New Holland E115SR Excavators Operation and Maintenance Instruction Manual 604.21.538.00 -

Operation and Maintenance Instruction Manual

E115SR

Operation and Maintenance Instruction Manual

E115SR

Print No. 604.21.538.00 English - Printed in Italy

PROVEN PERFORMANCE

PROVEN PERFORMANCE

E115SR OPERATION AND MAINTENANCE INSTRUCTION MANUAL ENGLISH Print No. 604.21.538.00

Edition: 02/2005 English - Printed in Italy Printed by Studio ti - 15605

WARNING

READ THIS MANUAL CAREFULLY BEFORE STARTING, OPERATING, SERVICING. REFUELLING OR CARRYING OUT ANY OTHER WORK ON THE MACHINE.

WARNING

This symbol is your alert sign and is specifically intended for safety purposes. It means: ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

WARNING

Read and comply with all precautionary statements following the key-words DANGER, WARNING and CAUTION.

WARNING

Machine-mounted safety signs are colour coded yellow with black borders and lettering when they refer to points where special ATTENTION must be paid as an ACCIDENT may occur. They are white with red borders and black lettering when they refer to a FORBIDDEN practice.

IMPORTANT: Data contained in this manual was current at the time of publication. It is the Manufacturer’s policy to constantly improve its products and such changes may affect information herein. If variances are observed, contact your Dealer and After-Sales Service.

WARNING

Read this manual before operating the machine Most accidents occurring during work are due to non-observance of simple safety norms and elementary precautions.

Many accidents can be avoided if the causes are known and opportune cautions taken beforehand.

There is no device or protection, no matter how advanced, that may prove so effective at avoiding accidents as a careful and attentive behaviour.

WARNING

Ensure that the attachment is safely resting onto the ground before repairing, adjusting or servicing machines fitted with hydraulically, mechanically or cable controlled attachments (such as, excavators, loaders, dozers, scrapers, etc.). Should it be necessary to partially or fully raise the hydraulically, mechanically or cable controlled attachment to gain access to certain items, make sure the attachment is adequately retained in the raised position by means other than the hydraulic lift cylinders, cables and/or mechanical devices used for controlling it.

MACHINE SERIAL NO. ENGINE TYPE

ISUZU BB-4BG1T

ENGINE SERIAL NO. NOTES VALID FOR MODELS

E115SR: YV04-03001~ E115SRL: LD04-01200~

COPYRIGHT BY NEW HOLLAND KOBELCO CONSTRUCTION MACHINERY Strada di Settimo, 323 - 10099 S. MAURO T.SE ( TO ) ITALY

S.p.A.

INDEX Index SECTION I Safety precautions ..........................................................................................................................................1 1.1 General safety information .......................................................................................................................... 2 1.2 Safety precautions ...................................................................................................................................... 2 1.3 Pre-start safety ............................................................................................................................................ 5 1.4 Safety during operation ............................................................................................................................... 8 1.5 Inspection & maintenance safety .............................................................................................................. 12 1.6 Battery safety ............................................................................................................................................ 15 1.7 Warning labels & tag ................................................................................................................................. 17 1.8 Prohibited machine operation ................................................................................................................... 26 1.9 End of work shift safety ............................................................................................................................. 27 1.10 Use of protective structures .................................................................................................................... 28 1.11 Use safety valve and overload alarm ...................................................................................................... 28 SECTION II Machine familiarization ................................................................................................................................. 29 2.1 Foreword ................................................................................................................................................... 30 2.2 Identification data ...................................................................................................................................... 31 2.3 Noise levels (2000/14/EC) ......................................................................................................................... 32 2.4 Basic components of the excavator .......................................................................................................... 33 2.5 Operator cab nomenclature ...................................................................................................................... 34 2.6 Component & controls nomenclature ........................................................................................................ 36 SECTION III Basic machine operation .............................................................................................................................. 67 3.1 Pre-start check .......................................................................................................................................... 68 3.2 Starting & stopping machine engine with temperature above 0° C (32° F) ............................................... 68 3.3 Starting & stopping machine engine with temperature below 0° C (32° F) ............................................... 69 3.4 Starting machine engine with booster cables ........................................................................................... 71 3.5 Machine warm up ...................................................................................................................................... 73 3.6 Controls decal ........................................................................................................................................... 74 3.7 Basic operation of hydraulic controls ......................................................................................................... 75 3.8 Practices to improve efficiency .................................................................................................................. 83 3.9 Flagman hand signals ............................................................................................................................... 87 SECTION IV Maintenance .................................................................................................................................................. 91 4.1 General information ................................................................................................................................... 92 4.2 General safety & precautions .................................................................................................................... 93 4.3 Inspection and maintenance chart ............................................................................................................ 97 4.4 Fluids and filters ........................................................................................................................................ 99 4.5 Pre-start inspection & maintenance ........................................................................................................ 101 4.6 50 hour & new machine break-in inspection & maintenance procedures ............................................... 112 4.7 100 Hour inspection & maintenance procedures .................................................................................... 119 4.8 250 Hour inspection & maintenance procedure ...................................................................................... 122 4.9 500,1000 Hours inspection & maintenance procedures ......................................................................... 125

