temperature of the operatorís cabin.

By pressing, the set temperature increases.

By pressing,

Higher

Each time the switch is pressed, the inner air circulation/ outer air induction are changed over and the following indication appears on the LCD display:

the set temperature decreases.

Inner Air Circulation

On the LCD display, the set temperature, from 18.0 through 32.0 (°C), is indicated.

Outer Air Induction

TEMP

R/F 1-0058 1-0059

E0670

1-31

Instruments/Controls

Explanation of device

7 Vent Change Switch When the AUTO is indicated on the LCD display, by pressing the change switch once, the AUTO is turned off and the vent change is fixed at the setting at that time. Each time pressing the switch, the vent change will be changed from FACE, VENT, HIGH LEVEL, FOOT to FACE again, in this order. Each vent change mark is indicated.

ԙ Ԛ ԙ Ԛ Ԝ

Ԙ

MODE

Ԝ Ԛ ԛ

1-0060 1-0028E

8 Defroster Switch

LCD Display

By pressing this switch, the vent change will be changed to defroster function.

The AUTO indication is turned off on the LCD display and will appear.

Use this function to defrost the front windscreen.

Vent Change Air vent direction

Ԙ FACE

Upper body front

VENT

Upper body front & back

HIGH LEVEL

Upper body Feet

FOOT

Feet Front window screen

DEF

Front window screen Foot

ԙ

DEF

Ԛ

1-0061

ԛ

Ԝ

1-32

E0680

Instruments/Controls

Explanation of device 4. To stop the operation, push the main power supply switch.

Auto Air Conditioner Before using it, start the engine.

1. Press the automatic control switch.

AUTO is indicated on the display.

ON OFF

AUTO

1-0054

1-0055

IMPORTANT ● Depending on the outer temperature, the fan air

2. Press the temperature control switch to set the desired temperature. ( : temperature decreases. : temperature increases.)

The adjustment range of temperature is between 18 and 32 °C.

volume may become low for a given time after the auto air conditioner is running to avoid the cooler vent. ● Once you set the desired temperature, do not move the temperature control switch unless it is necessary. It may take a longer time to achieve the set temperature. ● For your health, change vent directions and ventilate the cab occasionally, and do not come into direct contact with the cold air for a long time.

TEMP

1-0058

By following the step 1 and step 2 above, the fan air volume, vent change and air vent temperature are automatically controlled.

3. When using this without the cooling/dehumidifying function, press the air conditioner switch. ( on the display is turned off. In this case, the temperature can not be set lower than the outer temperature.)

A/C 1-0056

E0690

1-33

Instruments/Controls

Explanation of device

When rapid cooling or heating is needed

Manual Control

1. Rapid Cooling Push the auto control switch and set the temperature indication at 18.0 (maximum cooling) by using the temperature control switch. In this case, the vent change is fixed at vent and the fan air volume is fixed at the maximum without automatic control.

When it is necessary to run the air conditioner continuously at AUTO mode, set the desired temperature by the temperature control switch.

The fan air volume, vent change switch and defroster switch can be used in combination. Even in the AUTO control mode, the function which is once activated by pressing the switch overrides.

At this time, the AUTO indication on the LCD display will be turned off, but functions other than one which is activated by pressing the switch are automatically controlled.

To put back to the AUTO control, push the auto control switch.

To stop the operation, push the main power supply switch.

2. Rapid Heating Push the auto control switch and set the temperature indication at 32.0 (maximum heating) by using the temperature control switch. In this case, the vent change is fixed at foot and the fan air volume is fixed at the maximum without automatic control.

When it is necessary to run the air conditioner continuously at AUTO mode, set the desired temperature by the temperature control switch.

1. To change the fan air volume Press the fan air volume change switch and adjust the volume.

AUTO

1-0057

1-0055

2. To change the vent Press the vent change switch and select the vent.

TEMP

MODE

1-0058

1-0060

1-34

E0700

Instruments/Controls

Explanation of device 4. When you do not want the outer air to get into

3. To defrost the front window screen a) Press the defroster switch to change the vent to DEF,

the operatorís cab, press the inside/outside air change switch to change to the inside air .

DEF

R/F 1-0061

1-0059

b) Press the inside/outside air change switch to put it the inside air,

IMPORTANT ● While cooling, the cool wind hits the glass and the outer side of the window glass may fog up.

R/F

● When setting the vent change to the foot, the air also comes from the DEF.

● When setting the vent change to the DEF, the air also comes from the foot.

1-0059

c) By using the temperature control switch, put the set temperature to 32.0.

TEMP

1-0058

d) To remove frost quickly, set the fan air volume change switch to the highest.

1-0057

E0710

1-35

Instruments/Controls

Explanation of device

Spot Cooler When the door or front windows are fully opened, it functions as a spot cooler.

When the door or front windows are closed, the function returns to the original control.

1. While using the air conditioner with automatic control.

The vent change is automatically changed to FACE, it functions as a spot cooler. The fan air volume is automatically controlled.

2. While using the air conditioner with manual control When the vent change is selected, it will be automatically changed to FACE, and it functions as a spot cooler.

The fan air volume is automatically controlled.

By using the vent change switch, the vent can be switched over.

Hot & Cool box This is a box in which beverages can be kept warm or cool.

It can keep drinks warm or cool at a temperature in accordance with setting of the air conditioner.

Miscellaneous 1. If the solar radiation sensor (It is setup in the console the operator’s seat right side front.) is covered, it is impossible to measure exact inner temperatures. Do not place anything on the solar radiation sensor.

2. Be careful not to cool the air too low.

For you health, it is recommended that the temperature difference between the inside and outside air should be kept at about 5-6 °C.

1-36

E2530

Instruments/Controls

Explanation of device

Fuses Fuse ratings and name of circuit

Fuses protect the electrical components and cables from overheating.

If any lamp or electrical component does not operate, it may be the result of a blown fuse.

When replacing a fuse, select one of the proper amperage.

KHP12181

BACK UP RADIO, ROOM LAMP FUEL FEED PUMP 20A 10A

Fuse Replacement

ENGINE PRE-HEAT 30A

CLOCK

OPTION LINE

CIGAR LIGHTER KAB SEAT 15A

10A

CAUTION

AIR-CONDITIONER UNIT

Before replacing the fuse, be sure to turn off the power supply (turn the starter switch to OFF).

Fuse box location (rear console)

10A

DC CONVERTER

5A

10A

AIR-CONDITIONER BLOWER 15A

TRAVEL ALARM BEACON

AIR-CONDITIONER COMPRESSOR 5A

SPARE (CRANE) 15A

SOLENOID

ELEC. FUEL PUMP

10A

10A

10A

WIPER WASHER 15A

LAMP (SPARE) 15A

HORN 10A

LOCK LEVER (GATE) 10A

LAMP (BOOM, HOUSE)

LAMP (CAB)

15A

15A

LAMP (CAB)

15A

LAMP (BOOM, HOUSE)

15A

10A

10A

LAMP (SPARE) 15A

LOCK LEVER (GATE) 10A

SOLENOID

10A

SPARE (CRANE) 15A

ELEC. FUEL PUMP

AIR-CONDITIONER COMPRESSOR 5A

HORN

10A

WIPER WASHER 15A

10A

TRAVEL ALARM BEACON

DC CONVERTER

5A

AIR-CONDITIONER UNIT

10A

AIR-CONDITIONER BLOWER 15A

10A

CLOCK

CIGAR LIGHTER KAB SEAT 15A

ENGINE PRE-HEAT 30A

OPTION LINE

BACK UP FUEL FEED PUMP RADIO, ROOM LAMP 20A 10A

KHP12181

1-0030E

1-0029E

1. Stop the engine. (Turn the starter switch to OFF.) 2. Obtain a fuse of the proper amperage for the socket where the blown fuse was placed.

Purchase specified rating fuses indicated for automobile use at a car shop or gas station.

3. Replace the blown fuse with a new one.

4. Install the fuse cover.

If the reason for the blown fuse is unknown or the fuse blows out repeatedly, have the machine inspected at a Service Shop to determine the cause.

E0720

1-37

Instruments/Controls

Explanation of device

Battery Installation and Removal of Battery

WARNING

● For removal, first disconnect the ground side ter-

Before inspecting and handling the battery, be sure to turn off the power supply (turn the starter switch to OFF).

Since the battery generates inflammable hydrogen gas, it may catch fire and explode.

minal ((-) terminal side).

If any tool or other object should come into contact with the (+) terminal, there is the danger that a spark may be caused. ● For installation, connect the ground side terminal ((-) terminal side) last.

● Do not use any matches, cigarettes, or other sources of fire or sparks near the battery. ● Before charging the battery, remove it from the machine and remove all the plugs. Select a well ventilated area.

Removal

Terminal side

Sulfuric acid is used as the electrolyte. It is dangerous because it can cause burns or loss of eyesight.

● If the battery fluid comes into contact with

1-0033E

skin or clothes, immediately wash it off with lots of water. ● If the battery fluid gets into your eyes, immediately wash your eyes with lots of water and have your eyes treated by a doctor.

● Do not connect the battery with the terminal connections reversed (connection of (+) to (-) or (-) to (+). It may cause damage to the generator or others.

Installation

Terminal sid

1

0-0032E

1-38

E0730

Instruments/Controls

Explanation of device

Starting the Engine by Using Booster Cables 3. Removing the Booster Cables Remove the booster cables in the order of 1 to 4:

WARNING When connecting the cables, never allow the (+) and (-) terminals to touch.

Using the booster cables to start the engine can lead to accident if not done properly. Use extreme caution.

a) Remove the booster cables connected to the swing frame of the faulty machine. b) Remove the black cable connected to the terminal of the normal machine. c) Remove the red cable connected to the terminal of the normal machine.

1. Connecting Booster Cables a) Stop the engine.

d) Remove the red cable connected to the terminal of the faulty machine.

b) Connect the booster cables in the order of 1 to 4:

1 Connect one terminal of the red cable to the

Red cable

(+) terminal of the faulty machine.

2 Connect the other terminal of the red cable to the (+) terminal of a normal machine.

3 Connect one terminal of the black cable to the (-) terminal of the normal machine.

4 Connect the other terminal of the black cable to the faulty machine’s swing frame at a place away from the battery.

Terminal

c)

d)

b)

Normal machine battery Black cable

Faulty machine battery Terminal

a)

Faulty machine’s engine block or iron shoe 1-0036E

Red cable

Normal machine battery Black cable

Terminal

Faulty machine battery Terminal

Faulty machine’s engine block or iron shoe 1-0035E

2. Starting the Engine a) Make sure that the booster cables are connected correctly. b) Start the engine of the normal machine and wait for 4 to 5 minutes. c) Start the engine of the faulty machine.

(After cracking for 20 seconds and the engine does not start, wait for 2 to 3 minutes and try again.)

E0741

1-39

Instruments/Controls

Explanation of device 3. Check the battery regularly.

WARNING

a) Check the solution level and always fill it up if the level is low. b) Check the terminals and fixtures. c) Checking voltage using a tester is also recommended.

When using or charging the battery at the electrolyte level below the “LOWER Level” indicated at the side of battery, it may cause damage (exposition) to the battery.

IMPORTANT If the battery is continued to be used with the electrolyte level below the “LOWER Level” indicated at the side of battery, it may deteriorate the battery quicker.

The solution level is too low and the polar plates are exposed.

1. The battery requires added solution.

After being used for a given period, the solution inside the battery (dilute sulfuric acid) will decrease.

If the solution level is close to the LOWER level, add distilled water or regular battery solution up to the UPPER level. (if the label indication is not attached, verify it by using an indicator)

The filled hydrogen gas gets short circuited

Explosion!

Electrolyte level is low

1-0038E

Do not add the solution above the UPPER level line.

1-0037E

2. Explosion Accident Example a) If the battery is left with the solution level low, hydrogen gas tends to be generated and fill the inside of the battery. b) If the cells are exposed and deteriorated, the plus (+) polar plate and negative (-) polar plate easily get short-circuited. c) When the sparks caused by the short circuit ignite the inner gas, the battery may explode.

1-40

E0750

Instruments/Controls

Anti-theft Protection

Anti-theft Protection 2. Control the switch as illustrated below and enter password.

In order to protect the hydraulic excavator from being stolen, register your password number: if the password number does not match with the number registered when the engine is started, the anti-theft protection function will be activated.

1 Washer switch: Cursor shifts to the left.

2 Work lamp switch: Cursor shifts to the right.

3 Wiper switch: Code number increases.

4 Auto idling switch: Code number decreases.

Setting Anti-theft Protection Function Ԙ

Consult with our Service Shop for setting the function.

Ԛ

ԙ

Anti-theft Protection Function When the anti-theft protection is activated and the engine is started with the wrong password number, the machine turns under the following conditions :

AUTO

n/min

• Engine keeps idling • Travel alarm sounds • To operate, the engine will stop

Ԝ

ԛ

1-0084

3. Upon finishing entering the password number, press the travel mode change switch 5 to register. It returns to the normal screen when the registration complation is done.

Registration Password Number Register a password number when setting the functions.

1. When the starter switch is turned to ON, the password number register screen appears on the LCD monitor.

(Example) 1

?

?

?

?

1 1 1 1-0039E

Changing the Password Number

1-0069

Consult with our Service Shop for changing your password number.

IMPORTANT The excavator will not operate if a number entered by you does match the registered password number.

Always take note of your password number.

E0760

1-41

Instruments/Controls

Anti-theft Protection

Using the Anti-theft Protection Function

b) Control the switch as illustrated below and enter registered password.

1 Washer switch: Cursor shifts to the left.

2 Work lamp switch: Cursor shifts to the right.

3 Wiper switch: Code number increases.

4 Auto idling switch: Code number decreases.

1. Activating the Anti-theft Protection Function a) When stopping the engine, move the starter switch from ON → OFF → ON → OFF within 2 seconds.

Ԛ

Ԙ

b) The buzzer sounds and the key icon is displayed the monitor.

ԙ

A H SP AUTO

n/min

C

H

C

H

E

Ԝ

F

ԛ

1-0084

1-0086

c) After the password has been entered, press the travel mode change switch 5 to complete the entry.

When the entry completes, normal display appears on the monitor.

2. Not Activating the Anti-theft Protection Function a) When stopping engine, place the starter switch to OFF position to shut off the engine.

The anti-theft protection function will not operate.

IMPORTANT

(Example) 1

The anti-theft protection function will be activated by stopping the engine. If it is troublesome to enter the password number each time when you start the engine, shut off the engine by just moving the start switch to OFF. Then, you can use the machine without entering a password number.

1 1 1 1-0039E

If the entered password number is different from the number registered, the ERROR message is indicated on the monitor. You can start the engine but if you attempt to operate the machine, the engine will stop. : When the password number matches the registered number, normal indications are displayed on the monitor and the anti-theft protection function is deactivated. The excavator can be operated after starting the engine.

3. Entering password number (before starting the engine) a) When the starter switch is turned to ON before starting the engine, the password number register screen appears on the LCD monitor.

A H SP

(Example) 0

0 0 0 C

1-0040E

H

C

H

E

F

1-0072

1-42

E0770

Operating Instructions This OPERATING INSTRUCTIONS section describes the proper operation of the machine.

All operators should always operate the machine carefully and safely to prevent personal injuries and damage to the machine.

Contents • Operation of New Machine • Daily Inspections • Interference prevention system • Emergency Lowering Device • Starting and Stopping the Engine

OPERATING

• Warm-up Operation • Operations (Traveling) • Operations (Swing) • Operations (Attachment) • Operations • Special Attachment • Operating Instructions (Cautions) • Operating Instructions (Procedures) • Operation of magnet • Monitor operation in detail • Bucket: Turning Over and Replacement • On Completion of Daily Operations • Operating in Cold Climates • Operating under Extreme Conditions • Transportation • Storing * For operations of the instruments and controls, refer to the INSTRUMENTS AND CONTROLS section.

WARNING ● If any problem is found, immediately correct the problem.

Do not run or operate any machine which is not properly maintained. ● Before starting operations, check the job site conditions and take the necessary measures to ensure safe operations. ● Use extreme care in dangerous places. ● Make sure that unauthorized people can not enter the job site.

2-0

E6780

Operating

Operation of New Machine

Using a New Machine 4. Check if the machine is running properly.

Although a new machine is inspected and adjusted before being delivered, operating it under severe conditions before the end of the break-in period will affect its performance and shorten the service life.

5. Avoid running or swinging the machine rapidly.

6. Avoid giving the machine a shock by suddenly stopping the boom when lowering it, etc.

IMPORTANT Be sure to break in the machine for 50 to 100 hours (indicated by the hour meter) before working under full load conditions.

If the machine is operated at full load before it has been broken-in, seizing or scuffing may occur, resulting in shortening of the machine’s service life. Therefore, caution should be taken to prevent this from happening.

LM-0046

Breaking-in procedure (up to 50 to 100 hours)

7. Conduct the new machine 50 hours maintenance.

1. Conduct the daily inspection and check for any oil, fuel, and coolant water leaks.

8. Grease the front pins everyday (for greasing type machines).

2. Always warm up the engine before operation.

Warming up!

Hours of operation Element

LM-0028E

LM-0029E

3. Keep the speed of the engine below 80% of the maximum.

2-0002

2-1

Operating

Daily Inspections Check after starting the engine

To ensure the safety of the operator and to extend the service life of the machine, perform the following daily inspections.

1. Horn and operation of all gauges.

2. Engine start condition, noise and exhaust color.

3. Leakage of oil, fuel and coolant.

LM-0048

WARNING

LM-0001

If any problem is found during the inspection, immediately identify the cause and adjust or repair the machine to prevent further trouble.

If the machine is operated with the problem uncorrected, it may cause more serious problems or severe accidents.

Perform inspections before starting.

Daily Inspections Visual check Visually check the machine before starting the engine.

Thoroughly check the surroundings and the bottom of the machine for the following:

1. Leakage of oil, fuel and coolant.

2. Loose bolts and nuts.

3. • Make sure there are no electrical short circuits.

• Check the battery connections are properly tightened.

4. Oil stain.

5. Accumulation of foreign materials.

2-2

Operating

Daily Inspections

Item to check daily Inspections and maintenance

Procedure

Grease / oil (replacement parts)

Reference

Check prior to starting the engine Overall 1. Check any water or oil leakage 2. Check to ensure nuts & bolts are secure 3. Eliminate accumulated dust (from engine / inside cab) 4. Check physical exterior damage 5. Check inside the cab and window glass for cleanliness

Bolts

Tighten and secure Clean

Engine 1. Check engine oil level, and see if it needs changed 2. Check coolant level 3. Check radiator and oil cooler to see if damaged or plugged 4. Check the fan belt tension 5. Check if air cleaner element is clean / if it is clogged 6. Check parts for water / oil leakage, check hoses and pipes for breakage 7. Draining the water and sediments from the fuel filter (main and pre)

Refill or change Refill Repair or clean

Engine oil Soft water

Clean or replace

Element

Engine Engine Engine Engine Engine Fuel

Swing Unit 1. Check fuel level in fuel tank 2. Draining the water and sediments from the fuel filter 3. Check oil level in hydraulic oil tank 4. Check if hydraulic oil is clean 5. Check components for water / oil leakage, check hoses and pipes for integrity 6. Check components for physical damage or distortion 7. Check electrical wiring for short circuits Ensure terminals are secure 8. Adjust rear view mirror

Refill

Diesel Fuel

Refill

Hydraulic oil

Fuel Fuel Hydraulic oil

Track Travel Unit Travel Unit

1. Check shoe (track roller) for looseness, wear, or breakage 2. Check upper / lower rollers and idlers for oil leakage or wear 3. Ensure bolts are all secure, and not missing Work Unit 1. Check cylinders, hoses for oil leakage or breakage 2. Check magnet for wear or breakage 3. Ensure components around front of machine are properly greased or oiled 4. Ensure bolts are all secure, and not missing 5. Cable 1) Broken wire and damage(crack in appearance).

2) Slackening in sections being secured.

3) Wearing in hydraulic hode and in attachment.

4) Tightness of terminals.

6. Generator / Power distribution board 1) Cleaning of dust and dirt.

2) Tightness of bolts.

3) Tightness of terminals.

pressure grease

Check after starting the engine Overall 1. Check if engine starts fine, check exhaust hue, listen for any abnormal noise 2. Check hydraulic components, check any abnormal noise 3. Check components for oil / water leakage 4. Check horns, buzzers, working lights, windshield wipers, and monitors for proper operation 5. Check units for proper operation (travel, swing, and attachments) 6. Check swing brake for proper operation 7. Inspection of interference prevention system.

8. Inspection of emergency lowering device.

Refer to the Daily Inspection Prior to Operation section for check procedures for major components.

2-3

Attachments

Operating

Interference prevention system

Function of interference prevention system 1. When the attachment comes close to the cab while it is being controlled, the system slows down the movement of attachment and stops it automatically when it comes closer.

WARNING The interference prevention system is an auxiliary system that prevents interference between the cab and the attachment.

There is the possibility that the cab and the attachment can be interfered even while the system is being activated.

Do not operate in such way that the attachment will hit against the cab.

Always pay attention that the attachment will not hit against the cab as the interference prevention system may be broken down.

The company has no responsibility for an accident occurred during use of this system.

LM-0113

When the boom and the arm are retracted with the elevator being controlled.

2. When the attachment comes close to the cab while it is being controlled, the system slows down the movement of attachment and stops it automatically when it comes closer.

LM-0114

When the elevator is controlled with the boom and the arm are retracted.

2-4

Operating

Interference prevention system

Inspection of interference prevention system before starting operation Checking operation of interference prevention system

How interference prevention system is operated 1. Slow-down area (A) When the magnet enters into the area "A" (in the figure on the right) by carrying out operation to bring the magnet close to the cab, speed of attachment becomes slower.

This is to prevent the loads being attracted such as iron scrap from falling down when the attachment has been stopped.

When the standard arm is mounted, a larger slow-down area is to be set.

WARNING Be sure to warm-up the engine until the hydraulic oil temperature is raised to approx.

20°C (or water temperature meter indicates above "C") before carrying out the check.

To check its operation, put the throttle potentiometer at a low speed to control it slowly.

2. Automatic stop area (B) When the magnet enters into the area "B" (in the figure on the right) by bringing the magnet closer to the cab, the attachment stops automatically and the alarm buzzer sounds. ●Although operation of raising boom, retracting arm, and elevator up/down becomes impossible during automatic stop, other operation is possible.

Carry out operation with sufficient distance kept between the magnet and the cab.

1. Checking automatic stop Check if the attachment makes a complete stop automatically within the automatic stop area when the magnet is brought close slowly to the cab by putting the attachment as illustrated in the figure on the right.

After the attachment has been stopped, move it forward allowing the magnet to separate sufficiently from the cab to release the automatic stop.

20㨪60cm

20㨪60cm

LM-0116

LM-0115

A: Slow-down area (section A) B: Automatic stop area (section B)

A: Automatic stop area

WARNING When changing the mounting from the short arm to the standard arm and vice versa, the interference prevention system must be changed accordingly.

Consult a authorized LBX Link-Belt distributor for this change.

2-5

Operating

Interference prevention system

Instructions of anti-interference device KHP14520

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㧞㧚㧭㧾㧹‫ޓ‬㧻㧼㧱㧾㧭㨀㧱

㧟㧚㧱㧸㧱㨂㧭㨀㧻㧾‫ޓ‬㧻㧼㧱㧾㧭㨀㧱

㧞㧚㨀㧱㧹㧼㧻㧾㧭㧾㨅‫ޓ‬㧯㧭㧺㧯㧱㧸‫ޓ‬㧭㧺㧰‫ޓ‬㧱㧹㧱㧾㧳㧱㧺㧯㨅‫ޓ‬㧯㧭㧺㧯㧱㧸‫ޓ‬㧻㧲‫ޓ‬㧭㧺㨀㧵㧙㧵㧺㨀㧱㧾㧲㧱㧾㧱㧺㧯㧱‫ޓ‬㧰㧱㨂㧵㧯㧱 㧨㨀㧱㧹㧼㧻㧾㧭㧾㨅‫ޓ‬㧯㧭㧺㧯㧱㧸㧪 ‫ޓ‬㧶㧻㨅㧿㨀㧵㧯㧷‫ޓ‬㧯㧻㧺㨀㧾㧻㧸‫ޓ‬㨃㧵㧸㧸‫ޓ‬㧮㧱‫ޓ‬㧭㧮㧸㧱‫ޓ‬㨀㧻‫ޓ‬㧻㧼㧱㧾㧭㨀㧱‫ޓ‬㨃㧴㧵㧸㧱‫ޓ‬㧿㨃㧵㨀㧯㧴‫ޓ‬㧻㧺‫ޓ‬㧸㧱㧲㨀‫ޓ‬㧿㧵㧰㧱 ‫ޓ‬㧶㧻㨅㧿㨀㧵㧯㧷‫ޓ‬㧵㧿‫ޓ‬㧼㨁㧿㧴㧱㧰‫ޓ‬㧱㨂㧱㧺‫ޓ‬㧭㧺㨀㧵㧙㧵㧺㨀㧱㧾㧲㧱㧾㧱㧺㧯㧱‫ޓ‬㧰㧱㨂㧵㧯㧱‫ޓ‬㧵㧿‫ޓ‬㧭㧯㨀㧵㨂㧭㨀㧱㧰㧚 ‫ޓ‬㧭㨀㨀㧭㧯㧴㧹㧱㧺㨀‫ޓ‬㧹㧭㨅‫ޓ‬㧴㧵㨀‫ޓ‬㧯㧭㧮‫ޓ‬㨃㧴㧵㧸㧱‫ޓ‬㧭㧺㨀㧵㧙㧵㧺㨀㧱㧾㧲㧱㧾㧱㧺㧯㧱‫ޓ‬㧰㧱㨂㧵㧯㧱‫ޓ‬㧵㧿 ‫ޓ‬㨀㧱㧹㧼㧻㧾㧭㧸㧸㨅‫ޓ‬㧯㧭㧺㧯㧱㧸㧱㧰㧚

㧻㧼㧱㧾㧭㨀㧱‫ޓ‬㨃㧴㧵㧸㧱‫ޓ‬㧿㨃㧵㨀㧯㧴 㧔㧾㧵㧳㧴㨀‫ޓ‬㧿㧵㧰㧱‫ޓ‬㧶㧻㨅㧿㨀㧵㧯㧷㧕

㧨㧱㧹㧱㧾㧳㧱㧺㧯㨅‫ޓ‬㧯㧭㧺㧯㧱㧸㧪 ‫ޓ‬㧿㨀㧻㧼‫ޓ‬㧻㧼㧱㧾㧭㨀㧵㧻㧺‫ޓ‬㧭㧺㧰‫ޓ‬㧯㧻㧺㨀㧭㧯㨀‫ޓ‬㧻㨁㧾‫ޓ‬㧸㧻㧯㧭㧸‫ޓ‬㧰㧱㧭㧸㧱㧾‫ޓ‬㧵㧹㧹㧱㧰㧵㧭㨀㧱㧸㨅㧘‫ޓ‬㧵㧲 ‫ޓ‬㨃㧭㧾㧺㧵㧺㧳‫ޓ‬㧮㨁㨆㨆㧱㧾‫ޓ‬㧰㧻㧱㧿‫ޓ‬㧺㧻㨀‫ޓ‬㧿㨀㧻㧼‫ޓ‬㧻㧾‫ޓ‬㧻㧼㧱㧾㧭㨀㧵㧻㧺‫ޓ‬㧹㧭㧸㧲㨁㧺㧯㨀㧵㧻㧺㧿㧚㧭㧯㨀㧵㨂㧭㨀㧱 ‫ޓ‬㧱㧹㧱㧾㧳㧱㧺㧯㨅‫ޓ‬㧯㧭㧺㧯㧱㧸‫ޓ‬㧿㨃㧵㧯㨀㧴㧘‫ޓ‬㨃㧴㧱㧺‫ޓ‬㧹㧭㧯㧴㧵㧺㧱‫ޓ‬㧺㧱㧱㧰‫ޓ‬㨀㧻‫ޓ‬㧮㧱‫ޓ‬㧹㧻㨂㧱㧰‫ޓ‬㨀㧻‫ޓ‬㧿㧭㧲㧱㨀㨅 ‫ޓ‬㧯㧻㧺㧰㧵㨀㧵㧻㧺㧚 ‫ޓ‬㧭㧯㨀㧵㨂㧭㨀㧱‫ޓ‬㧱㧹㧱㧾㧳㧱㧺㧯㨅‫ޓ‬㧯㧭㧺㧯㧱㧸‫ޓ‬㧿㨃㧵㨀㧯㧴 ‫ޓ‬㧭㨀㨀㧭㧯㧴㧹㧱㧺㨀‫ޓ‬㧹㧭㨅‫ޓ‬㧴㧵㨀‫ޓ‬㧯㧭㧮㧚 㧔㧯㧻㨂㧱㧾‫ޓ‬㧵㧺㧺㧱㧾㧕

㧝㧚㨃㧭㧾㧺㧵㧺㧳‫ޓ‬㨁㧼‫ޓ‬㧹㧭㧯㧴㧵㧺㧱‫ޓ‬㧮㧱㧲㧻㧾㧱‫ޓ‬㧻㧼㧱㧾㧭㨀㧵㧻㧺㧚 㧞㧚㧰㧻‫ޓ‬㧺㧻㨀‫ޓ‬㧰㧵㧿㧭㧿㧿㧱㧹㧮㧸㧱‫ޓ‬㧿㧱㧺㧿㧻㧾㧿‫ޓ‬㧭㧺㧰‫ޓ‬㨃㧭㨀㧯㧴‫ޓ‬㧻㨁㨀‫ޓ‬㧲㧻㧾‫ޓ‬㧿㧱㧺㧿㧻㧾‫ޓ‬㧰㧭㧹㧭㧳㧱㧚 㧟㧚㧭㧺㨀㧵㧙㧵㧺㨀㧱㧾㧲㧱㧾㧱㧺㧯㧱‫ޓ‬㧰㧱㨂㧵㧯㧱‫ޓ‬㧰㧻㧱㧿‫ޓ‬㧺㧻㨀‫ޓ‬㧭㧯㨀㧵㨂㧭㨀㧱‫ޓ‬㧼㧾㧻㧼㧱㧾㧸㨅㧘 ‫ޓޓ‬㧵㧲‫ޓ‬㨁㧺㧿㧼㧱㧯㧻㧲㧵㧱㧰‫ޓ‬㧭㨀㨀㧭㧯㧴㧹㧱㧺㨀‫ޓ‬㧵㧿‫ޓ‬㧵㧺㧿㨀㧭㧸㧸㧱㧰㧚 㧠㧚㧭㨀㨀㧭㧯㧴㧹㧱㧺㨀‫ޓ‬㧹㧭㨅‫ޓ‬㧴㧵㨀‫ޓ‬㧯㧭㧮㧘‫ޓ‬㧵㧲‫ޓ‬㨀㧱㧹㧼㧻㧾㧭㧸㧸㨅‫ޓ‬㧯㧭㧺㧯㧱㧸‫ޓ‬㧿㨃㧵㧯㨀㧴 ‫ޓޓ‬㧻㧾‫ޓ‬㧱㧹㧱㧾㧳㧱㧺㧯㨅‫ޓ‬㧯㧭㧺㧯㧱㧸‫ޓ‬㧿㨃㧵㨀㧯㧴‫ޓ‬㧵㧿‫ޓ‬㧭㧯㨀㧵㨂㧭㨀㧱㧰㧚 -*2

2-6

Operating

Interference prevention system

Precautions in handling interference prevention system ● Mounted location of angle sensor

Operation of interference prevention system WARNING In order to secure correct operation of interference prevention system, be sure to observe the following: 1. Do not remove, attach, and overhaul the sensors and controllers for interference prevention system as this may cause system trouble.

Be sure to ask a authorized LBX Link-Belt distributor for inspection and repair.

2. Check the automatic stop for its operation when a sensor has been hit against something or an external flaw has been found.

In case where something wrong is found, be sure to ask a authorized LBX Link-Belt distributor for inspection and repair.

3. Do not carry out operation in which the sensor may be submerged.

In case of allowing it to be submerged, inspect the automatic stop for its operation.

If found something wrong, be sure to ask a authorized LBX Link-Belt distributor for inspection and repair.

4. Do not use the emergency reset switch except for moving the machine to a safe place when the system is out of order.

5. When an attachment other than that specified by LBX has been fitted and the arm has been changed to other arm, the interference prevention system will not make a correct operation.

In case where changing to an attachment other than that LBX specified or to other arm, consult a authorized LBX Link-Belt distributor.

6. If leaving the magnet in the air, it may interfere with the cab due to drop by gravity.

Be sure to lower the magnet to the ground if the attachment will not be operated.

7. In case where a magnet other than that specified by LBX has been fitted, pay special attention to operation as it may interfere with the cab.

LM-0117

A: Arm angle sensor B: Hydraulic cab riser C: Boom angle sensor

LM-0118

Be sure to lower the magnet to the ground if the attachment will not be operated.

● If a sensor or a proportional valve is broken down, alarm buzzer keeps on sounding.

Since it stops sounding when the engine is stopped, ask a authorized LBX Link-Belt distributor immediately for inspection and repair. ● Since there is the possibility that the controller of interference prevention system may make an incorrect operation by jamming from outside, consult a authorized LBX Link-Belt distributor before a radio equipment is installed.

2-7

Operating

Interference prevention system

Regarding machines shipped as the machine intended for commonly use both in the magnet and the other end-attachment Setting of the interference prevention system ● Machines shipped out of the factory as the machine intended for commonly use both in the magnet and the other end-attachment (*1) equips the interference prevention system of two(2) kinds.

● At the shipping out of the factory, the interference prevention system is set to match an end-attachment with larger working range in consideration of safety.

● If changing the end-attachment, consult a authorized LBX Link-Belt distributor as the interference prevention system needs to be changed. *1 Other end-attachment means that it is only applied to the attachment set when placing an order.

2-8

Operating

Emergency Lowering Device

Inspection of emergency lowering device before starting operation Functions of emergency lowering device

WARNING 1. Be sure to warm-up the engine until the hydraulic oil temperature is raised to approx.

20°C (or water temperature is above “C”) before carrying out the check.

2. Be sure to confirm that there is no persons or obstacles in the neighborhood (including in upper/lower directions) before checking the operation of emergency lowering device.

Otherwise, this may lead to invite a serious accident.

3. Ensure a sufficient distance between the operator ’s cab and the implement as they may be interfered each other while the emergency lowering device is being operated.

Emergency lowering device is only used in an emergency that the operator ’s cab cannot be lowered by normal lowering operation of the elevator.

Inspection of emergency lowering device for operation Checking emergency lowering Take a sufficient distance between the operator ’s cab and the implement 1, then check that the operator's cab can be lowered 2 by depression of emergency lowering switch 4 located either on the console on the right 3 or at the rear of the cab 5.

'/'4)'0%;

(refer to next page for mounted location of the emergency lowering switch.)

STAYING IN THE DANGER ZONE FORBIDDEN

KHP14500-00

LM-0023E

LM-0119

2-9

Operating

Emergency Lowering Device

Emergency lowering device KHP14510

'/'4)'0%;

EMERGENCY LOWERING DEVICE

CONSOLE (RIGHT)

SWITCH OPERATE KHP14510-00

2-10

Operating

Emergency Lowering Device

Points to notice when operating emergency lowering device Operation of emergency lowering device WARNING In order to make sure correct operation of the emergency lowering device in an emergency, be sure to observe precaution as follows: 1. Do not carry out removal, fitting, and overhaul of the switches and the solenoid valves related to emergency lowering device as this may cause the system failure.

Be sure to ask a service shop for inspection and repair.

2. Check the emergency lowering device for its operation every time when the switch or the solenoid valve has been hit against anything or an external flaw has been found in them.

In case where something wrong is found, be sure to ask a service shop for inspection and repair.

3. Emergency lowering device provides functions in an emergency.

Therefore, do not use it other than that the operator ’s cab fails to be lowered by normal lowering operation.

Since failure in operation by normal lowering operation may be due to trouble or breakdown of the elevator lifting device, ask a service shop immediately for inspection and repair.

4. Be sure to confirm that there is no persons or obstacles around the neighborhood or under the operator ’s cab before carrying out the check.

If failed, this may lead to invite a serious accident.

LM-0185

'/'4)'0%;

Turn ON ignition to actuate the emergency lowering device

LM-0120

Depress emergency lowering switch located either on the console on the right or at the rear of the cab

STAYING IN THE DANGER ZONE FORBIDDEN

KHP14500-00

LM-0023E

2-11

Operating

Emergency Lowering Device

In case where operation of the emergency lowering device is in trouble Operation of rear window

LM-0122

CAUTION Do not remove it except when using as an emergency exit.

Do not put an obstacle that may prevent when getting out of the cab in the operator ’s cab or at the rear window.

LM-0121

A: Rear window B: Ladder C: Operator's cab

The rear window can be detached outward by pushing it hard after the seat 2 has been taken away out of the window frame rubber completely by pulling the pull-ring 1.

If operator ’s cab will not be lowered when the normal operation and the emergency lowering device become inoperable, Operator can also go out of the operator ’s cab to get down to the ground by using the ladder of the elevator link.

WARNING In some conditions of weather or work site, the ladder may be slipped.

2-12

Operating

Starting and Stopping the Engine

Inspections before Starting the Engine 3. After starting the engine, always perform the warm up operation.

Note: If the engine runs at low r.p.m., vibration may occur. In this case, slightly increase the r.p.m. and the vibration will stop.

Before starting the engine, perform the daily inspection outlined in the previous section (Daily Inspection).

LM-0001

Perform inspections before starting.

Basic operation before starting the engine WARNING Check that the gate lock lever at the locked position.

1. After verifying that there are no problems with the machine and checking the surroundings, sit in the operator ’s seat.

2. Put the gate lock lever at the locked position.

3. Sit in the operator ’s seat and adjust the position so that the levers and pedals can be easily operated.

4. Put the operation levers into neutral.

Cautions for starting the engine 1. When it is cold, the engine becomes harder to start because the oil viscosity increases and the battery performance decreases. Start the engine at the first trial if possible.

2. Sound the horn to alert people in the surrounding area.

IMPORTANT When cold: In winter or when it is cold, before starting the engine the monitor shows readings and the engine will be automatically preheated.

Start the engine after completing preheating.

2-13

Operating

Starting and Stopping the Engine

Starting the Engine After performing the basic operations described in “Before Starting the Engine” section, start the engine.

IMPORTANT This machine adopt new type of engine equipped with the high-pressure fuel jet system to reduce load for environment and conform Tier III engine emission.

Basic operation for starting the engine 1. Put the gate lock lever at the locked position.

Therefor, this engine start after a little longer than former type of engine of cranking time and becomes stable. (Usually about 1second needed)

2. Insert the key into the starter switch and turn the key to the “ON” position. Check on the monitor for any problems.

At the start of the engine, it is to be run at an idling speed regardless of position of the throttle volume.

When controlling the lever or the throttle volume afterward, the engine runs at a speed according to the position of throttle volume.

IMPORTANT If the engine does not start in one try, operate the starter for up to 10 seconds then wait for 1 or 2 minutes before trying again. When it is cold, the engine is sometimes hard to start, but do not continue running the starter for more than 10 seconds.

IMPORTANT ● When activating antitheft function, the message “PASSWORD?” is displayed on the monitor.

Enter the password.

If the password has not been entered, the machine can not be operated. (Refer to operator’s manual for “antitheft function”. ● The engine will not start when the gate lock lever is at the released position.

5. After starting the engine, perform warm up operations.

3. Press the horn switch (on the top of the left operation lever) to sound the horn to alert people in the surrounding area.

4. Turn the key from the “ON” position to the “START” position.

Then the starter revolves and the engine will start. After the engine started, release the key.

The key will automatically return to “ON” position.

START ON ACC OFF

2-0008

2-14

E0830

Operating

Starting and Stopping the Engine

Inspections after Starting the Engine 5. Check if readings of water and hydraulic oil thermometers are correct.

WARNING If any problem is found, immediately stop the engine, identify the cause and correct it immediately.

IMPORTANT C

This machine has engine automatic warm up operation function. Although engine speed may increase during automatic warm up operation, it is not abnormal.

After automatic warm-up, the engine runs at an idling speed regardless of position of the throttle volume.

When controlling the lever or the throttle volume afterward, the engine runs at a speed according to the position of throttle volume.

H

C

H 1-0022

6. Check that all operations (travel, swing and attachment) are normal.

Basic operation after starting the engine

Warming up!

LM-0028E

After starting the engine, inspect and verify the following while warm up operation (see the “Warm Up Operation” section) is being done.

1. Engine running state, exhaust color and abnormal noise.

2. Operation and abnormal noise in hydraulic devices.

3. Leakage of water and oil in any area.

4. Check horn, buzzer, working lamp and monitor.

2-15

Operating

Starting and Stopping the Engine

Stopping the Engine (Normal Operation) Stopping the engine (Safety device)

1. Park the machine on flat, solid ground and lower the magnet to the ground.

Press the emergency stop switch and the engine will be shut down.

Position A: Operation of emergency stop.

Position B: Release of emergency stop.

LM-0027

A

2. When stopping the engine, keep the engine in low idling mode for about 5 minutes to lower the water temperature.

B

1-0017

● Stopping the engine suddenly without cooling

IMPORTANT

it off can cause damage to the engine parts.

● When B is located, the switch is released to the

SP H A

emergency stop.

● The engine emergency stop is not release by

SP

turning the key ON → OFF → ON.

2-0007

3. Turn the key in the starter switch to “OFF” position to stop the engine.

Pull out the key.

START ON ACC OFF

1-0008

2-16

Operating

Warm-up Operation

Warm-up Operation Warm-up procedures

WARNING

1. Warm up the engine

Neglecting the warm-up operation may cause delayed starting and stopping of each operation.

a) Automatic Warm-up After starting the engine, if the engine water temperature is low, the automatic warm-up starts and gradually increases the engine speed (for 10-15 minutes) to warm up the engine.

CAUTION ● Be sure to perform warm-up operation to prevent damage to the hydraulics as well as for safe operation. ● After warming up, be sure to confirm that the boom, arm, magnet, swing and travel operations can be properly performed before working the machine. ● Warm up the machine sufficiently in the winter or in cold areas.

C

The operating temperature of the hydraulic oil in this machine is 122-170°F (50-80°C) (the center of the oil thermometer.). If the machine is operated when the oil temperature is less than 68°F (20°C) [the second graduation of the gauge], the hydraulic components may be damaged.

C

2-0010

IMPORTANT The automatic warm-up is released by moving the throttle volume or operation levers.

Warm up the engine until the two of the water thermometers light (for liquid-crystal-equipped model)

After starting the engine and before beginning work, warm up the oil temperature to 68°F (20°C) (the second graduation of the gauge) by following the procedures.

E0862

H

b) Manual Warm-up Put the throttle volume to low-medium position and run for about 5-10 minutes.

2-17

Operating

Warm-up Operation 3. Confirm each operation

2. Warm up the hydraulics.

a) Repeat the following operations 3-5 times slowly to check whether they are normal or not.

If any abnormal operation such as delayed response occurs in any operation, warm up the hydraulics as described in step 2 again.

CAUTION ● Operating attachments should be done avoiding the interference with the machine’s body or the ground. ● Always verify the operation method before operating the machine. ● Do not run any component except magnet operation during warm up operation. ● Do not relieve for more than 30 seconds.

● Magnet operation

a) After warming up the engine, put the throttle control to medium position. b) Raise the gate lock lever. c) Slowly operate the arm (magnet) control lever and bring the cylinder to stroke end. d) Relieve it for less than 30 seconds. e) Slowly operate the arm (magnet) control lever and bring the arm and magnet to the opposite end. f ) Relieve it for less than 30 seconds.

LM-0050

● Arm operation

LM-0051

● Boom operation

LM-0049 LM-0052

g) Repeat step c)--- f) until the hydraulic oil thermometer bar graph indicates the second zone.

● Swing operation

LM-0053

H

C

H

● Travel operation 2-0012

LM-0054

2-18

1

Operating

Operations (Traveling)

This section explains the starting and stopping procedures of the machine.

4. Check the safety of the machine surroundings and sound the horn (give a signal), push the left and right travel levers slowly forward (travel forward) or pull them towards you (travel backward) to travel the machine.

How to start 1. Turn the throttle volume and increase the speed of the engine.

WARNING If the throttle volume is turned to high speed and the travel levers are operated rapidly, the machine will start rapidly.

Use extreme care when starting to more.

SP

SP H A

F R

2-0018

L

2. Fold the attachment so that it is 16-20 inches (40-50 cm) above the ground.

B

F Forward R Right turn L Left turn B Backward

40㨪50cm LM-0051E

The illustration may differ from that of actual machine.

A Travel unit 3. Check the direction of the crawler.

CAUTION When the travel unit is in the rear and the travel lever is pushed forward, the machine moves forward. When the travel lever is pulled towards you, the machine moves backward.

2-19

2-0020

Operating

Operations (Traveling)

How to stop IMPORTANT

CAUTION

For stopping the engine, refer to the section on starting and stopping the engine.

Park the machine on a hard, level and safe ground.

If it must be stopped on a slope, dig the magnet into the ground and block both tracks and take other necessary safety precautions.

1. Shift the travel lever into neutral.

N

2-0021

N Neutral 2. Turn the throttle volume to slow down the engine speed.

SP

SP H A

2-0066

3. Lower the magnet to the ground.

LM-0027

2-20

Operating

Operations (Traveling)

Travel lever When the travel unit is in the rear,

CAUTION

1 By pushing the right and left travel levers simul-

● Avoid rapidly turning the machine if possi-

taneously, the machine travels forward.

ble. Before spin turning the machine, come to a full stop. ● Traveling the machine on rough ground can cause damage and cause a shock loading to the machine.

Reduce the engine speed and travel slowly.

2 By pulling the left and right travel levers simultaneously, the machine will travel backward.

3 By pushing the left travel lever forward, the machine will turn right.

4 By pushing the right travel lever forward, the machine will turn left.

● By operating the left and right travel levers in opposite directions, the machine will turn around on the spot......Spin turn. Ԙ Ԛ

ԛ



ԙ

LM-0056

Right pivot turn (forward) Left pivot turn (backward) A Travel Unit

1-0034

WARNING ● Before operating the travel levers, verify the direction of the tracks.

When the travel unit is in the rear and the travel lever is pushed forward, the machine moves forward. When the travel lever is pulled towards you, the machine moves backward. ● When not traveling, do not place your feet on the travel pedals.





LM-0057

Left pivot turn (forward) Right pivot turn (backward) A Travel Unit

LM-0055



Forward Backward A Travel Unit

Spin turn Forward Backward A Travel Unit

2-21

LM-0058

Operating

Operations (Traveling)

Selection of travel speed Travel Speed

Indicator of Travel Mode

High (Lamp ON)

Low (Lamp OFF)

4. When traveling on rough ground, reduce the travel speed.

5. When changing direction, take care to make the largest possible turn. Avoid making rapid pivot turns or spin turns as much as possible.

Description Use when the ground is level. ● When climbing a slope and the power required becomes greater, it automatically changes to medium and when the power required becomes less, it returns automatically to high.

LM-0021

6. Check the route you will be traveling.

• Routes should be investigated in advance.