INDEX 4.10 2000 Hour inspection & maintenance procedures ................................................................................ 128 4.11 Miscellaneous ....................................................................................................................................... 140 SECTION V Transportation .............................................................................................................................................145 5.1 Ground transportation ............................................................................................................................. 146 5.2 Lifting machine ........................................................................................................................................ 148 5.3 Lifting machine (without attachment) ...................................................................................................... 150 5.4 Shipping dimensions ...............................................................................................................................151 SECTION VI Specifications .............................................................................................................................................. 155 6.1 General specifications ............................................................................................................................. 156 6.2 Specifications – optional attachments ..................................................................................................... 162 6.1 General specifications ............................................................................................................................. 163 6.4 Specifications – optional attachments ..................................................................................................... 168 6.5 Bucket and arm combinations .................................................................................................................169 6.6 Torque specifications ...............................................................................................................................169 6.7 Miscellaneous information ....................................................................................................................... 172 SECTION VII Troubleshooting ..........................................................................................................................................173 7.1 General troubleshooting .......................................................................................................................... 174 SECTION VIII Optional equipment ....................................................................................................................................181 8.1 Hydraulic breaker ....................................................................................................................................182 8.2 Safety precautions .................................................................................................................................. 186 8.3 Maintenance for nibbler / breaker ............................................................................................................ 188 8.4 Reinforcement of attachment .................................................................................................................. 188 8.5 Extra (grapple, clamshell, etc) & breaker ................................................................................................ 189 8.6 Dozer blade specifications ...................................................................................................................... 191 SECTION IX Special procedures .....................................................................................................................................193 9.1 General ................................................................................................................................................... 194 9.2 Releasing travel motor brakes .................................................................................................................194 9.3 Lowering attachment when sudden engine failure occurs ...................................................................... 197 9.4 Hydraulic tank pressure .......................................................................................................................... 198 9.5 Releasing swing brake ............................................................................................................................ 199

Section I SAFETY PRECAUTIONS

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

SECTION I - SAFETY PRECAUTIONS

1.1 GENERAL SAFETY INFORMATION WARNING WARNING DO NOT OPERATE OR PERFORM ANY MAINTENANCE ON THIS MACHINE UNTIL ALL INSTRUCTIONS FOUND IN THIS MANUAL HAVE BEEN THOROUGHLY READ AND UNDERSTOOD. IMPROPER OPERATION OR MAINTENANCE OF THIS MACHINE MAY CAUSE ACCIDENTS AND COULD RESULT IN SERIOUS INJURY OR DEATH. ALWAYS KEEP THIS MANUAL IN THE OPERATOR’S SEAT POCKET. IF IT IS MISSING OR DAMAGED, PLACE AN ORDER WITH YOUR DEALER FOR A REPLACEMENT.IIF YOU HAVE ANY QUESTIONS, PLEASE CONSULT YOUR DEALER.

1. Most accidents, which occur during operation, are due to neglect of precautionary measures and safety rules. Sufficient care should be taken to avoid these accidents. Erroneous operation, lubrication or maintenance services are very dangerous and may cause injury or death of personnel. Therefore all precautionary measures, NOTES, DANGERS, WARNINGS and CAUTIONS contained in this manual and on the machine should be read and understood by all personnel before starting any work with or on the machine.