Use when climbing or descending a slope or when the ground is rough.

7. When moving the machine in an area of poor visibility, always have a signal man who sends signals to the operator.

And also, before crossing a bridge, pay attention to allowable weight of the bridge.

CAUTION Do not change travel modes during traveling.

Stop the machine and then change speeds.

Cautions for traveling

LM-0019

CAUTION

8. When traveling on paved roads, avoid damaging the road surface by placing boards, etc.

Place signs at dangerous places or signal men and take other necessary safety precautions.

9. When traveling on a ground abundant in gravel and pebbles, reduce the speed and loose the tension of track shoes a bit for traveling.

1. Before traveling, check the position of the travel motor.

2. When you travel, select flat and firm ground as much as possible.

3. During traveling, avoid obstacles.

IMPORTANT For machines using or equipped with wider shoes, avoid traveling on rough terrain.

Wider shoes are more prone to bending and breaking of the shoe.

2-22

Operating

Operations (Traveling)

10. It is dangerous to travel with an iron scrap being stuck to the magnet

● This may allow the iron scrap stuck to be fallen by the shock of traveling.

● There may be a risk of overturn as stability of the machine will change while traveling.

LM-0025

11. Do not travel the machine with the elevator cab lifted up. ● Vibration of elevator mechanism may increase which in turn will damage the machine.

LM-0026

2-23

Operating

Operations (Traveling)

Driving uphill and downhill (slopes) 6. Parking or stopping on a slope is dangerous. Do not park or stop on a slope.

If parking or stopping on a slope is unavoidable, dig the magnet into the ground, put the levers in neutral and block both the tracks on the downhill side.

WARNING Traveling on a slope with attachments raised is very dangerous. It may cause a turn over. ● Travel at low speed and position the magnet 8-12" (20-30 cm) above the ground level. ● When the machine becomes unstable, ground the magnet and stop the machine.

LM-0028

LM-0024

1. Climb up and down the slope at a right angle.

2. Put the machine in low travel mode.

3. It is very dangerous to change the direction or swing the upper structure on a slope.

It is also very dangerous in particular to swing it towards the down side of slope with the magnet loaded with soil and the like.

(The machine may slide or turn over.)

4. Before traveling on a slope, clean the shoe if it is clogged and take other precautions to prevent slipping.

5. The maximum slope climbing ability is 35° (70%). This value varies depending on the shoe type and the road surface, limit traveling to slopes of 30° or less.

CAUTION Do not operate the engine with the machine at 35°.

The engine or hydraulic devices may be damaged.

2-24

Operating

Operations (Traveling)

Towing Method 2. Towing heavy objects (less than 10 tons)

WARNING

a) Attach wire rope to the towing lug on the lower frame using shackles. b) Position the rope in-line with the lower frame. c) To prevent collisions, tow slowly at low speed.

Use of an unsuitable wire rope and/or improper towing may invite a serious accident resulting in injury or death. ● When towing the machine, use wire ropes strong enough for the traction load. ● Do not use wire ropes which have kinks, twists, or damage for towing. ● Do not allow anyone between the towing vehicle and the excavator. ● Do not tow the machine on slopes because there is a risk of the machine sliding sideways. ● Take measures to prevent damage to ropes and the excavator by placing wood protectors between the towing wire ropes and the excavator. ● Tow the machine slowly in order to lessen the impact on the machine. ● Connect the excavator and towing vehicle to form a straight line.

2-0032

CAUTION Tow the machine slowly as to not to impact the machine. Collisions can cause damage to the lower frame and also accidents.

1. How to tow the machine when it can not pull out of soft ground. a) Attach wire rope to the lower frame. b) To prevent damage to the wire rope, always use padding on sharp edges. c) To prevent collisions, tow slowly at low speed.

2-0031

E0950

2-25

Operating

Operations (Swing)

Swing Operation 4. Since the swing continues for a while due to inertia even after the operation lever is returned to neutral, try to stop the swing safely before it hits anything.

WARNING ● Before the operation, verify the operating instructions.

● Make sure that unauthorized people can not enter the swinging job site. ● Before swinging, verify that the surrounding areas are safe. ● When using the machine equipped with a long arm or heavy weight attachments, stopping swinging may be delayed due to inertial force. ● Swinging on a slope may cause the machine to become unstable resulting in turning over. ● Avoid swinging on a slope because it may cause turning over or sliding. It is dangerous to swing on a slow towards the down side of slope with dirt loaded on the machine because it increases inertial force.

LM-0059

Do not enter the swinging area.

CAUTION Flattening earth or sweeping away rocks causes excessive force to be applied to booms and arms, and it may cause damage to the machine.

Do not press the magnet teeth into the ground during swinging.

When operating on slopes, keep the footing level.

KHP1532-00

0-0086E

Do not enter the swinging area.

When the machine makes a turn, you may be caught in the upper part of swinging body.

Do not attempt to enter within the range of the swing.

LM-0061

Never work with swing force.

Swing Operation Procedure 1. Put the lock lever to “Release” (Run) position.

2. Press the horn switch which is located on the top of the left operation lever to alert people in the job site.

3. After checking the surroundings for safety, operate the levers for the swing operation.

LM-0060

Swinging on a slope is dangerous.

2-26

Operating

Operations (Attachment)

Operations (Attachment) Arm Operation

WARNING Always verify the operation methods.

The machine is operated by the right and left operation levers.

ISO (JIS) Operation Method Right Operation Lever...

Used to control the boom and the magnet.

Left Operation Lever...

Arm and swing operation When you release your hand from the lever, it returns to the neutral position and the machine maintains that position.

LM-0064

Magnet Operation Boom down

Arm out

Swing left

Open the magnet

Swing Close the right magnet

Arm in

Boom up

ISO (JIS) Standard Operation Method

LM-0030E LM-0065

Swing Operation Boom Operation

2-0037

LM-0066

2-27

Operating

Operations Cautions for operations

Characteristics of Hydraulic Excavator

1. Listen for unusual noise from the engine, hydraulic equipment, reduction gear, travel unit and front attachment area.

The following are characteristics of the machine excavator and not problems.

a) Creaking from any parts b) Wearing noise c) Vibration noise d) Striking noise at constant intervals e) Irregular noise of hydraulic devices

● When the arm or magnet is operated in the air, it may stop suddenly. This is because the pump discharge can not keep up with the movement of the cylinder caused by the attachment weight. ● During swing or travel, or when starting or stopping, some sound may be heard in the hydraulic circuit. This sound comes from the brake valve. ● The reason the swing does not stop immediately after returning the swing lever to neutral is that the machine is being protected from shock and operator fatigue is being reduced. ● When lowering the boom, the sound heard is that of the oil flowing inside the valve.

2. If the H lights on the hydraulic oil and water thermometer gauge light up, slow down the engine speed and stop operations for the unit to cool.

Check coolant water and radiator.

3. If water or oil leakage is found or any problem with the meters, monitor or operation levers is found, stop and check and make repairs.

WARNING If an abnormality is detected in the machine, immediately stop the operation.

When you find something is wrong with the machine while operating, immediately stop the operation, check and repair the problem.

Do not use the machine until repairs have been finished.

LM-0016

2-28

Operating

Operations

Cautions for Interference Watch out for interference with the cab.

WARNING The magnet and the cab may interfere each other in some attachments being mounted.

Pay attention when operating the magnet near the cab.

LM-0067

Watch out for interference with the tracks. ● If the magnet is placed at right angle or at a slant to the footing, it may interfere with its shoe for which must be careful.

LM-0068

2-29

Operating

Special Attachment Selector switch for 2-speed

CAUTION

For machines equipped with 2-speed merging circuit, the first speed and the second speed can be selected by the switch illustrated below.

● When attaching hydraulic fork, etc., it is necessary to select models which are compatible with the excavator. When selecting special attachments, consult with our dealers or business offices in your area. ● When using special attachments, please read carefully the instructions for the special attachment and operate the machine safely preventing the possible damage to the excavator and the special attachments.

̖​̖​̖ CRUSHER (2 PUMP) ̖​̖​̖ DIGGING

MAGNET (1 PUMP) LM-0052E

2-30

Operating

Operating Instructions (Cautions)

Cautions for operations Cautions when attracting scrap iron

1. Do not use this machine except for permitted applications.

Hydraulic shovels are designed for use in excavation and loading. Usage other than applications for vehicle type construction machine is prohibited.

When attracting an iron scrap with the magnet suspended in the air, it may damage the machine by a shock when it is being attracted.

2. Never drive or operate this machine in a rough manner!!

All operators should always operate the machine carefully and safely to prevent injury to themselves and others and to prevent damage to the machine.

Operating on slopes

LM-0070

When operating on slopes, keep the footing level.

Boom Operation When lowering the boom, lower it as smoothly as possible to reduce shock loading.

LM-0012

Carry out warm-up operation When the oil temperature is still low, an alarm of speed drop in the generator may be issued.

In this case, perform warm-up operation.

2-0055

Warming up!

LM-0028E

2-31

Operating

Operating Instructions (Cautions)

Prohibition against an abrupt operation!

Observe rating of 60%ED for rating of actual operation for the magnet

When an iron scrap being attracted, do not make an abrupt operation such as when starting and stopping.

Otherwise, the scrap being attracted may fall.

Operation exceeding the rating causes to reduce attracting strength of and to damage the magnet.

The magnet mounted on this machine is for use at a normal temperature.

It is limited to use for steel materials with the temperature of less than 100°C. (Otherwise, machine may be damaged.)

Do not control the switch for selecting operation mode during attracting operation.

Otherwise, this may cause breakdown of the control equipment.

LM-0071

Prohibition against release of iron scrap being attracted!!

It is very dangerous to release an iron scrap being attracted in the air as the scrap dropped scatters.

LM-0074

Prohibition against operation of pushing and scraping up steel materials!!

Do not push out and scrape up steel materials such as iron scrap with the use of the magnet (This may cause the machine to be damaged.)

LM-0072

Prohibition against operation in the water!!

Although the magnet is constructed rain-proof, it cannot be operated in the water.

The machine will be damaged if operated in the water.

LM-0075

LM-0073

2-32

Operating

Operating Instructions (Procedures)

Magnet

efficiently.

Recommended magnet for mounting on this machine is of 60% ED rating.

★ "60% ED" means the operation in which 60% of the working hours is spent for attraction.

The rating allows the magnet operation such as attracting and releasing speed to be performed most

Attraction

Pause

Attraction

Pause Continuous

60%ED=6 minutes (attraction)

6 minutes (attraction)

4 minutes (pause)

4 minutes (pause) LM-0031E

(Value of "%ED" is indicated on the name plate by stamping.)

Or, as in the case of the above, energizing (attracting) time takes up 60% against total time of attraction plus pause.

CAUTION ● Longer time of attraction allows the coil temperature to rise excessively which in turn shorten the life of magnet due to deterioration of electrical insulation.

CAUTION ● Connect or disconnect the magnet plug after the engine has been stopped. ● Connection or disconnection of the plug while it is being energized (attraction or release) is very dangerous as high- tension voltage is applied.

In addition, the magnet itself and the equipment controlling electric current may be damaged by high voltage serge.

2-33

Operating

Operating Instructions (Procedures)

Operation of elevator cab Control the cab lifting switch on the console on the right to adjust the cab to a height required.

The switch cannot be operated when it is operated in magnet mode.

LM-0124

CAUTION Get on and off the elevator cab with the cab lowered to its extreme.

LM-0125

2-34

Operating

Operation of magnet

Operation of magnet the magnet to discharge so that it can release the scrap quickly then turning off power supply to the magnet automatically after a few seconds. *1 Minimum speed for the magnet mode:1500rpm-1 Minimum engine speed required for generation of electricity.

Ԛ

Ԙ

ԙ

LM-0126

Function of equipment ●Monitor (magnet mode) Throwing the mode selector switch located on the upper right of the monitor 1 upward allows it to turn into magnet mode.

Since the engine speed will not be dropped below the minimum speed (*1) for the magnet mode, the operation of the magnet can be possible.

If it is entered in the magnet mode with the engine speed of less than that below the minimum speed for the magnet mode, the engine speed automatically increases to the minimum speed for the magnet mode.

It is so designed that the elevator cannot be lifting up and down while operated in the magnet mode.

●Attraction/Release switch The switches on the control levers on both sides function as the switch for attracting and releasing while operated in the magnet mode.

Pushing the control switch on the left 2 makes it attract (strong excitation first then rated attraction), and pushing the switch on the right 3 makes it release then turning off power supply to the magnet.

The magnet attracts the scrap quickly with strong excitation immediately after attracting operation then switched to the rated voltage after a few seconds allowing it to keep it on attraction.

When releasing operation is carried out, it allows

2-35

Operating

Operation of magnet

Operation control Starting-up

Operation

1. Move the ignition key to "START" position by following the starting procedure for the standard machine.

3. When it has been turned into magnet mode, actual attracting and releasing operation can be possible.

START

LM-0127 LM-0032E

2. Throwing the mode selector switch located on the upper right of the monitor upward allows it to turn into the magnet mode.

1. Place the magnet on the scrap.

2. Confirm the safety around the work site, push the attracting switch once on the control lever on the left to allow the magnet to attract the scrap.

Left control lever

LM-0128

LM-0033E

3. An animation appears on the monitor screen indicating the scrap is being attracted.

LIFT

LIFT

LIFT

LIFT

LIFT

Magnet adjust

LM-0034E

2-36

Operating

Operation of magnet 6. Carry the magnet to a position where intended to be moved.

4. The scrap starts to be attracted to the magnet.

7. After the iron scrap has been carried, press the release switch on the control lever on the right once at the position to be released to allow the magnet to release it.

Right control lever

LM-0132

SP H A

5. Magnetic intensity can be adjusted while loads are being attracted.

Adjustment of loading amount or separation of loading materials is possible. (The magnet intensity can be adjusted to 5 levels.) * Refer to page 2-40 for adjustment of magnetic intensity.

START

ACC

ON

OFF

LM-0036E

8. An animation appears on the monitor screen indicating the scrap is being released.

LIFT DROP

DROP

DROP

DROP

Magnet adjust LM-0037E

LM-0035E

9. If release of the scrap is retarded, releasing action, while stand-by screen is being displayed, can be changed by adjusting the releasing current to 5 levels.

There is no need to adjust the releasing current if the scrap can be released quickly.

Control of engine key switch during attraction is prohibited!!

Do not control the engine key while operating attraction.

Otherwise, it may cause the lifted cargo to be dropped and the power switchboard to be broken.

STAND BY

OFF

Drop Adjust

LIGHT

LM-0038E

OFF

* Refer to page 2-39 for adjustment of releasing current.

LM-0134

10. Repeat the operation afterward.

2-37

Operating

Operation of magnet

Stopping 1. Confirm that the stand-by screen is displayed.

Do not stop the engine while operating attraction or release.

STAND BY

Drop Adjust

LIGHT

LM-0039E

2. Throwing the mode selector switch located upper right of the monitor downward turns it into the standard mode.

Rotation of generator stops when turned it into the standard mode.

LM-0139

3. Turn OFF the engine.

Never stop the engine while it is operated in the magnet mode.

Otherwise, the machine may be damaged.

OFF

LM-0140

2-38

Operating

Monitor operation in detail

Monitor operation in detail

2. Releasing current can be adjusted (5 levels) while it is on the stand-by screen.

Start-up screen Notch

Releasing current (% against set current)

On φ1,300 magnet (set current :18A)

2

120%

-21.6A

1

110%

-19.8A

0

100%

-18.0A

-1

90%

-16.2A

-2

80%

-14.4A

To adjust releasing current, it can be selected 2 ways: using panel switch and using dial.

Adjustment by using panel switch has been set on shipment out of factory.

In case where the adjusting method is changed, consult a SUMITOMO service shop.

LM-0053E

1. When the key-switch on the construction machine is turned ON and the mode selector switch is thrown upward (to magnet mode), it moves to the start-up screen.

In addition, the generator is driven changing it into the condition of preparing operation.

Dial adjusting release current

2. On the start-up screen in which the "magnet" will not be controlled, the generator will not be driven and an interlock circuit is provided so that attraction and releasing operation cannot be carried out.

STAND BY

Panel switch adjusting release current (normal)

Drop Adjust

Stand-by screen

LIGHT

STAND BY LM-0041E

3. If the monitor illumination disturbs visibility such as when operating at night, touch the "light out" button in the stand-by screen.

Back light (green) in the monitor goes out.

Drop Adjust

When under stand-by, releasing current can be adjusted (at 5 levels) LIGHT

STAND BY Current (increase) Level Current (decrease)

Drop Adjust

LM-0040E

1. Carrying out attraction while the stand-by screen is being displayed allows it to perform attraction and also the attraction screen appears on the monitor.

LIGHT

LM-0042E

2-39

Operating

Monitor operation in detail

Attraction screen

Release screen

LIFT

LIFT When in attraction screen, rated voltage can be adjusted (at 5 levels)

Magnet adjust

LM-0044E

1. After the release operation is completed, it returns to the stand-by screen automatically.

Voltage (increase) Level Voltage (decrease)

2. If release of the scrap is retarded, adjust the releasing current while stand-by screen is being displayed.

LM-0043E

1. When in attraction screen, rated voltage for attraction can be adjusted so that the magnet intensity can also be adjusted (selected to 5 levels).

Notch

Adjusted to magnetic intensity of

5

100% of rated intensity (200V)

4

50% of rated intensity (100V)

5

40% of rated intensity (80V)

2

20% of rated intensity (40V)

1

10% of rated intensity (20V)

LM-0139

3. When finishing the magnet operation, throwing the mode selector switch located upper right of the monitor downward (to standard mode) allows it to return to the start-up screen and the generator stops rotation.

2. Carrying out release while the attraction screen is being displayed allows it to perform release and also the release screen appears on the monitor.

2-40

Operating

Monitor operation in detail

Alarm (AL) screen

WARNING

Warning items are indicated

Reset Warning items appear

LM-0045E

1. Detection of warning allows it to shift to the alarm (AL) screen.

2. Waning is to be detected only while operated attraction and release.

3. Warning is detected when: • Generator rotation drops.

When the speed is dropped below 1,600rpm for more than 3 seconds.

• Over-current.

When it reaches more than 140% of the rated current.

• Magnet is over-heated.

When it reaches more than 140% of the rated current.

• Control panel is over-heated.

When temperature of IGBT reaches more than 80°C. When temperature of CPU reaches more than 70°C. • Battery voltage drops.

When battery voltage (24V) drops below 18V. • Voltage rise.

When voltage across the condenser rises above 800V. 4. When in an alarm (AL), the monitor color turns into orange, the back light flashes, and the alarm buzzer makes an intermittent sound.

5. Function of attraction and release is maintained to hold the lifted iron scrap even after the alarm (AL) has been actuated.

When the speed of generator drops however, the scrap being lifted up will fall down in proportion to the speed drop.

6. If the alarm (AL) has been actuated, release the scrap as quickly as possible, locate the cause of faults, and remove the failure to start the operation again.

2-41

Operating

Monitor operation in detail

Error (ER) screen

4. Indicating detail information by selection of error (EL) items When an error item occurred is selected, it shifts to the detail indication screen.

Remove the failure in accordance with "cause of failure" on the detail indication screen, to start the operation again.

ERROR

Drop of generator speed

5. Reset to shift it to start-up screen then the machine can be operated again.

Error (EL) detailed indication screen

Detail

Reset LM-0046E

1. Detection of a fault allows it to shift to the error (ER) screen.

2. Faults are to be detected only while operated attraction and release.

However, over-heat of the control panel is to be detected even while it is on stand-by so that operation of attraction and release becomes impossible.

Over-current

Over-heat

Over-current

Control panel Over-heat

Cause of failure

Cause of failure

• Cable is short-circuited • Cable is short-circuited to grounded • Plug is short-circuited

• Attraction time • Cooling fan is stopped • Air-filter is clogged

Inspection Repair

Inspection Repair

Return

Return

Reset

Reset

3. A fault is detected when: • Voltage rise.

When voltage across the condenser rises above 900V, it allows the device to stop.

Short-circuit

Voltage rise

Short-circuit

Voltage rise

• Over-current.

When current of more than 140% of the rated is kept flowing for 10 seconds, it allows the machine to stop.

Cause of failure

Cause of failure

• Cable is short-circuited • Cable is short-circuited to grounded • Plug is short-circuited Component failure

• Consult dealer or manufacturer

• Control panel is over-heated.

When temperature of IGBT reaches more than 90°C. When temperature of CPU reaches more than 75°C. Although 1 cycle of operation is to be maintained even after a trouble has arisen, ensure the safety and release the iron scrap within 3 minutes.

In order to protect the machine, it allows the machine to be stopped forcibly after more than 3 minutes have passed and attracted scrap drops as a result.

In case where it has been overheated, the machine cannot be operated unless temperature of IGBT drops below 80°C and that of CPU below 75°C.

Inspection Repair Return

Reset

Return

Reset LM-0047E

• Short-circuit.

If shot-circuit current flows, it allows the machine to be stopped.

2-42

Operating

Monitor operation in detail

On engine speed in magnet mode Throttle control One-touch idling SP H A SP

Right control lever

2-0066

While operating in magnet mode, it is automatically controlled so that the engine speed will not be dropped below the minimum speed for the magnet mode (*1).

SP H A

If it is entered in the magnet mode with the engine speed less than that below the minimum speed for the magnet mode, the engine speed automatically increases to the minimum speed for the magnet mode.

START

ACC

ON

OFF

LM-0103

In order to prevent the magnetic intensity from falling, the engine speed will not drop only to the minimum speed for the magnet mode (increasing speed is possible).

Low idling speed to/from original speed is switched every time the idling switch is pressed.

The idling speed while operated in the magnet mode gets to the minimum speed for the magnet mode (*1).

IMPORTANT Although the engine speed cannot be lowered only to the minimum speed for the magnet mode, this is not a fault.

Attraction will be impossible. *1 Minimum speed for the magnet mode:1500rpm-1 Minimum engine speed required for generation of electricity.

Auto idling

AUTO

n/min

1-0029

If the time has passed more than 5 seconds with the control lever put at its neutral position and also with the magnet acting no attraction while operating in magnet mode, the engine will run at an idling speed.

Carrying out one operation of control lever, of throttle potentiometer, or of attraction allows the speed to return automatically to original rotation.

The idling speed while being operated in the magnet mode gets to the minimum speed for the magnet mode (*1).

2-43

Operating

Bucket: Turning Over and Replacement

Bucket: Turning Over and Replacement 4. Keep sand or mud off the removed pin.

CAUTION

a) Removal Remove the ring 1 with a screwdriver 2 and pull out the lock pin 3. b) Installation After inserting the lock pin 3, install the ring rock 1.

● Park the machine on flat, solid ground.

When working with others, check that signals to be used are well understood. When performing hammer operations, use protective gear (safety glasses, safety shoes, etc.) ● After turning over or replacing the bucket, adjust the backlash of the bucket and check the operation before use.

ԙ

Ԙ

Removal 1. Position the back of the bucket 1 parallel to the ground.

Ԛ

2. Remove the lock pin 3 on the bucket link 2 and pull out the pin.

Ԛ

3. Remove the lock pin 5 on the arm side 4 and pull out the pin.

Removal/installation of lock pin

2-0058

Turning the bucket over 1. Remove the bucket. ԙ

ԛ

2. Slightly raise the arm and turn the bucket 180°.

Ԝ

3. Put on the bucket.

Ԛ

IMPORTANT When the bucket is turned over, it works as a shovel. The operation of the bucket levers (digging and dumping) are reversed compared to that of back hoe work.

Ԙ 2-0057

IMPORTANT ● When the pin is difficult to remove, it may be because the weight of the load is on it.

● Be careful not to damage the O-ring and dust seals when removing the pins.

ࠑ 2-0059

2-44

E1050

Operating

Bucket: Turning Over and Replacement

Installing the bucket 1. Clean the pin and pin hole of each area and grease them well.

2. Replace the O-rings and dust seals.

3. Align the bucket with the hole on the arm side 1 and insert the pin 2.

4. Align the bucket with the hole on the bucket link side 3 and insert the pin 4.

5. Install the lock pins and grease the pins.

(EM system type should be greased also.)

Ԛ

Ԙ ԙ

ԛ

2-0060

E1060

2-45

Operating

On Completion of Daily Operations

On Completion of Daily Operations Parking the machine

CAUTION

1. Stop the machine on level and solid ground which is free from the danger of falling rocks or standing water.

When parking the machine on the road, put up signals and/ or barricades which can be seen at night from other cars.

2. Position the arm vertically and lower the magnet to the ground.

LM-0029 LM-0027

3. Pull the gate lock lever to lock the magnet.

4. Idle the engine at low speed for about 5 minutes and cool down the engine.

5. Stop the engine and remove the key.

LM-0030

6. Close the windows and raise the left console box and gate lock.

7. Lock the cab door to prevent unauthorized persons from entering the machine.

2-46

E1070

Operating

On Completion of Daily Operations

Inspections after finishing operations 1. Cleaning and inspection Check each area for oil and water leakage and any damage.

Also wash the machine as part of the inspection.

In particular, clean dirt and sand from the crawler.

(When washing the machine, be careful to avoid splashing the electrical parts.)

WARNING Do not have flames near by while refueling.

2. Filling the fuel tank Stop the engine to fill the fuel tank. When filling the tank, take care to prevent dust or water from getting into the fuel tank.

● When it is cold (outdoor temperature less than +32°F [0°C]), drain the water which has collected in the space fuel system (fuel tank and fuel filter) to prevent freezing.

(Wipe off any spilled fuel.)

Check each part of the machine after operations. (including washing the machine).

● If any problem is found, correct it immediately! ● Fill the fuel tank to the full after daily operation is finished.

Specially, in the following situations, perform inspection and repair procedures: After operations at very dusty locations In freezing or very hot weather After operations in swamps or locations with soft ground

LM-0031

E1080

2-47

Operating

Operating in Cold Climates Anti-freeze mixing

When the temperature drops, the engine may become hard to start or the coolant may freeze. Take the following precautions in cold weather.

Anti-freeze is used to prevent the engine coolant from freezing during the winter or in cold areas. Mix it with water according to the lowest expected temperature.

Fuel and lubricants

Anti-freeze Mixing Ratio

Replace the lubricants for each device with that of lower viscosity. For the designated viscosity, refer to the section on “Fuel and Lubricants According to Ambient Temperature.”

As for fuel, use fuel with fluid point of 41°F (5°C) lower than the ambient temperature.

Battery

ࠑ F Lower Temp.(͠)

10.4 3.2 -4 -13 -22 -32.8 -45.4 (-12)(-16)(-20)(-25)(-30)(-36)(-43)

Mixing Ratio (%)

70 65 60 55 50 45 40

Anti-freeze 30 35 40 45 50 55 60 Water

Anti-freeze mixing ratio The machine has long-life coolant (LBX Company LLC genuine coolant - Clean Coolant) when it is shipped from the factory.

When the temperature is below 14°F (-10°C), refer to the anti-freeze mixture percentage chart and adjust the concentration.

WARNING Battery produces flammable gases, always keep flames away.

The battery liquid is dangerous. Prevent it from getting into the eyes or on the skin. If you spill it on your skin or get it into your eyes, wash it off with lots of water and see a doctor for treatment.

● It is recommended that the mixture ratio be controlled by coolant concentration gauge.

CAUTION

When the temperature lowers, the battery charge also lowers. If the battery charging rate is low, the battery solution may freeze.

Keep the charging rate close to 100% to prevent freezing.

Use of anti-freeze ● The concentration of the anti-freeze should be in the range of 30-60%. If the concentration is weak, the rust-proof performance is adversely affected. ● When water is reduced naturally, fill with 50% diluted water. ● Use always coolant with ASTM D3306 or equivalent, and do not mix with other kinds. ● Anti-freeze is flammable. Do not have open flames near it. ● Always use soft water for coolant.

● Measure the specific gravity and calculate the charging rate using the table below.

Liquid Temperature Charging Rate

68ࠑ F (20͠)

32ࠑ F (0͠)

14ࠑ F -4ࠑ F (-10͠) (-20͠)

100%

1.28

1.29

1.30

1.31

90%

1.26

1.27

1.28

1.29

80%

1.24

1.25

1.26

1.27

When the weather gets warmer

75%

1.23

1.24

1.25

1.26

When the seasons change and the weather gets warmer,

● When adding distilled water, add just before be-

● Change the lubricants for each device to the

ginning operations to prevent freezing.

proper viscosity. ● Completely drain the anti-freeze (unless permanent type is used), flush the cooling system and add clean soft water.

2-48

E1090

Operating

Operating under Extreme Conditions 4. Frequently check the level of electrolyte in the battery and add distilled water as necessary.

Refer to the section on “Fuel and Lubricants According to Ambient Temperature” to choose the suitable items.

5. During operations notice the water temperature and hydraulic oil thermometer. Do not allow these systems to overheat.

Operating in cold weather (below 32°F [0°C])

Operating in dusty or sandy areas

1. In winter or cold weather, warm up the machine with special care.

Extend the warm up time and cover the front of the radiator and oil cooler. After warming up, remove the covers.

1. Check Air Cleaner Frequently check the elements of air cleaners, and clean or change the elements and dust cups regardless of exchange intervals.

2. Until the machine is sufficiently warmed up, never attempt to rapidly swing the upper or operate the travel motor.

If any rapid operations attempted when the machine is not warmed up, the hydraulic components may be damaged.

2. Securely tighten the breather cap of the hydraulic oil tank to prevent sand and dust from entering the hydraulic circuit.

3. After warm up, be sure to confirm that the boom, arm, magnet, swing and travel operations can be properly performed before working the machine.

4. Clean radiator fin, oil cooler fin, and radiator grill.

4. A time lag may result when the operation levers are operated in the winter or in cold weather.

This is due to the hydraulic oil not being warmed.

1. Check that the drain valves, cocks, bolts, etc. are properly tightened to prevent any salt entry.

3. Always keep the lubricated parts such as the pins and bushings clean. Clean the grease fittings before greasing them.

Operating near the ocean

2. After operations, wash salt off from the machine thoroughly. Especially, take special care when cleaning electric devices and hydraulic cylinders to prevent erosion.

5. When the machine is left outside for more than 12 hours or longer in extremely cold weather, remove the battery and store it in a warm place.

6. Drain the water collected in the fuel system to prevent it from freezing.

Operating in wet or on soft ground

7. After operation, clean the tracks and place the machine on wooden blocks to prevent the tracks from freezing to the ground.

Minimize the exposed portion of the cylinder rods.

Wipe off any water on the exposed cylinder rod.

1. Moisture or mud will cause the paint, wiring and metallic parts to deteriorate. When operating the machine, keep it as dry as possible and grease it.

Operating in areas with the danger of falling objects

Operating in hot weather (above 95°F [35°C])

1. Attach the head guard for the cab.

1. Always fill the coolant to the specified amount, check cooling system for leakage, replace the coolant to flush the cooling system and prevent deposits or rust as required.

2. Keep the cooling fins of the radiator clean.

3. Always keep the belt on the water pump adjusted properly.

2-49

Operating

Transportation

Loading and Unloading

Switch settings during loading and unloading

WARNING

WARNING

1. Designate a signal man and follow his commands when loading and unloading the machine.

2. When loading and unloading, select level, solid ground and keep sufficient distance from a shoulder.

Be sure to apply the parking brake and block the tires of the transport truck.

3. The ramp used (to the track platform) should be strong enough to support the weight of the machine. Use hooked ramps which will not slip off the platform.

4. When it is raining or when there is snow, carry out measures to prevent slipping.

1. Press the auto idle switch to AUTO idle “OFF”.

(When it is in automatic, the engine speed sometimes decreases. Put it into one-touch to avoid this decrease.)

2. Put the machine in medium or low travel mode.

(If it is in high, the travel speed is faster which may cause shock loading on the machine and is dangerous when loading or unloading.)

3. Do not operate the idle switch.

(The engine speed changes, so do not operate it.)

4. Do not operate any lever other than the travel level when on a ramp.

AUTO

n/min

2-0061

Turning off the indicator is confirmed

Transportation CAUTION 1. Investigate road width, bridge, rode and traffic condition for planned routes in advance.

2-50

E1110

Operating

Transportation

Loading and Unloading 2. Align the centers of the machine to be loaded and the trailer platform. In addition, align the centers of the ramps and the shoes.

WARNING ● Never attempt to load or unload the machine by jacking it up with the boom just because the trailer floor is low. ● Clean the mud off the shoes to prevent the machine from slipping on the ramps. ● When climbing the ramp with the front attachment removed, position the counterweight upward.

A

B

C

E

D 2-0063

The illustration may differ from that of actual machine.

A Center of trailer platform and loaded machine B Trailer platform C Center of ramps and shoes D Tracks E Ramps 3. Do not steer the machine on the ramp. Drive up the machine at a low speed without stopping.

LM-0150

DANGER

The illustration may differ from that of actual machine.

A 15° or less B Support

Never attempt to steer the machine on the ramps. If it must be steered, drive it off the ramps first and correct the direction.

● Before loading or unloading the machine, warm up the machine sufficiently.

4. When the machine reaches the top of the ramps and it is about to touch the floor of the trailer, the center of gravity changes suddenly. Keep control of the machine.

1. Apply the brake of the trailer and block the tires to prevent the trailer from moving. Position and secure the ramps so that the centers of the machine and the trailer are aligned.

• Use ramps which are wide, long and thick enough to assure safe loading and unloading.

If the ramps deflect excessively, support them with blocks or similar objects.

E6870

2-51

Operating

Transportation

Tie down on transport vehicle

LM-0151

The illustration may differ from that of actual machine.

A Wire Rope B Block C Stop Block D Padding 1. Check that the machine is properly loaded in position and that the trailer is level.

2. Fold the magnet and then fold the arm. Place wooden blocks on the platform of the trailer.

Lower the boom slowly and adjust the wooden blocks so that the magnet and arm rest upon them.

3. Stop the engine.

• Make sure that the radio antenna is lowered.

• Adjust the mirror so that it will not hit against an object around the machine during transportation.

4. Lock the doors (the operator’s cab on both sides).

5. After verifying that there are no problems with the machine, block the tracks and tie down the machine with chains, wire ropes, etc. so that it does not move during transportation.

6. Verify that everything is blocked and tied down before transporting the machine.

CAUTION Movement of the machine during transportation is dangerous.

Secure the machine firmly with wire rope or the like so that it won’t move from vibration.

2-52

E6880

Operating

Transportation

How to lift up machine

5. Pass the wire rope through the truck frame on both sides to lift it up slowly.

Set the lifting angle 1 between 30° and 40°.

Warning ● Stop the engine before lifting up the machine.

● Use a wire rope with sufficient strength for lifting up.

● Do not apply an abrupt load to the wire

②

rope and/or to the tool for lifting up. ● Do not allow anyone to be under or around the lifted machine. ● Remove the special attachment before carrying out lifting operation.

Otherwise, it is dangerous as this allows losing balance of the machine. ● Carry out lifting operation on a flat ground.

③

1. Fully extend the magnet and the arm cylinder, and lower the boom slowly.

LM-0186

Ԛ

The illustration may differ from that of actual machine.

Ԙ

2 Wire rope 3 Supporting bar

ԙ

6. After the machine has been lifted off the ground, lift it up slowly while checking the hooking condition and the lifting position.

LM-0152

The illustration may differ from that of actual machine.

2. Stop the engine and get out of the machine.

3. Use an appropriate length of the wire rope 2 and the supporting bar 3.

The machine could interfere with the wire rope while it is being lifted up.

Protect the machine with blocks and clothes.

4. Position the crane at a suitable place.

E6890

2-53

Operating

Transportation

240X2-MH Outer Dimensions (units: mm)

Transportation mass 31.2 t

2-54

LM-0049E

Operating

Storing During Storage

If the machine will be stored for a month or longer, make sure the followings to prevent decrease in machine performance for the next time it is operated.

If the machine is stored for a month or longer, check the operation of each function and drive rust prevention every month. This will prevent rust in the engine, deterioration at the seals and rusting in hydraulic parts. Check if there is any coolant.

Before Storing 1. Wash off the machine, especially the crawler.

● Before operating the machine, wipe off the anti-

2. Lubricate each part.

• Grease the attachment and turntable bearing.

rust oil from the hydraulic cylinder rods.

● Carry out the operation of attachment, swinging,

3. Check the lubricant amount and cleanliness.

• Add if low.

• Replace when excessively dirty.

and traveling slowly with the engine running at a low speed.

4. Refer to the storage instructions in the operator’s manual for the engine. If the temperature is low with the possibility that the coolant may freeze, mix it with anti-freeze or drain it completely.

WARNING If the rust-prevention operation must be performed indoors, open the windows and doors for ventilation to prevent gas poisoning.

5. After cleaning and washing, store the machine in a dry, indoor site. If it must be stored outdoors, lay timber on the ground under the machine and protect the machine with covers.

LM-0085

(Outdoor storage) a) Select a well drained, ventilated area. b) The floor should be of level concrete, broken rocks or gravel or place a suitable wooden block under the tracks to prevent the machine from being in direct contact with the ground. c) After following steps 6-9 below, cover the machine to prevent rain from entering the house to prevent rust.

6. Lower the magnet to the ground and block the tracks.

7. Coat the exposed area of the piston rod of all hydraulic cylinders with anti-rust coating.

8. Put all the operation levers into neutral.

9. Remove the battery, completely charge it and store it or remove one terminal ((-) terminal).

2-55

Operating

Storing

After Storage (when the machine is used again) 1. Check the levels of oil and water and fill as necessary.

Especially check carefully if the coolant is in.

Since the lubricants and grease deteriorate during storage, check them carefully when the machine is used again.

2. Completely wipe off the anti-rust oil.

3. After starting the engine, take enough time to warm it up and repeat the travel, swing and digging operations several times each.

Warming up!

LM-0028E

● If the machine is stored without the monthly rustpreventing operation, contact the nearest distributor for instructions.

2-56

Inspections and Maintenance Inspections and appropriate maintenance of the machine is vital to keep it performing at its best longest and to prevent it from running down.

This section covers the regular checkup, maintenance, and adjustment procedures of the machine.Follow each step of the procedure carefully and safely when you work on the machine.

Contents • General Cautions • Periodic Maintenance Check List • Grease / Oil and Elements • Inspection Prior to Operation • Greasing Attachments • Greasing Elevator Cab • Fuel System • Engine • Hydraulic Oil • Battery • Inspection of accessories • Upper Frame • Swing Unit • Travel Unit • Magnet • Air Conditioner • Routine Replacement Safety Parts • Troubleshooting • Contacting Us

For specific details regarding the engine, refer to the manufacturer's Instruction for Use also.

3-0

MAINTENANCE

• Bolt Torque

Maintenance

General Cautions Release the hydraulic pressure prior to servicing or inspecting the machine.

Before you start working on the machine, study this section thoroughly to duly perform the service procedures.

For specific details regarding the engine, refer to the manufacturer's Instruction for Use also.

Safety WARNING Pay close attention sections marked with the symbol. They contain very important safety issues.

0-0082

To release hydraulic pressure

Self-initiated periodical inspections

1. Lower the attachment to the ground.

You must also have the hydraulic shovel adjusted thoroughly because this optimizes its functionality as well as stretching its life.

2. Turn the starter switch to the "OFF" position and stop the engine.

3. Turn the starter switch to the "ON" position.

4. Gate lock lever must be released (to the operating position).

Inspection and maintenance schedule Monitor the hour meter readings in the cab to guide you in keeping the regular service intervals. The recommended intervals are determined under normal working conditions. When you overload your machine, operate in severe weather, or operate under demanding conditions, you need to inspect the machine more frequently. Inspect when your machine has operated for the number of hours recommended for inspection, or the number of months recommended for inspection, whichever comes first.

5. Move the right and left operational levers back and forth, and left to right, for approximately ten times.

6. Turn the starter switch to the "OFF" position.

7. Release the pressure from the hydraulic oil tank.

(To release pressure, push in the tip 1 of breather rubber cap at the top of hydraulic oil tank.)

Ԙ

General cautions when performing inspections For crucial inspections and maintenance (i.e. adjusting/servicing hydraulic components or electronic components), your machine must go in a service shop.

3-0001

WARNING

CAUTION

Release the hydraulic pressure when you service or inspect the machine.

E3440

Hot hydraulic fluids may cause severe burns and bodily injury.

Before removing hydraulic tank cap, shut off engine and completely release tank pressure by opening.

3-1

Maintenance

General Cautions

Locking procedures of the elevator

3. Insert the link lock pin 5 to fit the beta pin 6 securely.

DANGER If it is unavoidable to enter under the elevator cab such as in case of carrying out inspection and maintenance, be sure to set the lock pin.

Otherwise, there is a risk that the elevator cab may be lowered accidentally inviting serious injury such as by being caught in.

Ԟ ԟ

ԝ

1. Take out the link lock pin 2 and the beta pin 3 from the tool box 1 located under the elevator bracket.

Ԝ

Ԙ

LM-0160

8 Elevator bracket

CAUTION Do not lift up and down the elevator cab with the link lock pin inserted as the link may be damaged.

Ԛ

4. Lower the elevator cab with the emergency lowering switch until the elevator link 7 touches the link lock pin 5.

ԙ

LM-0158

2. Lift up and down the elevator cab to bring the elevator link at a place higher than the link lock pin 4.

Ԟ

ԟ

ԝ ԛ

Ԝ

LM-0161

8 Elevator bracket

CAUTION Do not lower the elevator cab by using the cab lifting switch.

Otherwise, the link and the link lock pin may be damaged.

LM-0159

The illustration may differ from that of actual machine.

3-2

E6910

Maintenance

Periodic Maintenance Check List

Daily Inspections (Prior to Operation) Inspections and maintenance

Procedure

Grease / oil (replacement parts)

Reference

Check prior to starting the engine Overall 1. Check any water or oil leakage 2. Check to ensure nuts & bolts are secure 3. Eliminate accumulated dust (from engine / inside cab) 4. Check physical exterior damage 5. Check inside the cab and window glass for cleanliness

Bolts

Tighten and secure Clean

Engine 1. Check engine oil level, and see if it needs changed 2. Check coolant level 3. Check radiator and oil cooler to see if damaged or plugged 4. Check the fan belt tension 5. Check if air cleaner element is clean / if it is clogged 6. Check parts for water / oil leakage, check hoses and pipes for breakage 7. Draining the water and sediments from the fuel filter (main and pre)

Refill or change Refill Repair or clean

Engine oil Soft water

Clean or replace

Element

Engine Engine Engine Engine Engine Fuel

Swing Unit 1. Check fuel level in fuel tank 2. Draining the water and sediments from the fuel filter 3. Check oil level in hydraulic oil tank 4. Check if hydraulic oil is clean 5. Check components for water / oil leakage, check hoses and pipes for integrity 6. Check components for physical damage or distortion 7. Check electrical wiring for short circuits Ensure terminals are secure 8. Adjust rear view mirror

Refill

Diesel Fuel

Refill

Hydraulic oil

Fuel Fuel Hydraulic oil

Track Travel Unit Travel Unit

1. Check shoe (track roller) for looseness, wear, or breakage 2. Check upper / lower rollers and idlers for oil leakage or wear 3. Ensure bolts are all secure, and not missing Work Unit 1. Check cylinders, hoses for oil leakage or breakage 2. Check magnet for wear or breakage 3. Ensure components around front of machine are properly greased or oiled 4. Ensure bolts are all secure, and not missing 5. Cable 1) Broken wire and damage(crack in appearance).

2) Slackening in sections being secured.

3) Wearing in hydraulic hode and in attachment.

4) Tightness of terminals.

6. Generator / Power distribution board 1) Cleaning of dust and dirt.

2) Tightness of bolts.

3) Tightness of terminals.

pressure grease

Check after starting the engine Overall 1. Check if engine starts fine, check exhaust hue, listen for any abnormal noise 2. Check hydraulic components, check any abnormal noise 3. Check components for oil / water leakage 4. Check horns, buzzers, working lights, windshield wipers, and monitors for proper operation 5. Check units for proper operation (travel, swing, and attachments) 6. Check swing brake for proper operation 7. Inspection of interference prevention system.

8. Inspection of emergency lowering device.

Refer to the Daily Inspection Prior to Operation section for check procedures for major components.

3-3

Attachments

Maintenance

Periodic Maintenance Check List

Periodic Maintenance Check List For the recommended service interval hour figures in the table, refer to the following descriptions also. Whichever precedes the other in a set is when you need to service the machine.

10 hours (or Inspections prior to operation) 50 hours (or every week) 250 hours (or every month) 500 hours (or every three months) 1000 hours (or every six months) 2000 hours (or every 18 months) 5000 hours (or every 30 months) 10000 hours (or every 60 months) Areas to be checked or serviced

Engine

Grease attachments

Service interval 10

(other than EM System)

■

(EM System specifications)

■

Drain water from fuel tank

×

Fuel filter (Main)

×

Fuel filter (Pre)

×

Engine oil pan

■

50

250 ◯

Element

◎ ◎

Engine oil

◎

Element

■ ■

Every 2 years (when using long life coolant)

Clean radiator net and fan

□

Retighten nuts & bolts

△

■ ×

■

◎ △

◎

Element

Return filter

△

◎

Element

Swing unit

Suction filter

Crawler

Hydraulic oil

Pilot oil filter

□

Air breather

◎

Element Element

◎ ■

Check batteries

■

Turntable bearing

◯

Extreme pressure grease

Swing ring gear

◯

Extreme pressure grease

Gear oil of swing reduction gear

△■

◎

Gear oil of travel reduction gear

△■

◎

Gear oil Gear oil

Upper roller, take-up roller

■

Engine oil

Lower roller

■

Gear oil

Air conditioner

□

■

Adjust clearances of bucket installer pins

When necessary

Adjust tension of track shoe

When necessary

○：Grease △：Check or replace when brand new ◎：Change oil or replace element □：Clean ×：Drain water / sediment ■：Retighten, check, and adjust

*2

Element

◎

Replace hydraulic oil

Miscellaneous

Long life coolant

□

Air cleaner element

Retighten hoses

*1

Element

◎

Check and adjust fan belt

Drain sediment out of hydraulic oil tank

Extreme pressure grease

◯

Engine oil filters

Radiator coolant

Grease / oil Notes 500 1000 2000 5000 10000 (Replacement parts)

◎

Element

Notes: *1 Grease daily if you work in wet or damp conditions.

Grease every 10 hours if not equipped with our genuine bucket. *2 Replace every 500 hours if you use tap water.

3-4

E6920

Maintenance

Periodic Maintenance Check List

Fuel / Lubricants for Different Ambient Temperature Settings IMPORTANT Consult your distributor for recommended fuel / lubricants when you operate the machine outside the temperatures ranging between 32°F and 104°F (-20°C and 40°C).

Fuel / Oil Refer to the table for proper fuel / oil according to the temperature range.

Refer to Grease /Oil and Element for proper oil level.

Antifreeze Add antifreeze when the temperatures falls below 32°F (0°C).

As for the ratio, refer to the section for cold weather conditions.