2. Operation, inspection, and maintenance should be carefully carried out, and safety must be given the first priority. Messages of safety are indicated with marks. The safety information contained in this manual is intended only to supplement safety codes, insurance requirements, local laws, rules and regulations.

3. Messages of safety appear in this manual and on the machine. All messages of safety are identified by the words "DANGER", "WARNING" and "CAUTION".

DANGER Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

2

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

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 possible damage to the machine and its components.

4. It is very difficult to forecast every danger that may occur during operation. However, safety can be ensured by fully understanding proper operating procedures for this machine according to methods recommended by the Manufacturer.

5. While operating the machine, be sure to perform work with great care, so as not to damage the machine, or allow accidents to occur.

6. Continue studying this manual until all Safety, Operation and Maintenance procedures are completely understood by all persons working with the machine.

1.2 SAFETY PRECAUTIONS

WARNING THE PROPER AND SAFE LUBRICATION AND MAINTENANCE FOR THIS MACHINE, RECOMMENDED

BY THE MANUFACTURER, ARE OUTLINED IN THIS MANUAL FOR THE MACHINE. IMPROPER PERFORMANCE OF LUBRICATION OR MAINTENANCE PROCEDURES ARE DANGEROUS AND COULD RESULT IN INJURY OR DEATH. READ AND UNDERSTAND THIS MANUAL BEFORE PERFORMING ANY LUBRICATION OR MAINTENANCE.

The serviceman or mechanic may be unfamiliar with many of the systems on this machine. This makes it important to use caution when performing service work. A knowledge of the system and or components is important before the removal or disassembly of any component.

SECTION I - SAFETY PRECAUTIONS Because of the size of some of the machine components, the serviceman or mechanic should check the weights noted in this manual. Use proper lifting procedures when removing any components.

Weight of components table is shown in the section “SPECIFICATIONS”.

device from a system that utilizes pressure.

7. Lower the bucket, blade, or other attachments to the ground before performing any work on the machine. If this cannot be done, make sure the bucket, blade, ripper or other attachment is blocked correctly to prevent it from dropping unexpectedly.

The following is a list of basic precautions that must always be observed.

8. Use steps and grab handles when mounting or dismounting a machine. Clean any mud or debris from steps, walkways or work platforms before using. Always face the machine when using steps, ladders and walkways. When it is not possible to use the designed access system, provide ladders, scaffolds, or work platforms to perform safe repair operations. Refer to the sction I “MOUNTING & DISMOUNTING MACHINE”.

1. Read and understand all Warning plates and decal on the machine before Operating, Maintaining or Repairing this machine.

2. Always wear protective glasses and protective shoes when working around machines. In particular, wear protective glasses when using hammers, punches or drifts on any part of the machine or attachments. Use welders gloves, hood/goggles, apron and the protective clothing appropriate to the welding job being performed.

Do not wear loose fitting or torn clothing. Remove all rings from fingers, loose jewelry, confine long hair and loose clothing before working on this machinery.

3. Disconnect the battery and hang a “Do Not Operate” tag in the Operators Compartment.

Remove ignition keys.

4. If possible, make all repairs with the machine parked on a level, hard surface. Block the machine so it does not roll while working on or under the machine. Hang a “Do Not Operate” tag in the Operators Compartment.

5. Do not work on any machine that is supported only by lift, jacks or a hoist. Always use blocks or jack stands, capable of supporting the machine, before performing any disassembly.

9. To avoid back injury, use a hoist when lifting components which weigh 23kg (50lbs) or more.

Make sure all chains, hooks, slings, etc., are in good condition and are the correct capacity. Be sure hooks are positioned correctly. Lifting eyes are not to be side loaded during a lifting operation.

10. To avoid burns, be alert for hot parts on machines which have just been stopped and hot fluids in lines, tubes and compartments.

11. Be careful when removing cover plates. Gradually back off the last two capscrews or nuts located at opposite ends of the cover or device and carefully pry cover loose to relieve any spring or other pressure, before removing the last two capscrews or nuts completely.