What to use according to different temperature settings Where to refill

Type of oil

+14 (-10)

+32 (0)

+50 (+10)

+68 (+20)

SAE 10W-20 CD SAE 30 CD Engine oil pan

Engine oil SAE 10W-30 CD SAE 15W-40 CD

Swing reduction gear Gear oil

SAE 90

Hydrauric oil tank

Hydrauric oil

ISO-VG46

Fuel tank

Diesel fuel ASTM-D-975

Travel reduction gear

No. 2D No. 1D Water+Antifreeze Cooling system

E1220

Water+Long Life Coolant

Add antifreeze Depends on mixing ratio

3-5

+86 (+30)

+104 ࠑ F (+40) (͠)

Maintenance

Periodic Maintenance Check List

Genuine LBX Company LLC Parts and Elements Listed below is our genuine oil. We guarantee the premium quality for heavy machinery use.

We recommend that you use our genuine products to fully enhance the performance of you machine.

IMPORTANT We strongly recommend that you refill your hydraulic tank using the identical product (same product ID, same manufacturer) that you initially had in your tank.

Mixing two different products will lower the functionality of the oil, and causes your hydraulic components to run down.

3-6

E3420

Maintenance

Periodic Maintenance Check List

Disposable Items Replace disposable items, such as filter elements and bucket teeth, either when the service intervals recommend or before they reach maximum life span.

We recommend that you use our genuine parts / elements guaranteed for premium quality.

Monitor those disposable items and replace when necessary. This will save your money in the long run.

The few items in parentheses ( ) in the list need to be replaced with the matching item to be replaced.

Name of disposable item

Quantity

Part ID No.

When to replace

1

KHH0533

Every 500 hrs.

Main

1

KHH0534

Every 500 hrs.

Pre

1

KHH12030

Every 250 hrs.

Pilot oil filter element

1

KHJ10950

Every 2000 hrs.

Return filter element

1

KRJ15830

Every 2000 hrs.

1

Outer element KBH0921

Every 1000 hrs.

1

Inner element

Every 1000 hrs.

1

KRJ3461

Every 1000 hrs.

1

KRJ3463

̆​̆​̆

1

KRJ10590

Every 5000 hrs.

Engine oil filter Fuel filter element

Air cleaner element

(Double type)

Air breather element Packing Suction filter element

E6930

3-7

KBH0922

Maintenance

Grease / Oil and Elements 㧸㨁㧮㧾㧵㧯㧭㨀㧵㧻㧺‫ޓ‬㧯㧴㧭㧾㨀

REF. NO.

# $ % & ' ( ) * + , -

NO. POINTS

DESCRIPTION (4106 #66#%*/'06 2+0 '/5 67406#$.' $'#4+0) 59+0) 4+0) )'#4 59+0) )'#4 4'&7%'4 '0)+0' 1+. 2#0 64#8'. )'#4 4'&7%'4 *;&4#7.+% 57/2 6#0'0)+0' 4#&+#614 (7'. 6#02+.16 .+0' (+.6'4 /#+0 24'

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176'4 +00'4

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176'4 +00'4

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(4106 #66#%*/'06 2+0

(7'. (+.6'4

SPECIFICATION

.7$4+%#6' )4'#5'

%*#0)' 1+. 14 4'2.#%' '.'/'06

㧵㧺㨀㧱㧾㨂㧭㧸㧔㨔㨞㧕

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%.'#0

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4'%1//'0&'& )4'#5' #0& 1+. 52'% #4' #5 (1..195 016'5 .7$4+%#6+10 +5 4'%1//'0&'& (14 6*' (4106 #66#%*/'06 2+05

'2 )4'#5' .+6*+7/ )4'#5' 01

#(6'4 6*' 12'4#6+10 +0 6*' 9#6'4 +5 %1/2.'6'&

'0)+0' 1+. 5'' 12'4#614 5 /#07#.

4'('4 61 4'%1//'0&'& 1+. 52'%+(+%#6+105 +0

#4 1+. #2+ ). 5#'

&'6#+. 5*190 +0 6*' 12'4#614 5 /#07#.

*;&4#7.+% 1+. 5'' 12'4#614 5 /#07#.

6*+5 %*#46 +5 24+14 61 6*' '0)+0' +05647%6+10 /#07#. +06'48#. *1745 10 6*+5 %*#46 #4' $#5'& 10 (1..19+0) 14 &#+.; 14 /106*.; 14 /106*5 14 ;'#45 9*+%*'8'4 1%%745 (+456 14 9''-.; 14 /106*5 14 ;'#4

:

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) *

,

-

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:

%

:

$

' & $ %

:

#

( +

:

-$2

:

# :

# J

#

:

# -42

REF. NO. A

DESCRIPTION

NO., POINTS

Elevator link and cylinder

10

3-8

SPECIFICATION EP. GREASE NO.2

Maintenance

Inspection Prior to Operation

Inspections Prior to Operation Walk-through checks

Attachments (work unit)

Check prior to starting the engine.

Visually check the areas around and under the machine, and

1. Check oil leakage on high-pressure hoses and at linkage, and on hydraulic cylinders.

1. Check to see if there is any leakage of oil / fuel / coolant from any component.

1 Check condition of grease on and around

2. Around magnet linkage. Check if magnet play is appropriate.

(Refer to the section on magnet for specific instructions for adjusting play.)

2. Check and ensure all nuts & bolts are secure.

3. Check if there is any wire breakage or short circuit in electrical wiring. Ensure battery terminals are secure.

3. Check electric cables for break and damage, and terminals for tightness.

4. Check if oil / grease is clean in related components.

5. Eliminate accumulated dust and clean the area.

Ԙ LM-0020E

The illustration may differ from that of actual machine.

0-0034

3-9

Maintenance

Inspections Prior to Operation

Inspection prior to starting engine

2. Checking coolant level / refilling Check the coolant level in reservoir tank. If low, remove the radiator cap and refill with coolant.

An emptied reservoir tank may cause water leakage. After inspection, repair it if found faulty.

1. Checking oil level / refilling

Ԙ

ԙ

Ԛ

① ②

ԛ

3-0006

3-0004

1 Full 2 Low

1 Dipstick 2 Radiatorcap 3 Oil filter port 4 Fan belt

WARNING Never open the radiator cap when the coolant is hot. You may get splashed with boiling coolant.

● Perform oil level check either prior to starting the engine, or thirty minutes or more after turning off the engine.

Use the dipstick to check if the oil level is appropriate.

If low, refill engine oil through oil filler port.

Recheck the oil level after 10-15 minutes.

3. Checking the fan belt tension Push in between the fan pully 1 and the generator pully 2. If the deflection is about (Model: 210/240 0.24-0.31 in (6-8 mm)) responding to the force of approximately 100N, it is normal.

If the deflection falls outside the specified range above, refer to the section on “adjusting fan belt tension and adjust tension”.

Ԙ ԙ

0.24㨪0.31 in {6㨪8 mm} 100N{10kgf} 3-0005

1 Appropriate oil level 2 Dipstick

Ԙ

ԙ

Ԛ

3-0007

1 Fan pulley 2 Generator pulley 3 Krank pulley

3-10

E1280

Maintenance

Inspections Prior to Operation

4. Checking the air cleaner Chech the cover installation of air cleaner.

Clean the air cleaner if indicated on the monitor display as AIR FILTER .

When checking hidrauric oil

ԙ Ԙ Ԙ

ԙ Ԛ ԛ LM-0163

Ԛ

The illustration may differ from that of actual machine.

3-0008

1 Hydraulic oil filler 2 Fuel filler port 3 Fuel level gauge 4 Hydraulic oil level gauge

1 Cover 2 Element 3 Vacuator Valve 5. Swing unit

b) Checking the hydraulic oil level / refilling When checking the hydraulic oil level, keep the machine on a level surface and place it in the checking position. ● Check and ensure that the hydraulic oil level is around the middle of the level gauge.

If the oil level is found low, refill the tank with hydraulic oil by referring to “hydraulic oil” illustrated in the section, Inspection/Maintenance.

a) Checking the fuel level

WARNING Do not overfill the fuel tank (never to the top of fuel tank).

Check the fuel level on the display gauge or on the fuel level gauge 3 at the right of cab.

If low, refuel from the fuel filler port 2 of the fuel tank.

Refill the tank at the end of each work day, and make this a habit.

Level gauge

3-0010

E

F

c) Check and ensure that the bolts on the fuel tank / hydraulic oil tank are secure. Also check if any fuel / hydraulic oil leakage exists. d) Check to see if the bolts on electrical components and batteries are secure. Also check wiring for short circuits.

1-0023

E6960

3-11

Maintenance

Inspections Prior to Operation Inspection after starting the engine

6. Crawler a) Check the shoe (track roller) to see if it is loose. Also check for wear or breakage. b) Check to see if there is any oil leakage from travel unit, upper / lower rollers, and take-up roller. Also check for wear. c) Check components and ensure that bolts are all secure and not missing.

a) Check the horn and gauges for proper operation. b) Check to see if the engine starts fine. Check the exhaust hue, and listen for any abnormal noise. c) Check for any oil / fuel /coolant leakage

WARNING Immediately investigate anything unusual that you encounter during inspection. When you find the source of the problem, fix it or make the necessary adjustment on the spot. This will keep your machine from running down.

Please be aware that you are risking your machine into bigger failures or major accidents if you leave the problems unattended and keep operating it.

Ԝ Ԛ

ԛ

ԙ Ԙ

3-0011

The illustration may differ from that of actual machine.

1 Take-up roller 2 Upper roller 3 Lower roller 4 Shoe 5 Travel unit

LM-0048

3-12

Maintenance

Greasing Attachments

Greasing Front Attachment Pins • Maintenance: every 250 hours • Maintenance for EM System: every 1000 hours CAUTION ● Always grease after completing work in water or extreme wet conditions.

(Particularly around the magnet pins) Use E.P. grease No. 2

● When using an attachment other than a genuine magnet (breaker, hammer, etc.), grease the mounting pins every 10 hours.

Front attachment pin's greasing points (18 points) (No.) Reference drawing

Greasing Points

Number of greasing points

Boom Foot Pin Boom Cylinder, Top Pin Arm Cylinder, Foot Pin

Ԙ

2.

2.

2.

Boom Cylinder, Foot Pin

ԙ

2.

Ԛ

1.

2.

1.

1.

1.

ԛ

1.

2. (total of 4 points) 1.

Bucket Cylinder Top, Foot Pin Bucket Cylinder to Bucket Linkage, Pin Bucket Linkage to Bucket, Pin Arm to Bucket Linkage, Pin Arm to Bucket, Pin Bucket Cylinder, Foot Pin Arm Cylinder, Top Pin Boom to Arm, Connecting PinBoom Foot Pin

Concentrated greasing (total of 6 points)

(total of 6 points)

Ԙ

ԙ

Ԛ

Ԛ

ԛ

Grease the mounting pins of the attachments other than the genuine bucket every 10 hours.

LM-0006E

The illustration may differ from that of actual machine.

E6980

3-13

Maintenance

Greasing Attachments

1 Concentrated greasing

3 Bucket and related (Total of 6 points)

[Maintenance: every 1000 hours]

[Maintenance: every 1000 hours]

Boom foot pin Boom cylinder pin Arm cylinder pin total of 6 points

Bucket Cylinder Top Pin Bucket Cylinder to Bucket Linkage, Pin Arm to Bucket Linkage, Pin [Maintenance: every 250 hours] Bucket Linkage to Bucket, Pin Arm to Bucket, Pin

LM-0016E

2 Boom cylinder, Foot Pin [Maintenance: every 1000 hours]

3-0090

Total of 2 points

4 Connected part of Boom and Arm [Maintenance: every 1000 hours] Bucket Cylinder Foot Pin Arm Cylinder Top Pin Boom to Arm Connecting Pin Total of 4 points

3-0089

LM-0017E

3-14

E7200

Maintenance

Greasing Elevator Cab

Greasing Elevator Cab Where in the elevator cab is to be

lubricated (10 places)

Reference No.

Number of points to lubricate

When to lubricate

Elevator link pin

1

4 Intensive lubrication

Every 500 hours (or every 3 months)

Elevator link pin

2

4 Intensive lubrication

Every 500 hours (or every 3 months)

Elevator cylinder

3

2

Every 500 hours (or every 3 months)

Where to lubricate

Lubricant

Extreme-pressure grease, class 2

Ԙ

Ԛ ԙ

Ԛ The illustration may differ from that of actual machine.

E6990

3-15

LM-0167

Maintenance

Fuel System

Fuel WARNING ● Sufficient care is necessary during inspection and maintenance. ● Be especially careful about fire. (Do not smoke while working.) ● Wipe off any diesel fuel that is spilled during refilling, inspection or maintenance, because it may cause a fire.

● Fuel leaking from the fuel hose, injection pump, fuel filter or joint may result in a fire. If any fuel leakage is found, repair the area immediately. ● Do not use any substitute fuel because it may cause poor performance or even a fire.

Engine fuel and maintenance of fuel filters

2. Applicable standards for diesel fuel Applicable Standard

Recommendation

In order to meet the emission control regulation of 3rd-stage, the engine components have been made precisely and they are to be used under high-pressure conditions. Therefore, the specified fuel must be used for the engine.

As a matter of course, not only the guarantee will not be given for the use of a fuel other than the specified but also it may invite a serious breakdown. In addition, since suitable specifications for the fuel filter elements have been established for this engine, use of the genuine filter is essential. The following describes the specifications and the requirements of the fuel to be applied, and maintenance of the fuel and the fuel elements.

ASTM (AMERICAN SOCIETY TESTING AND MATERIALS)

D 975

JIS (JAPANESE INDUSTRIAL STANDARD)

NO.2

DIN (DEUTSCHE INDUSTRIE NORMEN)

DIN 51601

SAE (SOCIETY OF AUTOMOTIVE ENGINEERS) Based on SAE-J-313C

NO.2-D

BS (BRITISH STANDARD) Based on BS/2869-197

Class A-1

If a standard applied to the fuel for the diesel engine is stipulated in your country, check the standard for details.

3. Requirements for diesel fuel Although conditions required for the diesel fuel are illustrated above, there are other requirements exerting a big influence on its service durability and service life.

Be sure to observe the following requirements for selecting fuel.

Fuel to be applied 1. Selection of fuel Following conditions must be met for the diesel engines, that is the one; (1) In which no dust even fine one is mixed, (2) With proper viscosity, (3) With high cetane rating, (4) With good flow properties in lower temperature, (5) With not much sulfur content, and (6) With less content of carbon residue.

Sulfur content

2500 ppm or less

HFRR*

460 μm or less

Water content

0.05 wt% or less

* HFRR (High-Frequency Reciprocating Rig.): An index showing lubricating properties of the fuel.

Sulfur content reacts to moisture to change into sulfuric acid after combustion. Use of a fuel containing much sulfur content allows it to accelerate internal corrosion and wear. In addition, much sulfur content quickens deterioration of engine oil allowing its cleaning dispersive property to be worse which results in acceleration of wear of sliding portions.

HFRR is an index that indicates lubricating property of a fuel. Large value of the index means poor lubrication so that seizure of the machine components may result if such a fuel is used.

3-16

E1330

Maintenance

Fuel System 2. Two kinds of fuel filter, the pre-filter and the main filter, are mounted on the machine.

Be sure to use the genuine fuel filters and replace them at a periodic intervals.

Since a fuel with high HFRR value also has lower viscosity, it can easily be leaked out. If the fuel is mixed with the engine oil, the oil is diluted to deteriorate its lubricating property resulting in acceleration of wear. Water content allows inside of the fuel tank to rust which in turn blocking the fuel line and the fuel filter. This may also cause wear and seizure of the machine components. If atmospheric temperature goes below the freezing point, moisture content in the fuel forms fine particle of ice allowing the fuel line to be clogged. Obtain table of analysis for the fuel you are using from the fuel supplier to confirm that it meets the criteria described above.

Replacement criteria Every 250 hour of use Every 500 hour of use Pre-filter Main filter

○

Since the pre-filter and main filter also has a function of water separation, discharge water and sediment when the float reaches lower part of the filter elements.

3. Time to replace filters may be advanced according to properties of the fuel being supplied.

Running the engine with the fuel filter blocked may cause the engine to be stopped due to establishment of engine error code.

If much foreign objects are found in the fuel, carry out earlier inspection and regular replacement of the filters.

IMPORTANT If a fuel which does not meet the specifications and the requirements for the diesel engine, function and performance of the engine will not be delivered. In addition, never use such a fuel because a breakdown of the engine or an accident may be invited.

Guarantee will not be given to a breakdown caused by the use of a improper fuel. Some fuels are used with engine oil or additives mixed together with diesel engine fuel. In this case, do not use these fuels because damage to the engine may result as the fuel has been contaminated. It is natural that the emission control regulation of 3rd-stage will not be cleared in case where a fuel that does not meet the specifications and the requirements is used. Use the specified fuel for compliance of the exhaust gas control.

4. If dust or water get mixed with the fuel, It may cause the engine trouble and an accident.

Therefore, take measures to prevent dust and/ or water from being entered in the fuel tank when supplying fuel.

When supplying fuel directly from a fuel drum can, leave the drum as it stands for a long period of time to supply clean fuel standing above a precipitate.

If it is hard to leave the drum for a long period of time, install a fuel strainer and a water separator before the fuel tank of the machine to supply clean fuel.

Maintenance of fuel filters 1. Be sure to use the genuine fuel filters.

The fuel injection system is precisely constructed and the genuine filter employs finer mesh than conventional filters to improve protection of machine equipment.

If a filter with coarse mesh is used, foreign object passing through the filter enters into the engine so that machine equipment can wear out in a short period of time.

5. Water drain cock is provided on the bottom side of the fuel tank.

Drain water before starting the engine every morning.

In addition, remove the cover under the tank once a year to clean up inside of the tank.

IMPORTANT If a fuel filter other than the genuine filter is used, guarantee will not be applied to a fault caused by the use of a wrong filter.

E1340

○

3-17

Maintenance

Fuel System 6. Maintenance of electromagnetic feeding pump

IMPORTANT It you use diesel fuel which contains much sulfur content more than 2500ppm, be sure to follow the items below for the engine oil selection and maintenance of engine parts.

Guarantee will not be given to breakdowns caused by not to follow these items.

ԛ Ԝ Ԙ ԝ ԙ

(1) Selection of engine oil Use API grade CF-4 or JASO grade DH-1.

Ԛ

(2) Exchange the engine oil and engine oil filter element by periodical interval below.

Engine oil -- Every 250 hour of use Engine oil filter element -- Every 250 hour of use

3-0098

3 Filter(KHP11890) 2,4 Gasket(KHH11900) (Electromagnetic feeding pump is located near the pre-fuel filter.)

(3) Inspect and exchange the EGR parts and fuel injector parts of engine by periodical interval below.

EGR(*) parts -- Every 3000 hour of use Fuel injector parts -- Every 3000 hour of use *EGR : Exhaust Gas Recirculation

● Points to notice when carrying out maintenance of built-in filter Check the metal mesh filter 3 for external damage and/or for defects to clean it with a light oil (or blowing air lightly is possible).

If it is found damaged and/or defective, replace it with the new mesh filter.

After disassembly in addition, be sure to replace both gaskets 2, 4 with new gaskets and thoroughly remove dirt and stains stuck on the cover 1 and the magnet 6, the body 5 and inside of the body to assemble then.

During cleaning, pay special attention that any dirt and dust will not enter into the body 5 inside.

Also, be sure to carry out thorough airtight check. ● Disassembly and assembly Unfasten the cover 1 counter-clockwise with a spanner (17mm) to remove it.

After removal of the cover, the gasket (large size) 2, the metal mesh filter 3, and the gasket (small size) 4 can be removed in this order.

When carrying out assembly, do it in reverse order in disassembly described above.

In this, Mount the gasket (large size) 2 into the cover 1 and tighten up the cover 1 to the body securely with a spanner (17mm) .

For the detail of inspection and replacement for the above engine parts, please contact your nearest SUMITOMO outlet.

(4) In addition above, if the value of HFRR(*) or water content in the fuel you use is more than limitation in above table of this manual, please also contact your nearest SUMITOMO outlet. *HFRR (High-Frequency Reciprocating Rig.) : An index showing lubricating properties of the fuel.

3-18

E3831

Maintenance

Fuel System

Fuel Refilling and Fuel Level Checking WARNING

② ①

Do not overfill the fuel tank (never to the top of fuel tank).

Check the fuel level on the display gauge or on the fuel level gauge 5 at the right of cab. If low, refuel from the fuel filler port 2 of the fuel tank.

⑤

Refill the tank at the end of each work day, and make this a habit.

E

F

③ 1-0023

Drainage of Water and Sediments in the Fuel Tank • Maintenance: every 10 hours 1. Obtain a container to collect the drained contaminants.

(Performing drainage before starting the engine in the morning is the most effective method.)

④ 3-0012

2. Loosen the drain valve 4 located at the bottom of the tank and drain the accumulated sediment and water.

1 Strainer 2 Fuel filler port 3 Fuel tank 4 Drain valve 5 Level gauge

3. After draining, tighten the drain valve.

IMPORTANT Remove the fuel strainer 1 from the fuel filler port 2 for cleaning.

E1352

3-19

Maintenance

Fuel System

Draining Water from the Pre Fuel Filter • As Necessary When the float 4 reaches the bottom of element 7, 1. Loosen the air bleeding plug 1 and also drain plug 5 and drain the water and sediments.

2. When the float sinks to the bottom, tighten the air bleeding plug 1 and the drain plug 5.

Air bleeding : 10±2 N•m Moisture may be frozen up in cold temperature.

Drain water after the frozen moisture has thoroughly melted.

3. Verify that no fuel leaks.

WARNING 3-0013

Completely wipe off any spilled diesel fuel. It may cause a fire.

Ԙ

CAUTION ԙ

Tightening it with torque exceeding the specified may cause the rubber section of gasket to be damaged.

ԟ

Ԟ

Ԛ

ԛ ԝ Ԝ 3-0014

1 Air bleeding plug 2 Head 3 Case 4 Float 5 Drain plug 6 O-ring 7 Element 8 O-ring

3-20

E1362

Maintenance

Fuel System

Pre Fuel Filter Replacement • Maintenance: every 250 hours 1. Fuel cock A is shut.

WARNING Completely wipe off any spilled diesel fuel after replacing an element or air bleeding.

Ԙ

ԙ ԟ

Ԟ

Ԛ

A 3-0015

ԛ ԝ

2. Loosens the bleeding plug 1 and also drain plug 5 then discharge fuel.

Ԝ

3. Using a tool, turn the case 3 counterclockwise and remove the old element from it.

3-0014

4. Install a new element 7.

1 Air bleeding plug 2 Head 3 Case 4 Float 5 Drain plug 6 O-ring 7 Element 8 O-ring

5. Replace the O-ring 6, 8 for a new parts.

Head 2 is cleaned.

6. Before installation, apply a thin coat of fuel oil on the packing area of the element and turn the case the packing comes into contact with the mounting surface.

Using a tool, tighten the case as: Case : 27.5 - 31.3 N•m 7. Tighten the bleeding plug 1 and also draining 5.

Air bleeding : 10±2 N•m 8. The fuel cock A is opend.

9. After installation, bleed the air from the lines and filter.

CAUTION Tightening it with torque exceeding the specified may cause the rubber section of gasket to be damaged.

E1373

3-21

Maintenance

Fuel System Fuel Filter (Main) Replacement • Maintenance: every 500 hours

Draining Water from the Fuel Filter (Main) • Daily Inspections(Prior to Operation)

WARNING

Ԙ

Completely wipe off any spilled diesel fuel after replacing an element or air bleeding.

ԟ Ԟ

ԙ

ԝ

Ԛ

Ԝ ԛ 3-0016

1 Air bleeding plug 2 Head 3 Case 4 O-ring 5 Drain plug 6 O-ring 7 Element 8 Priming pump

A 3-0015

A Fuel cock (Refer to operator's manual for the engine.)