12. Be careful when removing filler caps, breathers and plugs on the machine. Hold a rag over the cap or plug to prevent being sprayed or splashed by liquids under pressure. The danger is even greater if the machine has just been stopped because fluids can be hot.

WARNING DO NOT OPERATE THIS MACHINE UNLESS YOU HAVE READ AND UNDERSTAND THE INSTRUCTIONS IN THIS MANUAL. IMPROPER MACHINE OPERATION IS DANGEROUS AND COULD RESULT IN INJURY OR DEATH. 6. Relieve all pressure in air, oil or water systems before any lines, fittings or related items are disconnected or removed. Always make sure all raised components are blocked correctly and be alert for possible pressure when disconnecting any

13. Always use the proper tools that are in good condition and that are suited for the job at hand.

Be sure you understand how to use them before performing any service work.

14. Reinstall all fasteners with the same part number.

Do not use a lesser quality fastener if replacements are necessary.

3

SECTION I - SAFETY PRECAUTIONS 15. Repairs which require welding should be performed only with the benefit of the appropriate reference information and by personnel adequately trained and knowledgeable in welding procedures. Determine type of metal being welded and select correct welding procedure and electrodes, rods or wire to provide a weld metal strength equivalent at least to that of the parent metal. Make sure to disconnect battery before any welding procedures are attempted.

16. Do not damage wiring during removal operations.

Reinstall the wiring so it is not damaged nor will be damaged in operation of the machine by contacting sharp corners, or by rubbing against some object or hot surface. Do not connect wiring to a line containing fluid.

17. Be sure all protective devices including guards and shields are properly installed and functioning correctly before starting a repair. If a guard or shield must be removed to perform the repair work, use extra caution and replace the guard or shield after repair is complete.

18. The maintenance and repair work while holding the bucket raised is dangerous due to the possibility of a falling attachment. Don’t fail to lower the attachment and place the bucket to the ground before starting the work.

19. Loose or damaged fuel, lubricant and hydraulic lines, tubes and hoses can cause fires. Do not bend or strike high pressure lines or install ones which have been bent or damaged. Inspect lines, tubes and hoses carefully. Do not check for leaks with your hands. Very small (pinhole) leaks can result in a high velocity oil stream that will be invisible close to the hose. This oil can penetrate the skin and cause personal injury. Use card-board or paper to locate pinhole leaks.

20. Tighten connections to the correct torque. Make sure that all heat shields, clamps and guards are installed correctly to avoid excessive heat, vibration or rubbing against other parts during operation. Shields that protect against oil spray onto hot exhaust components in event of a line, tube or seal failure must be installed correctly.

4

21. Do not operate a machine if any rotating part is damaged or contacts any other part during operation. Any high speed rotating component that has been damaged or altered should be checked for balance before reusing.

22. Be careful when servicing or separating the tracks (crawlers). Chips can fly when removing or installing a track (crawlers) pin. Wear safety glasses and long sleeve protective clothing. Tracks (crawlers) can unroll very quickly when separated.

Keep away from front and rear of machine. The machine can move unexpectedly when both tracks (crawlers) are disengaged from the sprockets.

Block the machine to prevent it from moving.

23. Do not breathe dust generating when cleaning parts such as radiators: their inhalation can be harmful for your health.

SECTION I - SAFETY PRECAUTIONS

1.3 PRE-START SAFETY Many failures that occur during machine operation or servicing result from neglecting fundamental safety precautions. The following safety precautions are given to prevent such failures, but they are only a part of what you must follow. Read, understand and follow all safety precautions found in this manual and on the machine thoroughly before operating the machine.

F1437

OBSERVE ALL SAFETY PRECAUTIONS

A. OBSERVE SAFETY PRECAUTIONS Follow all safety rules, precautions, and operating procedures. If there are other personnel and flagmen working in the area, have them observe the specified signs.

B. WEAR PROTECTIVE CLOTHING Wear well fitting safety shoes, hard hat, and working clothes, and put on protective glasses, face shield, ear protection and gloves. When necessary, wear reflective vest.