1. Fuel cock A is shut.

1. Loosen the air bleeding plug 1 and also drain plug 5 and drain the water and sediments.

2. Loosens the bleeding plug 1 and also drain plug 5 then discharge fuel.

2. When the water and sediments and discharged, tighten the air bleeding plug 1 and the drain plug 5.

Air bleeding : 10±2 N•m Moisture may be frozen up in cold temperature.

Drain water after the frozen moisture has thoroughly melted.

3. Using a tool, turn the case 3 counterclockwise and remove the old element from it.

4. Install a new element 7.

5. Replace the O-ring 4, 6 for a new parts.

Head 2 is cleaned.

6. Before installation, apply a thin coat of fuel oil on the packing area of the element and turn the case the packing comes into contact with the mounting surface.

Using a tool, tighten the case as: Case : 27.5 - 31.3 N•m

3. Verify that no fuel leaks.

WARNING Completely wipe off any spilled diesel fuel. It may cause a fire.

7. Tighten the bleeding plug 1 and also drain plug 5.

Air bleeding : 10±2 N•m

CAUTION

8. The fuel cock A is opend.

Tightening it with torque exceeding the specified may cause the rubber section of gasket to be damaged.

9. After installation, bleed the air from the lines and filter.

3-22

E1382

Maintenance

Fuel System

Bleeding Air from the Fuel System

5. Next, tighten the air bleeding plug 2 which had been loosened in step 1 and continue to move the feed pump 1 handle. When the handle becomes difficult to move, air bleeding is completed.

Air bleeding : 10±2 N•m

ԙ

Ԙ

6. Set the feed pump 1 handle to the original position.

Ԛ

7. Completely wipe off any spilled fuel, start the engine and check for any fuel leakage.

CAUTION Tightening it with torque exceeding the specified may cause the rubber section of gasket to be damaged.

ԛ

3-0017

1 Feed pump 2 Air bleeding plug 3 Discharge hose 4 Case When the pre fuel filter element or the fuel filter element is replaced or when draining the water or when the fuel tank is emptied, air enters the lines and stops the fuel flow. Therefore, air bleeding is necessary.

1. Loosen the air bleeding plug 2 on fuel filter.

Do not loosen the air bleeding plug of the pre fuel filter.

2. Insert the key into the starter switch and turn the key to the “ON” position. Electromagnet feed pump operates by this.

CAUTION Do not turn ON the starter switch for more than 5 minutes unless bleeding air has been completed.

Otherwise, this may cause breakdown of the electromagnetic fuel pump.

3. Turn the handle of the feed pump 1 to the left and it will spring up due to the spring inside the handle.

4. Move this handle and expel from the discharge hose 3 the fuel with which air bubbles were mixed. This action is the back-up of electromagnet feed pump 1. Move this handle until air bubbles are lose in fuel.

E1393

3-23

Maintenance

Engine

Engine Oil Replacement • Maintenance: every 500 hours Engine Oil Filter Replacement • Maintenance: every 500 hours (Refer to operator's manual for the engine.)

WARNING

Draining engine oil

Just after the engine is stopped, each part (main body, muffler, oil, etc.) may be very hot.

Do not touch any of them because it may cause a burn.

Wait until all parts have cooled down before beginning the inspection/maintenance work.

1. Wipe clean around the oil filler cap B taking care so that no foreign particles entry. Remove the filler cap B. 2. Loosen the cap F of oil drain cock and remove it. Connect the oil drain hose G to the oil drain cock D and drain the oil.

It is advisable that draining be done while the engine is warm, to minimize the draining time.

CAUTION If the engine oil is contaminated or extremely deteriorated, replace it regardless of the maintenance interval.

Specified Lubricants

D

Use engine oil of API rating Class CD or higher which is suitable for the temperature.

G

F

3-0018 Selection Depending on Temperature

Refilling Point

Oil Type

-14

+32

(-10)

(0)

+50

+68

(+10)

(+20)

3. After the completion of draining disconnect

ࠑF

+86 +104

the hose G and wipe off the oil on the drain cock D.

͠

(+30) (+40)

SAE 10W-20 CD Engine oil pan

4. Turn the cap F of oil drain cock slightly and settle it. From that position, turn more about 60 to 90 degrees.

SAE 30 CD

Engine oil

SAE 10W-30 CD SAE 15W-40 CD

A

CAUTION

B

Use a receptacle to receive the drained oil so that the engine and equipment may not be stained with the drained oil.

D

E

ADipstick BOil filler cap COil pan

C 3-0042

DDrain plug EOil filter

3-24

E1400

Maintenance

Engine

Main oil filter element removal Main oil filter (Spin-on type)

Engine oil refilling 1. Disconnect the oil drain hose and reinstall the cap of drain cock.

Set a wrench at the hexagonal section of the second stage above the cartridge, and remove the main of filter.

There may remain the used engine oil in the cartridge, and care should be taken not to spill it when removing the filter.

Discard the used filter.

2. Fill with new engine oil by the oil filler port.

Wait about fifteen minutes until the oil gets down to the oil pan.

Then check the oil level with a dipstick.

Do not insert the dipstick by force. The dipstick may be broken.

Check after Oil and Filter Changes Oil leakage check Idle the engine to raise the oil pressure, then check for oil leakage.

Oil level recheck Stop the engine and keep it stationary about twenty minutes.

Use the dipstick to recheck the oil level.

Replenish with engine oil, if necessary, to the specified level.

3-0092

Oil filter element installation

CAUTION

1. Apply lightly engine oil to the O-ring.

When the engine started, the level will slightly drop from the initial level as the oil fully comes into the entire oil circuit.

3-0093

2. Turn in new cartridge until its sealed face comes in contact with the O-ring.

3. Use a filter wrench to further turn in the cartridge by one full turn.

E1410

3-25

Maintenance

Engine

Cooling System

Inspecting and Refilling Coolant • Daily Inspection

WARNING When the radiator water temperature is high, do not remove the radiator cap.

Hot water may come out forcefully.

Wait until all parts have cooled down before beginning the inspection/maintenance work.

Check the level of coolant in the reserve tank. If low, remove the cap, and add the coolant (long-life coolant). (The proper level is between FULL and LOW.)

①

CAUTION

②

When the overheat warning is displayed on the monitor and the buzzer sounds, check the coolant level, radiator clogging and V-belt tension.

Mix the coolant with anti-freeze (long-life coolant) according to the ambient temperature.

3-0006

1 Full 2 Low

WARNING Since the coolant is toxic, do not swallow it, put it on the skin, and get it in the eye.

Make it vomit if swallowed and wash well it off with water if in contact with skin or eye, then see a doctor for medical treatment.

3-26

E1420

Maintenance

Engine

Replacing the Coolant • Long-Life Coolant: Every 2 Years • When Anti-Freeze is Used, Twice a Year: Spring and Autumn (Refer to operator's manual for the engine.)

3. Close the drain valves 2, 3, fill the radiator with tap water (warm water is preferable), run the engine at slightly higher speed than idling speed for about 10 minutes raising the temperature to over 170°F (about 80°C) and then drain the water.

CAUTION ● Since discharged coolant is harmful, do not discharge it into a draining trench.

● Consult an expert company or a our authorized service shop for disposal of the coolant to be discharged.

CAUTION Be careful not to get burned when draining the hot coolant.

1. Remove the radiator cap 1, loosen the drain valves 2 on the radiator and drain the coolant.

Repeat the radiator cleaning until the drained water is clear.

Ԙ

4. Fill the radiator to the radiator cap 1 with coolant water (long-life coolant), run the engine for about 10 minutes and sufficiently expel air from the cooling system.

5. Stop the engine and check the coolant level. Refill if low. For the mixture ratio of the long-life coolant, refer to section on “Operating in Cold Climates”.

6. Add coolant into the reserve tank until the level reaches to the “FULL” line.

ԙ

3-0019

2. Loosen the drain valves 3 on the engine and drain the coolant.

Ԛ 3-0059

E1430

3-27

Maintenance

Engine

Cleaning and Inspecting the Radiator Net and Fin • Maintenance: every 500 hours WARNING Wear safety goggles when using compressed air.

CAUTION When using pressured washing steam, keep a distance from the fin. Using the pressured washing steam near the object causes the deformation of the radiator fin.

Clogging in the radiator net, radiator fin, and oil cooler fin can lead to overheating.

Blow away any mud and debris clogged on the net and fin using compressed air. Steam or pressured water can be used instead of compressed air.

Cleaning the radiator net Remove the radiator net and clean it.

When working mainly in dusty sites, check the clogging on the net every day, and clean the net if it is clogged.

3-0020

Cleaning the radiator fin and oil cooler fin Clean the oil cooler fin and also the radiator fin.

3-28

E1440

Maintenance

Engine

Cleaning and Replacing the Air Cleaner (double elements) • Cleaning: every 250 hours • Replacement: every 1000 hours CAUTION ● Before maintaining the element, stop the engine.

● When cleaning the outer element, do not hit it or knock it against other objects. ● When the AIR FILTER is indicated on the monitor system, clean or replace the element. ● Do not clean the inner element.

3-0021

b) When washing with water, (1) If the element is contaminated due to smoke, soot, oily materials, etc., wash it with element detergent (Donaldson Brand ND-1500, etc). Use of warm water of about 100°F (40°C) makes washing more effective.

(2) After washing off the dirt and detergent with clean water, dry the element in a wellventilated place.

Use a fan to speed up drying.

Do not use heat for drying.

Since it takes time to dry the element after washing, it is recommended that a spare element be used for replacement.

(3) After cleaning, project a light from the inside of the element.

Do not reuse if there are holes, damage or thin area.

Cleaning the Air Cleaner (Outer element) 1. Remove the cover 1 and take out the element 2.

2. Before cleaning inside the body, cover the engine intake port so contaminants do not get inside.

ԙ Ԙ

Ԛ 3-0008

3. Clean the outer element. a) When using compressed air, Blow compressed air (0.69MPa (100 psi) or less) to the element along its flutes from the inside.

3-0022

WARNING When using compressed air, use safety goggles.

E1450

3-29

Maintenance

Engine

IMPORTANT ● When an outer element is cleaned 6 times or used for 1000 hours, replace it with a new one.

Installing the air cleaner 1. Installing the element.

2. Attach the cover according to the direction shown on the label.

Fit the element securely with the cover.

Replacing inner element ● Replace the inner element every 1,000 hours. ● Do not reuse an inner element by cleaning.

Replace the inner element with a new element together with the outer element when it is replacing. ● Replace the inner element speedily.

3-30

E1460

Maintenance

Engine

Inspection and Adjustment of Fan Belt • Maintenance: every 250 hours 2. Tension Adjustment a) Loosen the upper and lower mounting bolts 1 and 2 on the generator. Turn adjusting bolts 3 of the generator and move the generator to adjust the tension. b) After adjustment, securely tighten the bolts.

WARNING Be sure to stop the engine before carrying out inspection/adjustment of belt tension.

Otherwise, your finger might be cut off.

(Refer to operator's manual for the engine.)

Ԛ

Fan belt

Ԙ

If the belt is loose, it will cause the battery to be insufficiently charged, the engine to be overheated or the belt to wear out early.

ԙ 1. Inspection Check to see if the belt tension is adequate.

Press the belt at the center between the fan pulley 2 and the generator pulley 3 with your finger with a force of about 100 N (10 kgf). Deflection of about 0.24-0.31 in (6-8 mm) is normal.

CAUTION ● After adjustment, it is important to securely tighten the bolts and nuts, but overtightening will damage the bolts or bearings. ● Take care to prevent grease from sticking to the belt. The belt will slip and service life will be shortened. ● If the belt is stretched so long that there are no adjustment marks or if it is cracked or cut, replace it. ● When two belts are used, replace both belts at the same time.

After replacing the belt(s), run the machine for about one hour and then recheck the tension of the belt(s).

Ԙ

ԙ

Ԛ

3-0023

1 About 0.24-0.31 in (6-8 mm) at center (Push down force: about 100 N <10 kgf>)

2 Fan pulley 3 Generator pulley

E1470

3-0024

3-31

Maintenance

Bolt Torque

Bolt and Nut Torque • After the first 50 hours/Maintenance: every 250 hours Tighten the bolts and nuts according to the table. After daily work, check the bolts and nuts for looseness and for any missing. Tighten if loose and replace if missing.

Tighten the bolts and nuts after the first 50 hours of operation and every 250 hours thereafter.

Tightening Torque Table) No.

Tightening Point

Tightening Torque

Bolt Diameter

Wrench

①

Running Motor

M16

24mm

267-312

②

Drive Sprocket

M16

24mm

267-312

③

Take-up Roller

M16

24mm

267-312

④

Upper (Carrier) Roller

M20

30mm

521-608

⑤

Lower (Track) Roller

M18

27mm

371-432

⑥ 7

Track Guard

M18

27mm

400-462

Shoe Bolt

M20

30mm

After tightening at 300N•m tighten 120°±5°additionally

8

Counterweight

M33

50mm

1960-2156

[N•m]

9

Turntable Bearing (Lower Frame)

M24

36mm

784-914

10

Turntable Bearing (Swing Frame)

M24

36mm

784-914

⑪

Swing Equipment

M24

36mm

784-914

⑫

Engine (Engine Mount)

M16

24mm

265-314

⑬

Engine Bracket

M10 M16

17mm 24mm

64-73 206-247

14

Radiator

M16

24mm

147-177

⑮

Hydraulic Pump

M10 M20

17mm Hex. Socket

64-73 367-496

⑯

Oil Tank

M16

24mm

232-276

⑰

Fuel Tank

M16

24mm

232-276

⑱

Control Valve

M16

24mm

267-312

⑲ 20

Rotating Joint

M12

19mm

88-107

Rotating Joint

M12

19mm

109-127

21

Cab

M16

24mm

245-297

22

Battery

M10

17mm

20-29

Note: Use Loctite No. 262 (adhesive) equivalent on those marked with 〇 and tighten to the torque listed in the above table.

Tightening torque is N•m ÷ 9.8=kgf•m

The tightening torque for the bolts and nuts not listed above are as follows: Bolt Diameter (size)

M6

M8

M10

M12

M14

M16

M18

M20

㨇mm㨉

10

13

17

19

22

24

27

30

Tightening Torque 㨇N㨯m㨉

6.9

19.6

39.2

58.8

98.1

157.0

196.0

294.0

㨇mm㨉

5

6

8

10

12

14

14

17

Tightening Torque 㨇N㨯m㨉

8.8

21.6

42.1

78.4

117.6

176.4

245.0

343.0

Wrench Hex. Bolt

Hex. Socket Head Bolt

Wrench

3-32

E7120

Maintenance

Bolt Torque

ԧHydraulic oil tank

ԦHydraulic oil pump

ԩControl valve

ԢSwing unit

ԣ,ԤEngine Counterweight

ԨFuel tank

Radiator 22 Battery

7 Shoe

Ԫ Rorating joint

Ԙ,ԙTravel motor

9,10 Turntable bearing

ԜLower roller ԝTrack guard

21 Operator's cab

ԛUpper roler ԚTake-up roller

The illustration may differ from that of actual machine.

1,2

LM-0010E

6 Ԙ

ԙ

FRONT

FRONT

ԝ

3-0044

3,4,5,7

8

④

7

3-0045

FRONT

③

8

⑤ 3-0046

E7000

3-33

3-0047

Maintenance

Bolt Torque

9,0

A

⑪

10

9

3-0048

3-0387E

B,C

D ⑬

14 ⑬

⑫

3-0051

3-0050

E

F Ԧ

Ԧ

ԧ 3-0053

3-0052

G

H ⑱

⑱

Ԩ 3-0054

3-34

3-0055

E7010

Maintenance

Bolt Torque

I,20

21 ⑲

20

21 3-0056

22

22

3-0058

E1511

3-35

3-0057

Maintenance

Hydraulic Oil Refilling Hydraulic Oil

WARNING

1. Put the machine in the position for hydraulic oil check.

During inspection, strictly observe the following points: ● Release the hydraulic pressure from the circuit.

Refer to the “Procedure for Releasing the Hydraulic Pressure”. ● The hydraulic oil is hot just after stopping the engine. Wait until the oil cools down (less than 100°F (40°C)) before beginning work.

2. Remove the 4 bolts 1 to remove the cover 2 and O-ring 3 from the hydraulic oil filler port.

3. Refill oil through the filler port.

4. Observing the level gauge 4 on the side of the tank, check that the oil level is proper.

5. After refilling, replace the filler port cover 2 and O-ring 3.

Types of hydraulic oil

Ԙ

Use the our recommended oil range: WEB0150 (20 ) (ISO-VG46).

ԙ Ԛ

Hydraulic Oil Level Inspection • Daily Inspection 1. Park the machine on a level ground in the position for hydraulic oil check to inspect the oil level of the hydraulic oil tank.

ԛ

2. Check if the hydraulic oil level is between the high and low marks on the oil level gauge 2. If low, refill through the hydraulic oil filler port 1.

● When the oil level is low, unusual noise may be heard from the hydraulic devices.

● Oil is sometimes trapped at the bottom of the hydraulic oil level gauge. Use care to read the gauge properly.

3-0026

When checking hydraulic oil

CAUTION When refilling hydraulic oil, prevent dust, water, sand or other contaminants from entering the tank.

Ԙ

ԙ LM-0168

The illustration may differ from that of actual machine.

1 Hydraulic oil filler port 2 Hydraulic oil level gauge 3-36

E7020

Maintenance

Hydraulic Oil

Draining Water and Sediment from the Hydraulic Oil Tank • Maintenance: every 250 hours 1. Press the rubber cap on the breather 1 located at the upper part of the hydraulic tank to release the pressure inside the tank.

2. Loosen the drain plug 2 on the lower part of the tank to drain the sediment and water at the bottom of the tank. (Have a drain pan ready.)

3. After draining, tighten the drain plug 2.

4. Check the hydraulic oil level and add oil if the level is low.

①

②

A

B

3-0006E

A Shut B Open

E1530

3-37

Maintenance

Hydraulic Oil

Hydraulic Oil Management • Maintenance: every 1,000 hours Hydraulic Oil Replacement • Maintenance: every 5,000 hours 9. Install the O-ring 3 and filler port cover 2.

If the O-ring 3 is damaged, replace it with a new one.

WARNING The temperature of the hydraulic oil is hot right after stopping the engine. Wait until the oil cools down (less than 100°F (40°C)) before beginning the maintenance.

10. Bleed air from the hydraulic components.

11. Start the engine and run it for about 5 minutes without load.

Operate the travel and swing functions, and all hydraulic cylinders slowly several times. Then, put the machine in the oil check position, and stop the engine.

CAUTION ● When replacing the hydraulic oil, take care

12. Check if the hydraulic oil level is within the proper range.

to prevent dust, water, sand or other contaminants from entering the tank. ● Always replace with new filters and elements when the replacing the hydraulic oil. ● When using the hydraulic breaker, the deterioration and or contamination of hydraulic oil progresses faster compared to ordinary digging work. Be sure to carry out the full hydraulic oil maintenance more often. ● Hydraulic oil management at every 1,000 hours Check oil for the contamination and deterioration by sampling.

① ② ③ (KNJ0381)

⑥ ④

1. Place the machine in the hydraulic oil check position.

2. Press the rubber cap of the breather 1 located at the upper part of the hydraulic tank to release the pressure inside the tank.

3. Remove the 4 bolts on the filler port to detach the filler port cover 2 and O-ring 3.

4. Using a pump, discharge the hydraulic oil into an empty waste container.

5. Remove the drain plug 5 on the bottom of the tank and drain the remaining oil from the tank.

(Have a drain pan ready beforehand.)

6. Remove the suction filter 4 and return filter 6, and install new ones. (Refer to the replacing suction filter and return filter)

⑤

7. Tighten the drain plug 5 securely.

8. Refill with the specified hydraulic oil to the specified level.

3-0007E

3-38

E1540

Maintenance

Hydraulic Oil

Bleeding Air from the Hydraulic Components

● Follow the procedures below for air bleeding.

Air bleeding procedures

IMPORTANT

Air bleeding Air bleeding Air bleeding from swing from pump from cylinder motor

Check

‫ڈ‬

‫ڈ‬

Hydrauric oil/pump replacement

After replacing the hydraulic oil, bleed air from the hydraulic components.

‫ڈ‬

Cylinder replacement

‫ڈ‬

‫ڈ‬

‫ڈ‬

Swing motor replacement

Air bleeding procedures after replacing the hydraulic oil

‫ڈ‬

‫ڈ‬

Air Bleeding from Hydraulic Pump

1. Bleed air from the hydraulic pump.

2. Bleed air from the cylinders.

3. Bleed air from the swing motor.

4. Bleed air from the whole circuit by slowly operating each function (travel, swing and each cylinder).

CAUTION If air is not completely bled, the life of the pump will be reduced or serious problems can occur.

5. Stop the engine and check that no air bubbles remain in the hydraulic oil tank.

WARNING

● Do air bleeding with drain plug 4 if it is not equipped with air bleeding plug 1.

Release internal air pressure from the tank before beginning work.

The hydraulic oil is hot just after stopping the engine.

Wait until it cools down (less than 100°F[40°C]) before beginning work.

1. Stop the Engine.

Loosen the plug 1 to check that oil comes from the air bleeding port.

2. If oil does not come out, remove the plug 1 and fill hydraulic oil into the pump case through the filler port.

3. Temporarily tighten the plug 1.

CAUTION

4. Start the engine and low speed it without load until oil comes out from the air bleeding port.

If any metallic powder or chips are found when the filter or element is replaced, contact our approved Service Shop. If left unattended, it may lead to serious problems.

Avoid dropping any tools or small parts into the tank.

5. Stop the Engine.

6. Tighten the air bleeding plug 1 fully.

① ②

Air Bleeding Procedures CAUTION After replacing hydraulic oil, repairing or replacing hydraulic components or removing hydraulic lines, bleed air from the hydraulic circuit.

E1550

③

2 To engine 3 Outer side

3-39

④

3-0029

Maintenance

Hydraulic Oil

Air Bleeding from Cylinder 3. Temporarily tighten the drain plug A.

CAUTION

4. Idle the engine at low speed and continue to run it until oil comes out from the drain port A.

If air is not bled from the cylinder, the piston packing and other parts may be damaged.

5. Tighten the air drain plug A fully.

6. Idle the engine at low speed and slowly swing the machine left to right evenly 2 turns or more.

1. Idle the engine at low speed, and extend and retract each cylinder 4 or 5 times without reaching the stroke end (about 4 inches (100 mm) before the end of the cylinder).

Check After air bleeding is completed, stop the engine for 5 minutes and check that no air bubbles remain in the oil in the hydraulic oil tank.

2. Then, operate each cylinder 3 or 4 times to the stroke end to bleed air completely.

Air Bleeding from Swing Motor CAUTION If air is not completely bled from the swing motor, the motor bearing or other parts may be damaged.

1. Idle the engine at low speed, loosen the drain plug A and check the oil comes out from the drain port A. At this time, do not attempt to swing the machine.

A

3-0094 2. If no oil comes out, stop the engine, remove drain plug and the hydraulic oil is filled from the drain port A to the motor case.

3-40

E7030

Maintenance

Hydraulic Oil Replacing Return Filter • Initial change after the first 250 hours • Maintenance: every 2,000 hours

Cleaning and Replacing Suction Filter • Cleaning: every 2,000 hours • Replacement: every 5,000 hours

1. Press the rubber cap top on the breather 1 located at the upper part of the hydraulic tank to release the pressure inside the tank.

1. Press the rubber cap top on the breather 1 located at the upper part of the hydraulic tank to release the pressure inside the tank.

2. Remove the cover A and O-ring B. 3. Take out the spring C, valve D and return filter E from the tank.

2. Remove the cover 2 and O-ring 3.

3. Remove the suction filter 5 from the tank

4. Replace the filter with a new one. Wash the spring and valve and assemble them.

4. Wash filter with cleaning solution, dry completely and check the filter.

If there is any damage on the surface, replace it with a new one.

5. Check the O-ring B. If it is worn or damaged, replace it with a new one.

6. Install the cover A.

IMPORTANT Replace the suction filter with a new one every 5,000 hours or when the hydraulic oil is replaced.

A

5. Assemble the spring 4 to the filter and put them in place inside the tank.

B

6. Check the O-ring 3. If it is worn or damaged, replace it with a new one.

C

7. Install the cover 2.

D

E

Ԙ

ԙ Ԛ ԛ

Ԝ

3-0031

E1580

3-41

Maintenance

Hydraulic Oil

Replacing Air Breather Element • Maintenance: every 1,000 hours

Replacing Pilot Oil Filter Element • Initial change after the first 250 hours • Maintenance: every 2,000 hours

WARNING The hydraulic oil is hot right after stopping the engine. Wait until the oil cools (less than 100°F [40°C]) before beginning work.

WARNING Be sure to release the hydraulic pressure in the circuit.

(Refer to the "Procedure for Releasing Hydraulic Pressure" )

1. Press the rubber cap top on the air breather 1 located at the upper part of the hydraulic tank to release the pressure inside the tank.

2. Remove in following order: rubber cap 1 hexagonal nut 2 cover 3.

1. The bottom of the filter cartridge 2 (hexagonal part) is loosend with a spanner.

3. Replace the old filter element 4 with a new one.

When installing the new filter element, put the sponge packing B on top.

2. Remove the filter cartridge 2 by the hand.

3. Apply clean hydraulic oil to a new filter cartridge and install it in the filter base 1.

4. Adjust the notch portion A, install the cover 3 and install the hexagonal nut 2, then rubber cap 1.

4. Tighten 1/3 rotation by the hand when the filter cartridge 2 is installed in the filter base 1.

Ԙ ԙ A Ԛ B ԛ

①

A

②

3-0033

3-0032

3-42

E1591

Maintenance

Hydraulic Oil

Checking Hoses and Lines • Daily inspections • Maintenance: every 50 hours Check the hydraulic system hoses, pipes, plugs, connectors and fittings for oil leakage and the mounting bolts and nuts for looseness. If any faults are found, rectify them by repairing, replacing and additional tightening as required.

3-43

Maintenance

Battery Battery Inspection and Charge • Maintenance: every 250 hours

③ ⑥ ① ④

CAUTION

⑤

● Do not touch the battery when your body

②

is statically charged. Static electricity may cause ignition leading to an explosion.

Touch a metal part of the machine body with bare hand to let charged static electricity escape before carrying out inspection or maintenance. ● Use a piece of rug wetted with water for cleaning of the battery, do not use a dry rug for this purpose. Otherwise, it may be ignited by static electricity leading to an explosion. ● Do not clean the battery with organic solvent such as benzene, thinner and gasoline, or with a detergent and a chemical scrubbing cloth. Battery may be damaged causing leakage of battery electrolyte. ● When an unusual smell is felt around the battery during operation of the vehicle, do not continue operation with this situation left as it is. Otherwise, it may cause a fire or an explosion.

3-0034

1 Hydrometer 2 Exhaust hole 3 Negative (-) terminal 4 Positive (+) terminal 5 Handle 6 Caution label

WARNING ● Be sure to read the instructions on the caution label stuck on the battery top for proper use of it. ● Be sure to carry out inspection and service of the battery after turning off the power (starter switch OFF). ● When using or charging the battery with the hydrometer in the battery indicated in black, the battery generates flammable hydrogen gas which in turn may cause damage (such as explosion) to it. ● Do not bring an open flame such as of match and of cigarette near the battery or produce sparks. ● Since dilute sulfuric acid is used in the electrolyte of battery, carry out inspection and service very carefully. ● If the electrolyte is stuck to the skin or to the clothes, wash it away with water immediately then wash well it off by using soap.

In addition, in case of getting it in the eye, wash well it off with plenty of water then see a doctor for medical treatment. ● The battery can be used at an ambient temperature range between 5°F~140°F (-5°C~60°C) continuously and between -22°~167° (-30°C~75°C) for a short time.

Use of the battery beyond the temperature range described above may cause freezing or overheat by which may result in damage or deformation.

• Check that no crack, split, chipping, and leaking of liquid is in the battery. If found anything wrong, remove the cause or replace the battery.

• Check that the battery has been firmly secured by the mounting hardware. If found loose, re-tighten the nuts on the mounting hardware until the battery is firmly fastened.

• If poor connection of the terminal of the cable to the machine with the battery terminal is found, re-tighten the nut on the cable terminal until it is firmly fastened.

3-44

E1610

Maintenance

Battery

How to read hydrometer

Cleaning Battery Terminal

1. Since this is a battery (which equiped at the new machine) of sealed type that will not need to supply water until the last of its service life, no liquid inlet plug is provided.

Check the battery for charged condition by the color on the hydrometer.

● Clean the battery with a piece of rug wetted with

Color of hydrometer

Charged condition

clogging, and if it is blocked with mud and the like, wash it with water to remove the clogging.

Use of the battery with the exhaust hole clogged up allows the inside pressure to be increased by the gas generated from battery which may cause damage to it. ● If the terminal is dirty, clean it. If it is corroded and generates white powder, wash the terminal with hot water.

It is considerably corroded, clean it with a wire brush or sand paper. ● After cleaning, apply a thin coat of grease on the terminal.

Measures to be taken

Green

Good

Use as it is.

Black

Discharged (specific gravity of electrolyte is dropped).

Charge battery until color of hydrometer turns green.

Electrolyte level is low.

If engine fails to be started, it means last of battery life.

Replace battery as soon as possible.

Transparent (white)

water and do not use a dry rug for this purpose.

● Check the exhaust hole of liquid inlet plug for

2. Look at the hydrometer from right above it.

3. When the hydrometer indicates in transparent (white) or in light green, tap it to check that no bubbles are stuck on, and then observe the hydrometer again.

3-0035

Replacing Battery When replacing a battery, do not mix using old and new batteries together. (The service life of the new battery will be shortened.)

Specific Gravity of Electrolyte (The battery which requires added solutions)

Storing battery

Measure the charge rate of the battery with a battery tester or specific gravity gauge. Specific gravity varies with the temperature.

Referring to the table below, check the charge rate.

Measure the specific gravity of the battery with a specific gravity gauge.

Remove the battery out of the machine to store it at a place where well ventilated and no source of fire is expected.

Since battery discharges gradually, check the charge rate once a month to recharge it periodically (3 to 6 months).

Battery charge rate depending on the battery specific gravity Liquid Temperature 68゜ F 32゜ F 14゜ F F -4゜ (20℃) (0℃) (-10℃) (-20℃) Charge Rate 100% Satisfactory

1.28

1.29

1.30

1.31

90% Satisfactory

1.26

1.27

1.28

1.29

80% Charge

1.24

1.25

1.26

1.27

75% Charge

1.23

1.24

1.25

1.26

Replace the battery when still 75% even after charging.

E1622

3-45

Maintenance

Inspection of accessories

Inspection of accessories WARNING ● After inspection and maintenance of such as the generator, the power distribution board, the power plugs, close the doors and the covers so that moisture and/or dust will not enter inside. ● Electric charge of high potential will remains for some time in the circuit for supplying power to the power magnet even after the machine has been stopped operation.

In case where a work requiring access such as to the power distribution board, the electric equipment, the wiring, and the terminals is carried out for the purpose of inspection, maintenance, repair and the like, stop the machine and do not touch any part of the circuit in the power distribution board for at least 10 minutes.

In addition, carry out the inspection after it has been confirmed that

the charge lamp has been OFF and voltage across the generator, the condenser, and between the output terminals has measured "0 volt" with a circuit tester.

Otherwise, there is a risk of serious accident resulting in injury or death caused by a high potential electric shock. ● Do not disconnect an electric cable while the machine is being operated.

(This may cause an electric shock and damage to the machine.) ● Do not blow high-pressure steam against the generator, the power distribution board, the power plugs, and the connector of magnet directly.

(This may cause damage to the machine.)

Be careful of remaining charge voltage!!

Inside the power distribution board Charge lamp

LM-0050E

3-46

Maintenance

Upper Frame Greasing Swing Ring Gear • Maintenance: every 500 hours

WARNING Before inspecting and greasing the turntable bearing and swing ring gear, low the magnet to the ground and stop the engine.

Inspection method 1. Remove the inspection port cover 1 and visually check for damage and the greasing condition of the gear surface.

Turntable Bearing Greasing • Maintenance: every 500 hours

2. If the gear surface is not well greased, add extreme pressure grease #2. (about 0.4 kg).

3. If the grease is white due to moisture or other substance it is necessary to replace it with new grease. ● Contact our office or Service Shop for ring gear repairs and grease replacement.

Greasing Supply extreme pressure grease #2 to the grease fittings (2 places) of the turntable bearing.

(Grease amount: Pump the grease gun 5-10 times at each grease fitting.)

4. If water has accumulated, remove the grease discharge port cover on the inside and discharge the water. a) Remove the guard cover of the lower center part. (If equipped) b) Remove the grease discharge port plug 2 on the lower inside. c) Discharge water or cloudy grease. d) Install the discharge port plug. e) Insert new extreme pressure grease #2 through the inspection port 3.

Refer to the page of the "Grease/oil and elements" for greasing amounts.

LM-0191

The illustration may differ from that of actual machine.

②

① ③

LM-0192

The illustration may differ from that of actual machine.

E7040

3-47

Maintenance Recommended Lubricants Gear Oil: API rating GL-4 class SAE90

Swing Unit Grease: Extreme Pressure Grease #2

Oil Level Inspection and Refilling of Swing Reduction Gear • Maintenance: every 250 hours

Ԙ

Remove the dipstick and check if the oil level is within the satisfactory range. If the level is low, refill gear oil through the filler port.

Ԛ

Satisfactory amount

Oil Replacement for Swing Reduction Gear • After first 250 hours • Maintenance: every 1,000 hours

ԙ 3-0009E

WARNING ● Wait until all areas cool down before beginning work.

● Slowly loosen the dipstick to release the pressure, otherwise, the oil may fly out if a certain pressure remains in the case.

CAUTION Check the drained oil for foreign matter such as metallic chips or powder. (If any foreign matter is found, contact our Service Shop.)

1. Have a drain pan for the gear oil ready.

2. Take out the dipstick 1, remove the drain plug 2 and drain the oil. After draining is completed, tighten the drain plug 2.

3. Remove the filler plug 3 and fill with the specified amount of gear oil through the filler port.

4. Check the oil level, with the dipstick, after 10 minutes.

5. If the oil level is satisfactory, install the filler plug 3.

3-48

E7050

Maintenance

Travel Unit Oil Replacement for Travel Reduction Gear • After first 250 hours • Maintenance: every 1,000 hours

Travel Reduction Gear WARNING ● The motor, shoe and oil are hot just after stopping the machine to travel. Wait until all the parts have cooled down before beginning work. ● Slowly loosen the plug to release the pressure, otherwise, the oil or plug may fly out if a certain pressure remains in the case.

1. Remove the oil filler plug 1 and drain plug 2, and drain the oil.

Check the drained oil for foreign matter such as metallic chips or powder.

2. After the oil is completely drained, wrap seal tape on the drain plug 3 and install it. Refill the specified mount of gear oil through the oil filler port.

Recommended Lubricants Gear Oil: API rating GL-4 class SAE90

Oil Level Inspection and Refilling of Travel Reduction Gear • Maintenance: every 250 hours

3. After refilling the oil, remove the level plug 2, and check the oil level.

4. Wrap seal tape on the filler plug 1 and level plug 2 and install them.

5. Slowly travel the machine and check for oil leakage.

1. Stop the travel motor in the position as shown in the below figure.

2. Slowly loosen the filler plug 1 to release the pressure. Otherwise, the oil or plug may fly out if a certain pressure remains in the case.

3. Remove the level plug 2 and check if the oil flows out.

4. If no oil flows out, remove the oil filter plug 1 and add oil up to the level plug 2 throgh the oil filler port.

5. Wrap seal tape on the filler plug 1 and level plug 2 and install them.

6. Slowly travel the machine and check for oil leakage.

Motor stop position during inspection and refilling

Ԙ

ԙ Ԛ 3-0061

1 Oil filler plug 2 Level plug 3 Drain plug E1660

3-49

Maintenance

Travel Unit

Inspecting Upper/Lower Take-up Roller (Idler Wheel) • As necessary

Inspection and Tightening of Shoe Plate • As necessary

Recommended Lubricants Engine Oil: API rating CD class SAE30 (Take-up Roller /Upper Roller)

If the machine is operated with loose track shoe bolts, the bolts can break and cause additional damage. Immediately tighten the shoe bolts whenever the looseness is found.

Gear Oil:Mobile Gear Oil SHC320 (Lower Roller)

Tightening Sequence The upper and lower rollers 1,2 use a floating seal type sealing mechanism. The service life lasts until overhaul, but check visually everyday before work for oil leakage.

If oil leakage is found, contact our Service Shop since the roller is required to be overhauled.

①

Tighten the bolts in the sequence shown in the below figure and check that the nuts and shoe are closely fitted to the link joining surface.

②

3-0063

IMPORTANT

3-0062

Wide shoes are designed for use in work on the soft ground or flat places.

If a wide shoe is used in the rocky place, the shoe will be deformed or damaged. Do not use wide shoes for work in the rocky or rough surface ground.

1 Lower roller 2 Upper roller

Cleaning Crawler • As necessary ● After finishing work on wet surface ground, remove the earth and mud attached between shoe and travel unit (sprocket). If left with earth attached, the earth gets solid and may cause damage to shoe and the travel performance will be affected. ● After finishing work on the beach or other salt covered places, wash off all salt completely. If washing off is not enough, the crawler will get rusty and cause early wearing and operational faults.

3-50

E1670

Maintenance

Travel Unit

Inspection and Adjustment of Track Shoe Tension • As necessary Tension adjustment

It is very important to adjust the track shoe tension to the proper level in order to extend the service life of the track and travel unit.

WARNING Slowly loosen the check valve. When the grease begins to flow out, do not loosen it any further. (Since the pressure inside the cylinder is very high, the grease will spout out or the plug will fly out if the valve is loosened too much.)

Tension inspection Swing the upper structure, press the magnet against the ground and use the boom cylinder to raise one side of the main body. Measure the clearance between the lower surface of the track frame and the upper surface of the shoe at the center of the crawler.

Depending on the conditions of the working area, slightly tighten for hard ground and slightly loosen for soft or sandy ground.

To tighten the tension of the track shoe, add grease through the grease nipple. To loosen the tension, loosen the check valve little by little to release the grease.

LM-0170

The illustration may differ from that of actual machine.

Proper clearance between the lower surface of the track frame and upper surface of the shoe: Model: Iron Shoe ---- 11.0 - 11.8 in (280 - 300 mm) 3-0066

If any space 1 exists between the take-up roller shaft and the track frame, you may use pressure to apply the grease. If the shoe tension is still loose, repair is necessary. Contact our approved Service Shop for the service.

3-0065

Ԙ 3-0067

1 It’s OK, if there is any allowance!!

3-51

Maintenance

Magnet

Adjustment of Magnet Backlash • As necessary 6. Adjusting Method a) Loosen the hexagonal socket head bolt 1 to remove the plate 2. b) Remove the shim plates 3 (as required) the amount corresponding to the backlash amount of the joining area (wear amount). c) Install the plate 2 and tighten the hexagonal head socket bolt 1. d) As the hexagonal socket bolt 1 is tightened, the plate 2 will be pressed against the steel bushing to reduce the clearance.

Clearance amount of about 0.05 in (1.2 mm) is preferable.

7. Apply grease as necessary.

WARNING Stop the engine before adjusting the magnet backlash.

Magnet Backlash Adjustment The machine is provided with a magnet adjustment mechanism which eliminates the backlash of the magnet-to-arm joining area caused by wear.

Due to this mechanism, the sealing condition of the O-rings is kept stable and the wear is delayed. The service life of the bushings and pins thereby increases.

IMPORTANT Too small amount of clearance may cause scuffing or seizure. Always check the clearance.

LM-0171

D

The illustration may differ from that of actual machine.

IMPORTANT

C

If the magnet backlash adjustment is not carried out properly, scuffing, unusual noise and backlash will occur, which causes damage to the Orings.

G

① F ② ③

Adjustment

E

A B

1Hexagonal socket head bolt 2Plate 3Shim plate ADust seal BO-ring CArm DClearance ESteel bushing FAttachment pin GMagnet

1. Set the hydraulic magnet as shown in the above figure and have it lightly touch the ground.

2. Turn it slightly to the left and position it so the arm end is pressed to the side which is not to be adjusted. (When the magnet is turned over, turn it to the right.)

3. Stop the engine.

4. Measure the clearance between the magnet and the arm joining portion.

5. If the clearance is more than 0.08 in (2 mm), remove the shim plate and adjust as follows.

3-52

LM-0172

Maintenance

Air Conditioner

Inspection and Care of Air Conditioner Inspecting air conditioner

4. Inspecting connecting lines and hoses Visually inspect the connecting parts of the air conditioner lines and hoses for oil, dirt and dust.

For continuous and comfortable use of the air conditioner, inspect it per the procedures below before beginning work.

1. Cleanliness of the condenser When the condenser is dirty, the heat dissipation ability is adversely affected. Wash with water to clean it.

IMPORTANT ● Do not wash the condenser with highly pressurized water. ● When the condenser installed in front of the radiator is very dirty, wash it with water.

3-0082

2. Inspecting fan V-belt tension When the tension of the V-belt is loose, it may slip or vibrate which causes shortened service life. Press down with your hand and check for deflection; tighten as required.

A

C

B

3-0081

A With a force of about 100 N (10 kgf), a deflection of 0.24 - 0.31 in (6 - 8 mm) should be kept.

3. Adjusting the tension of V-belt a) Loosen the nut B. b) Adjust the tension to tight tension bolt C. c) After adjusting, tight the nut B and fix.

E1741

3-53

Maintenance

Air Conditioner

Handling Air Conditioner

Maintenance of Air Conditioner

1. Before using the air conditioner in the summer, which has not been used for a long time.

WARNING

a) Refer to the "Inspecting the air conditioner" section and carry out the whole inspection. b) When operating the air conditioner, do not suddenly increase the compressor revolutions.

● When using compressed air, wear protective goggles.

● Do not wash inside air filter and air intake filter by water.

IMPORTANT

Cleaning fresh air intake filter Cleaning interval: every weeks

Inspecting the air conditioner before use will lengthen its service life and function.

1. Open the house door at the rear of the operator's cab to open the filter cover 3 of the cab.

2. Handling during off-season Whether it is summer or winter, leave the air conditioner installed because it has refrigerant inside it.

2. Remove the fresh air intake filter 2 to clean it.

3. After cleaning, attach the filter and close the filter cover 3.

IMPORTANT Leave the compressor drive belt as it is regardless of the season.

3. When not using for a long time Operate the air conditioner 1-2 times every 2-3 weeks.

This care prevents oil loss in the components and helps improve the compressor's service life and performance.

③ ②

①

3-0083

Cleaning inside air filter Cleaning interval: every weeks 1. Open the cover on the side of the air conditioner in the rear of operator's cab.

2. The filter is located light side the fuse box.

3. Remove the inside air filter 1 to clean it.

4. After cleaning, attach the filter and close the cover.

3-54

E1750

Maintenance

Air Conditioner

Routine Inspection Chart To enjoy lasting and comfortable use of the air conditioner, it is necessary to inspect it routinely. It leads to unnecessarily expensive repair costs to repair the air conditioner after problems occur.

It is highly recommended that preventive maintenance is carried out according to the chart below.

If the air conditioner should break down, turn the switch to OFF and ask for necessary repair.

WARNING ● The air conditioner circuit is filled with high pressure gas and if the lines or compressor parts are loosened, gas will spray out, which is very dangerous. ● Special tools and gauges are needed for the refilling or refrigerant and other maintenance. Always have the air conditioner serviced at a properly equipped service shop. Use R134a as a refrigerant (gas).

Inspection Intervals (Every)

Item Inspection Item

Components Compressor

Operating condition

Condenser

Cleanliness,clogging

12 months

6 months Evaporator

Cleanliness,clogging

Switch motors

Operating condition

12 months

Refrigerant

Filling amount

6 months

Receiver dryer

Damage, aging

12 months

V-belt

Damage, aging

6 months

Hoses

Damage, aging

12 months

Hose connection

Refrigerant leakage

6 months

Air conditioner main body

Lines

Mounting part

Refrigerant leakage, 6 months looseness, contact, damage

Filter

Cleanliness

E1760

Every week

3-55

Maintenance

Air Conditioner

Inspecting Refrigerant Amount

Inspections and refilling should be conducted in our Service Shop. (Inspection method) Operate the air conditioner, increase the engine speed slightly (1,400-1,600 rpm) and compared with bubbles observed through the sight glass with the chart.

WARNING ● With excess refrigerant, overcharge occurs and cooling is deficient. Also, the pressure inside the circuit becomes abnormally high and is dangerous. Operate the system with proper level of refrigerant. ● Operating the air conditioner with no refrigerant (gas) adversely affects the compressor. ● The indication of the sight glass is a guide.

Depending on the outside air conditions, it is difficult to determine situations based on the sight glass indication. Check highpressure changes while carrying out inspection (a sudden pressure increase occurs when being overcharged).

Refrigerant Amount

◯ Sufficient

×

Sight glass of receiver dryer

3-0084

Sight Glass Condition (1 minute after starting the air conditioner) Just after turning the air conditioner ON, few bubbles are visible, then they become transparent and turn into light milk-white color (transparent milk-White color) Bubbles flow is visible.

Check the fittings and refill refrigerant.

Insufficient

×

No bubbles are visible at all immediately after turning the air conditioner ON.

Overcharge

3-56

E1770

Maintenance

Routine Replacement Safety Parts

WARNING Routinely replace important safety parts listed in the chart below, which specially are related to safety and fire prevention.

It is difficult to determine the service life of these parts by visual inspection or from operations, so routinely replace them early one either every 2 years or every 4000 hours.

Important Safety Parts Chart ● Fuel System Routine Replacement Safety Parts Fuel Hose (Fuel Tank to Engine) Fuel Hose (Fuel Filter to Injection Pump)

Replacement Interval Every 2 years or every 4,000 hours, whichever comes first.

● Hydraulic System Routine Replacement Safety Parts

Pump Exit Hose (Pump to Operation Valve)

Routine Replacement Safety Parts Boom Cylinder Line Hose Arm Cylinder Line Hose Bucket Cylinder Line Hose

Replacement Interval Every 2 years or every 4,000 hours, whichever comes first.

Replacement Interval Every 2 years or every 4,000 hours, whichever comes first.

If any problem is found with any of these parts before the replacement interval, repair or replace as required.

Regarding the hoses, if any deformation, cracks, deterioration, etc. is found with the hose clamps, replace the clamps at the same time as the hoses.

Regarding hydraulic hoses not included in the routine replacement safety parts, carry out the inspection described below. If any problem is found, retighten, replace them or take necessary measures.

● Replace O-rings and gaskets at the same time as hose.

● Contact our office or Service Shop for replacement of safety parts. ● Carry out inspection of the hydraulic hoses and fuel hoses at the routine inspection listed below.

E1780

3-57

Inspection Classification

Inspection Item

Start-Up Inspection

Fuel, Hydraulic hose connections, Oil Leakage from caulked parts

Special Independent Inspection (Monthly Inspection)

Fuel, Hydraulic hose connections, Oil Leakage from caulked parts.

Fuel, Hydraulic hose damage (cracks, wear, gouge)

Special Independent Inspection (Yearly Inspection)

Fuel, Hydraulic hose connections, Oil Leakage from caulked parts.

Fuel, Hydraulic hose interference, squeezing, aging, twisting, damage (cracks, wear, gouge).

Maintenance

Troubleshooting

To extend the machine service life and improve the rate of operation, daily inspection and lubrication are necessary as well as for isolating any problem found and dealing with it. If the machine is operated with the problem uncorrected, it may cause major problem and sometimes lead to a serious accident or injury.

If problem occurs, search for the cause in the items described below and make adjustments, repairs, or take measures as necessary. If the cause is not identified, contact our dealer or Service Shop.

Engine and Related Area Refer to "Operator's Manual for Engine".

Problem

Cause

Remedy

Possible seizure in engine Incomplete air bleeding of fuel system No fuel in fuel tank Poor Fuel Quality Fuel filter clogged Low compression Defective fuel injection pump

Connect, repair connection (improper connection on battery terminals) Discharged battery, starter problems, contaminated or loose wiring connectors Inspect and replace as necessary Preheat with air heater Warm up the coolant (add hot water) Repair* Bleed air completely Refill Inspect and replace as necessary Clean and replace as necessary Repair* Repair*

Engine stops during operation

No fuel in fuel tank Fuel filter clogged Air is mixed in the fuel system

Refill Clean or replace Retighten fuel line connection

Improper oil pressure (Engine oil pressure)

Improper oil Defective oil pressure switch Oil filter clogged Low oil viscosity

Refill Replace* Replace element Replace with oil of viscosity matching temperature Adjust, clean, or replace if necessary* Repair

Engine does not start

Defective starter switch (Starter does not run) Defective rotation of starter (Starter rotates slowly) Improper viscosity of engine oil Excessive cooling of engine (Cold weather)

Improper oil pumping Oil leakage

Improper fuel injection timing Low compression

Drain oil to proper level Replace with oil of viscosity matching temperature Cover over radiator or replace parts if necessary Adjust* Disassemble and repair, replace parts*

Engine exhaust shows black or dark gray hue

Improper fuel Improper valve clearance Improper injection pumping Low compression Insufficient air intake (air cleaner clogged)

Replace with correct fuel Adjust Adjust or replace if necessary* Disassemble and repair, replace parts* Clean or replace element

Excessive fuel consumption

Improper injection pumping Improper spray from fuel injection nozzle Improper fuel injection timing Improper fuel Low compression Insufficient air intake

Adjust or replace if necessary* Adjust or replace if necessary* Adjust or replace if necessary* Replace with correct fuel Disassemble and repair, replace parts* Clean or replace element.

Engine exhaust shows white or blue hue

Excessive oil level Low oil viscosity Excessive cooling on radiator

* For items marked with *, contact our Service Shop.

3-58

E1790

Maintenance Problem Excessive engine oil consumption

Troubleshooting Cause

Remedy

Excessive oil level Low oil viscosity Oil leakage Worn cylinder piston ring

Drain oil to proper level Replace with oil of viscosity matching temperature Retighten and replace parts if necessary Disassemble and repair, replace parts*

Unusual noise (Fuel or mechanical)

Poor fuel quality Damage inside muffler

Replace Replace

Engine overheat (Water temperature is too high)

Low coolant Water leakage from each part Over stretch of belt or oil stain on belt Defective radiator Broken fan Excessive amount of antifreeze in the mixture Defective thermostat Defective water pump Defective water temperature gauge

Refill Repair Clean or replace Clean or replace* Replace* Replace Replace* Replace* Replace*

Defective battery charge

Improper belt tension Electrical wiring problems Defective battery Defective regulator Defective alternator

Adjust Repair Replace Replace* Repair or replace*

Clogged on air cleaner

Clogged on air filter element Clogged in air intake system, or foreign substance exists

Clean or replace Clean

* For items marked with *, contact our Service Shop.

Display Monitor Contact a service shop for repair of electronic parts (for controller, etc.).

Problem

Cause

Remedy

OVER HEAT

Water leakage from each part Over stretch of belt or oil stain on belt Defective radiator Many relieving work Broken fan Excessive amount of antifreeze on the mixture Defective thermostat Defective water pump Dirty oil cooler (clogged) Dirty radiator (clogged) Defective dust-protective net (clogged) Defective monitor

Repair Clean or replace Repair or replace* Operate without relieving Replace* Replace Replace* Replace* Clean Clean Clean Replace*

LOW OIL PRESS

Low engine oil Oil leakage on connection Defective engine oil pressure switch Low engine oil viscosity Improper engine oil pumping function Defective monitor Clogged on engine oil filter Defective sensor

Refill Repair Replace* Replace with oil of viscosity matching temperature Adjust, clean or replace if necessary* Replace* Change oil and replace oil filter if necessary Replace*

Low fuel Defective sensor

Refill Replace*

LOW FUEL

* For items marked with *, contact our Service Shop.

E1800

3-59

Maintenance Problem

Troubleshooting Cause

Remedy

ALTERNATOR

Belt tension Electrical wiring problem Defective battery Defective regulator Defective alternator

Adjust Repair Replace Replace* Repair or replace if necessary*

LOW COOLANT

Improper coolant Defective sensor

Refill Replace*

ELEC. PROBLEM

Short circuit, etc.

Inspect and repair*

AIR FILTER

Indicates the air filter is clogged Stopped up of suction system Foreign body invasion

Cleaner replace Clean

CHECK ENGINE

Breakdown of electric system of the engine failure Fault of sensor

Inspect and replace*

Trouble in intercooler Overloaded operation

Clean and inspect Operate it at a low idling for a while.

BOOST TEMP. HIGH

Replace*

* For items marked with *, contact our Service Shop.

Operation Problem Heavy operation motion

Cause

Remedy

Contaminants caught on control valve spool Valve sticking Insufficient lubrication on lever linkage Lever linkage sized

Wash control valve* Repair or replace valve assembly* Reapply grease / oil Reapply grease / oil

* For items marked with *, contact our Service Shop.

Hydraulic pump Problem

Cause

Remedy

No oil from hydraulic pump

Insufficient hydraulic oil Clogged on suction filter

Refill Replace filter, or change hydraulic oil if dirty

Hydraulic pump does not build pressure

Oil leakage inside hydraulic pump Air inside the hydraulic pump Main relief valve pressure is set too low

Replace hydraulic pump* Refill oil or check hose on suction side Adjust pressure*

Abnormal sound from hydraulic pump

Cavitation resulting from damaged hose on the suction side or suction filter is clogged Joint of the suction side is loose or hydraulic oil is low and air is entering.

Cavitation resulting from excessively high viscosity of hydraulic oil

Replace filter and/or replace hydraulic oil if dirty Retighten or grease the joints Check that oil is filled to proper level inside casing Replace with oil of correct viscosity

Oil leakage from hydraulic pump

Defective seal on hydraulic pump

Replace oil seal or hydraulic pump*

* For items marked with *, contact our Service Shop.

3-60

E1810

Maintenance

Troubleshooting

Working Attachments Problem

Cause

Remedy

Insufficient engine output Decreased performance due to wear of hydraulic pump Defective main relief valve Low hydraulic oil Incorrect viscosity of hydraulic oil Clogged on suction filter

Refer to ""Operator's manual for engine" Repair / replace hydraulic pump*

Defective operations

Damaged hydraulic pump Insufficient hydraulic oil level

Replace with hydraulic oil* Refill

Insufficient work power

Setting pressure for main or port relief valve is low or incorrect Damaged hydraulic cylinder packing Damage hydraulic cylinder piston

Adjust pressure or replace relieve valve*

Attachment lowers

Damaged hydraulic cylinder packing Damaged hydraulic cylinder piston / cylinder Oil leakage inside control valve Oil leakage inside holding valve

Replace hydraulic cylinder packing* Replace hydraulic cylinder piston or assembly* Repair valve assembly or replace if necessary* Repair valve assembly or replace if necessary*

Unusual noise from joints of the attachment

Insufficient grease Connecting pin seizure

Grease Replace the bushing and / or pin

Overall low power

Adjust the pressure or replace* Refill Replace with hydraulic oil of proper viscosity Replace suction filter

Replace hydraulic cylinder packing* Replace hydraulic cylinder piston or assembly*

* For items marked with *, contact our Service Shop.

Travel Problem

Cause

Remedy

Insufficient travel power

Pressure setting for main relief valve is too low Defective counterbalance valve Low performance of travel motor Swivel joint packing damaged Low performance of hydraulic pump

Adjust the pressure* Replace the counter balance valve* Replace travel motor* Replace swivel joint packing* Replace hydraulic pump*

Rough travel

Track too tight Stone or other object caught in track Defective valve Low performance of travel motor Air in travel motor

Adjust to proper tension Remove stone or foreign matter Repair / replace valve* Replace travel motor* Refill with oil

Crooked travel

Left and right tracks are not tensioned equally

Bleed air on right and left and adjust tracks to equal tension Replace hydraulic pump* Replace Hydraulic motor* Replace valve housing assembly* Replace swivel joint packing* Adjust

Low performance of hydraulic pump Low performance of travel motor Oil leakage inside control valve Damage swivel joint packing Lever linkage is loose * For items marked with *, contact our Service Shop.

E1820

3-61

Maintenance

Troubleshooting

Swing Problem

Cause

Remedy

Insufficient swing force

Low performance of swing motor Thermal seizure of swing shaft

Replace swing motor* Supply grease or replace the swing shaft*

During braking, swing does not stop

Low setting of brake valve Clogged valve Low performance of swing motor Internal oil leakage of control valve

Adjust pressure* Clean valve* Replace swing motor* Repair or replace valve assembly*

During stopping, swing slips

Low setting of port relief valve or break valve pressure Clogged valve Low performance of swing motor Internal oil leakage of control valve

Adjust the pressure*

Air in swing motor Insufficient lubrication of swing bearing

Grease Grease

Unusual noise during swing

Clean the valve* Replace swing motor* Repair or replace valve assembly*

* For items marked with *, contact our Service Shop.

Hydraulic Cylinder Problem

Cause

Remedy

Insufficient hydraulic cylinder power

Low setting of relief valve pressure Oil leakage inside hydraulic cylinder Damaged hydraulic cylinder piston or rod Oil leakage inside control valve

Adjust pressure* Replace cylinder packing* Replace hydraulic cylinder piston or rod* Repair or replace valve assembly*

Oil leakage outside hydraulic cylinders

Damaged hydraulic cylinder packing Damaged cylinder rod

Replace hydraulic cylinder packing* Replace cylinder rod*

* For items marked with *, contact our Service Shop.

3-62

E1830

Maintenance

Contacting Us

When ordering parts or asking questions about problems, give us the following information:

● Machine Serial Number & Engine Serial Number ● Service Meter Hours The Machine Serial Number and Engine Serial Number are on the warranty certificate as well as on the nameplate.

Machine Serial Number

Engine Serial Number

(Engine Model) (Number) 4HK1 - 000000

Machine Serial Number Stamped LM-0008E

3-0013E

The illustration may differ from that of actual machine.

Service Meter Hour Meter

● The engine running time is recorded on this meter.

The last digit indicates 1/10 of an hour (6 minutes). ● This is used as a standard for inspection and maintenance intervals of the machine.

TM

Model No.

Serial No.

TRIP

Manufacturer No.

ODO

12345.6 MADE IN JAPAN BY

1/10H 731-1 NAGANUMAHARACHO, INAGE-KU,CHIBA,JAPAN

KHP11160-00

3-0012E

TRIP 3-0269E

3-63

Specifications Contents • Conversion Factors • Specifications

Notice Please note that the specification of a vehicle delivered to you may be different from a model described in this manual because of continuing product improvement.

SPECIFICATIONS

4-0

Specifications

Conversion Factors

CONVERSION FACTORS Metric to U.S. MULTIPLY

BY

TO OBTAIN

Area:

sq. meter hectare

10.763 91 2.471 05

square foot acre

Force:

newton newton

3.596 942 0.224 809

ounce force pound force

Length:

millimeter meter kilometer

0.039 370 3.280 840 0.621 371

inch foot mile

Mass:

kilogram

2.204 622

pound

Mass/Area:

kilogram/hectare

0.000 466

ton/acre

Mass/Energy:

gr/kW/hr.

0.001 644

lbs/hp/hr.

Mass/Volume:

kg/cubic meter

1.685 555

lb/cubic yd.

Power:

kilowatt

1.341 02

horsepower

Pressure:

kilopascal bar

0.145 038 14.50385

lb/sq. inch lb/sq. inch

Temperature:

degree C

1.8 x C + 32

degree F

Torque:

newton meter newton meter

8.850 748 0.737 562

lb/inch lb/foot

Velocity:

kilometer/hr.

0.621 371

miles/hr.

Volume:

cubic centimeter cubic meter cubic meter milliliter litre litre litre litre

0.061 024 35.314 66 1.307 950 0.033 814 1.056 814 0.879 877 0.264 172 0.219 969

cubic inch cubic foot cubic yd. ounce (US fluid) quart (US liquid) quart (imperial) gallon (US liquid) gallon (imperial)

Volume/Time:

litre/min. litre/min.

0.264 172 0.219 969

gallon/min. (US liquid) gallon/min. (Imperial)

4-1

Specifications

Specifications DRAWN

CHK'D

APPR.

DATE

'08.Feb.25

BKBU7036-A

SPECIFICATIONS OF 240X2-MH HYDRAULIC EXCAVATOR (TIER 3 EMISSION ENGINE) FOR LBX Company

4-2

Specifications

Specifications

1. ENGINE Type

: Water-cooled, 4-cycle diesel, 4-cylinder in line, direct injection (electric control), Turbocharger with air cooled intercooler

Model

: ISUZU AH-4HK1X

Rated flywheel horse power (SAE J1349 NET)

: 132.1 kW (177 HP) at 2000 min-1 (rpm)

Piston displacement

: 5193 cc (317 cu in)

Maximum torque (SAE J1349 NET)

: 636 N-m (469 lbf-ft) at 1500 min-1 (rpm)

Bore and stroke

: 115 mm × 125 mm (4.53 in × 4.92 in)

Voltage

: 24 V

Alternator

: 50 Amp

Starter

: 24 V 5.0 kW

2. HYDRAULIC SYSTEM (a) Main pumps (1) Max. oil flow

: 2 variable displacement axial piston pumps with regulating system : 2 × 234 liter/min (61.8 US gpm) at 2000 min-1 (rpm)

(2) Working circuit pressure Boom/Arm/Bucket

: 34.3 Mpa (4970 psi, 350 kgf/cm2) : 36.8 MPa (5330 psi, 375 kgf/cm2) with auto power up

Swing circuit

: 28.9 MPa (4190 psi, 295 kgf/cm2)

Travel circuit

: 34.3 MPa (4970 psi, 350 kgf/cm2)

(b) Pilot pump

: 1 gear pump

(1) Max. oil flow

: 20 liter/min (5.3 US gpm)

(2) Working circuit pressure

: 3.9 MPa (570 psi, 40 kgf/cm2)

(c) Magnet operating pump

: 1 axial piston pump

(1) Max. oil flow

: 68 liter/min (18.0 US gpm)

(2) Working circuit pressure

: 25.0 MPa (3626 psi, 255 kgf/cm2)

(d) Control valves

: With Boom/Arm holding valve : One 4-spool valve for Right track travel, Bucket, Boom and Arm acceleration : One 5-spool valve for Left track travel, Auxiliary, Swing, Boom acceleration and Arm

(e) Swing device (1) Motor

: Fixed displacement axial piston motor

(2) Brake

: Mechanical disc brake

(3) Final drive

: Planetary gear reduction

(4) Turn table bearing

: Ball bearing type with internal gear

(5) Maximum swing speed

: 10.7 min-1 (rpm)

BKBU7036

4-3

Specifications (f) Cylinders

Specifications NO.of cylinders - bore × Rod diameter × Stroke

Boom

: 2 - φ 140 mm

× φ 95 mm

× 1126 mm

Arm

: 1 - φ 125 mm

× φ 90mm

× 1280 mm

Bucket

: 1 - φ 120 mm

× φ 85 mm

× 1010 mm

(g) Cooling system Fan

: φ 650 mm (25.6 in) with 7-blades

Radiator capacity

: 89.8 kW (77,200 kcal/h)

fin type fin space

: Corrugated fin (wavy type) : 2.0 mm

Long life coolant

: Coolant 55 %, Water 45 %

Oil cooler capacity

: 54.1 kW (46,500 kcal/h)

fin type fin space Intercooler capacity fin type fin space Fuel cooler capacity fin type fin space

: Corrugated fin (wavy type) : 1.75 mm : 18.7 kW (16,100 kcal/h) : Straight fin : 1.75 mm : 1.3 kW (1,150 kcal/h) : Corrugated fin (wavy type) : 2.0 mm

(h) Filters Suction filter

: 105 μ m

Return filter

:6μm

Pilot line filter

:8μm

3. HYDRAULIC CONTROLS (a) Boom/Arm/Bucket/Swing.................... Pilot pressure control system (ISO control pattern) (b) Travel.................................................. Pilot pressure control system (c) Work mode select (1) SP- mode ...................................... Super power operating mode (2) H - mode........................................ Heavy duty operating mode (3) Auto - mode................................... Automatic operating mode (d) Travel mode select (2-speed travel) (e) Attachment cushion control (f) Hydraulic lock (gate lock, left side tilt console) (g) Lifting magnet operating mode

4-4

BKBU7036

Specifications

Specifications

4. ELECTRICAL SYSTEM (a) Engine control (1) Dial type throttle control (2) One touch idle / Auto deceleration system (3) Emergency stop (b) Monitor system (1) Message display (Caution,condition, etc......)

(2) Work mode display (SP, H, Auto) (3) Machine condition (Power boost, etc......)

(4) Alarm display and buzzer (5) Water temperature (6) Hydraulic oil temperature (7) Fuel level (8) Diagnosis system (c) Wire harness Waterproof type connector (d) Safety (1) Travel alarm (2) Double horn (e) Battery

: 2 × 12 V 92Ah / 5HR

(f) Lights (1) Working light Upper

: 24 V 70 W × 1

Boom

: 24 V 70 W × 1

(2) Operator’s cab room

: 24 V 10 W × 1

5. OPERATOR ENVIRONMENT (a) Operator's cab (1) Smooth and round shape design cab, fabricated by press work (2) Safety glass for front window (3) Shock-less cab suspension by 4-point fluid mounting (4) Sliding front window with auto lock (5) Built-in type LCD monitor display (6) Membrane switch on monitor display (7) Windshield wiper & washer (8) AM/FM Radio with auto-tuner (9) Floor mat

BKBU7036

4-5

Specifications

Specifications

(10) Hinged skylight (11) Auto air conditioner (12) Hydraulic cab riser (b) Operator's seat KAB 815

: Low frequency mechanical suspension with helical springs and double acting hydraulic damper.

With following features Manual weight adjustment

Backrest angle adjustment

Seat height and tilt adjustment Adjustable pivoting armrests Adjustable headrest

Retractable seat belt

(c) Others (1) Rear view mirror (Cab side & Right side)

6. UNDERCARRIAGE (a) Travel motor

: Variable displacement axial piston motor

(b) Brake

: Mechanical disc brake

(c) Hydraulic service brake

: Brake valve

(d) Final drive

: Planetary gear reduction

(e) Travel speeds

: High

5.5 km/h (3.4 mph)(Automatic travel speed shifting)

Low

3.5 km/h (2.2 mph)

(f) Drawbar pull

: 216.0 KN (45,560 lbf)

(g) Number of carrier rollers (each side)

:2

(h) Number of track rollers (each side)

:9

(i) Number of shoes (each side)

: 51

(j) Type of shoe

: Triple grouser shoe

(k) Link pitch

: 190 mm

(l) Width of shoe

: 600 mm (S.T.D)

(m) Grade-ability

: 70 % (35°)

7. Mass (a) Operating mass 30,700 kg (67,700 lb)

with 5.00 m Arm , φ1370 Sumitomo Magnet , 600 mm grouser shoe operator, lubricant, coolant and full fuel tank

(b) Shipping mass 28,100 kg (62,000 lb)

Operating mass - (operator mass (75kg) + 90 % of fuel mass + magnet mass (2240kg))

4-6

BKBU7036

Specifications (c) Ground pressure

Specifications : 0.068 MPa

(with 5.00 m Arm, φ1370 Sumitomo Magnet , 600 mm grouser shoe)

8. DIMENSIONS (5.00 m Arm) Overall length (without attachment)

5580 mm

Overall length (with attachment)

10230 mm

Overall height (with attachment)

3240 mm

Minimum cab height

3240 mm

Maximum cab height

5540 mm

Cab riser stroke

2300 mm

Upper structure overall width

2820 mm

Swing (rear end) radius

2950 mm

Clearance height under upper structure

1100 mm

Minimum ground clearance

460 mm

Wheel base (Center to center of wheels)

3840 mm

Crawler overall length

4650 mm

Track gauge

2590 mm

Undercarriage overall width (with 600 mm shoes)

3190 mm

Crawler tracks height

940 mm

9. WORKING RANGES (5.00 m Arm) Boom length

7100 mm

Maximum reach at GRP

11420 mm

Maximum reach

11580 mm

Maximum depth

3660 mm

Maximum height

12630 mm

BKBU7036

4-7

Specifications

Specifications

10. SYSTEM FLUID CAPACITIES AND SPECIFICATIONS Capacities

Specifications

Hydraulic system

250 liter (66 US gal)

ISO VG 46

Hydraulic sump tank

147 liter (39 US gal)

ISO VG 46

Fuel tank

410 liter (108 US gal)

Light oil (Diesel)

Cooling system

25.6 liter (6.7 US gal)

Coolant 55 %, Water 45 %

Final drive case (per side)

5.0 liter (1.3 US gal)

API GL-4 90

Swing drive case

9.7 liter (2.6 US gal)

API GL-4 90

Engine crank case (With Remote Oil Filter)

23.1 liter (6.1 US gal)

API CD SAE 15W-40

11. PAINTING (a) Design and color Per the separate agreement reached between LBX and Sumitomo.

However, paint color of the inside of the machine house shall be made per Sumitomo's design. (b) Paint Cab .....................Melamine resin coating for baking finish Others .................Attachment & Upper Structure: Urethane resin coating Undercarriage

: Special modified acrylic resin coating

(c) Paint specification Method of application and type of paint shall be per Sumitomo standard.

NOTE ; (1) Sumitomo is constantly improving its products and therefore reserves the right to change design and specification at any time.

(2) Illustrations may include optional equipment and may not include all standard equipment.

(3) This specifications is made referring to ISO 7135 (Earth-moving machinery -Hydraulic excavators Terminology and commercial specifications) first edition dated 1993-08-15.

4-8

BKBU7036

Specifications

BKBU7036

Specifications

4-9

Specifications

Specifications

4-10

BKBU7036

Specifications

BKBU7036

Specifications

4-11

Optional Components Contens • Selector Valve

OPTION

5-0

Optional Components

Selector Valve

Selector valve (2-way) Switching method

When a selector valve is equipped, the operation patterns of the right/left operation levers can be changed by switching over the valve.

1. Lower the bucket to the ground level and shut off the engine.

2. Open the door behind operator’s cab.

WARNING

3. Remove the cover of the selector valve under the air cleaner.

Before operating the machine, make sure of the operating method: otherwise, it could lead to misoperation and it is very dangerous.

To prevent the accident caused by misoperation, operate the machine after confirming the movement of machine is the same as the control pattern card in the operator’s cab without fail. When differing, exchange the control pattern card before operating the machine. Or, change the operation method. When you change the operation method, be sure to stop the engine.

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4. Pull knob 1, move lever 2, and set the lever to a desired operating pattern.

5. The removed cover is installed.

6. Close the door behind operator’s cab.

7. Change the operation control pattern card in the operator’s cab to the one corresponding to the codes which have been switched over.

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8. Start the engine, and make sure that the control pattern card matches the operating method.

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5-1