F1438

WEAR PROTECTIVE CLOTHING

C. READ AND UNDERSTAND THE OPERATOR’S MANUAL Before operating the machine, read and understand this operator’s manual thoroughly in order to use the machine effectively and safely.

D. KEEP OPERATOR’S MANUAL IN MACHINE CAB Keep this manual in the specified storage area located behind the operator’s seat for quick reference. Should the operator’s manual become lost or damaged, contact your Dealer to order the operator’s manual.

F15644

READ MANUAL / KEEP IN MACHINE CAB

E. HOW TO HANDLE LIFE HAMMER A life hammer is provided on the left side of cab.

In case of emergency, take the life hammer, break the cab glass, and escape from the cab.

In addition, the life hammer is equipped with a cutter on the lever side to cut the seat belt, etc.

HOW TO HANDLE LIFE HAMMER

5

SECTION I - SAFETY PRECAUTIONS F. PREPARE FOR EMERGENCIES Have a fire extinguisher and first aid kit ready for emergencies. Know how to operate the fire extinguisher and know where the first aid kit is located for easy access in case of emergency.

F1440

PREPARE FOR EMERGENCIES

G. ENSURE SAFETY AT THE WORK SITE Know the work area! Before operating the machine, carefully survey and record the land and worksite features to prevent the machine from falling or the soil from caving in.

F16313

WORK SITE SAFETY-KNOW THE AREA

H. PERFORM PRE-START INSPECTION Before starting the machine, perform a PRESTART inspection of the machine. If any problems are found, repair or replace defective components immediately. DO NOT OPERATE THE MACHINE until all problem areas are properly repaired.

Always keep the windshield, working lamps, and mirrors clean for good visibility.

F15977

I. ENGAGE SAFETY LOCK LEVER BEFORE LEAVING MACHINE Before leaving the operator’s seat, move the safety lock lever to the “LOCKED” (Up) position.

This will not allow operation of any hydraulic controls should they be accidentally moved. If the lever is not set to the "LOCKED" position and hydraulic controls are touched accidentally, the machine may move suddenly resulting in serious injury.

Also before leaving the machine, lower the bucket to the ground, place the safety lock lever in the “LOCKED” (Up) position, stop the engine and remove the starter switch key.

6

PRE-START INSPECTION THE MACHINE

LOCK (UP) POSITION

SAFETY LOCK LEVER

SECTION I - SAFETY PRECAUTIONS J SIGNS, SIGNALS & FLAGMEN Install signs on soft shoulders and ground areas, and have a flagman direct the operation if necessary. The operator should note marks and follow signals from the flagman. All personnel should know the meaning of the signs, marks, and signals. Only one flagman should give the signs and signals.

F20209

SIGNS, SIGNALS & FLAGMEN

K. KEEP FIRE AWAY FROM FUEL AND OIL Oil, antifreeze, and especially fuel are highly flammable. Never use fire near the machine.

Securely tighten all fuel and oil caps. Keep fuel and oil in the designated storage areas. Promptly clean up any oil spills and dispose of waste properly.

FUEL

F1475

KEEP FIRE AWAY FROM FUEL & OIL

L. USE CAUTION NEAR NOISE If noise is high during operation, hearing loss may result. Approved hearing protection should be used if personnel will be exposed to high noise levels for a long period of time.

F1439

USE CAUTION NEAR NOISE

M. MOUNTING & DISMOUNTING MACHINE When getting on and off the machine, always maintain three point contact by using the handrails and step. Inspect and clean handrails, step, and mounting parts. Remove slippery materials, such as lubricants, and mud. Always place the cab entrance parallel to the tracks (crawlers) before stopping the engine for dismounting.

KEEP STEP CLEAN AND IN GOOD CONDITION

USE GRIP BARS AND STEP RAILS

MOUNTING/DISMOUNTING MACHINE

7

SECTION I - SAFETY PRECAUTIONS N. AVOID HOT SURFACES & AREAS Immediately after the machine is operated, the temperature and pressure of the engine coolant, engine oil, and hydraulic oil are very high. Burns may result if caps are removed, or oil, water, or filters are changed under these conditions. Wait until the temperature goes down, before attempting to check fluids or change filters.

F1469

HOT SURFACES

O. USE THE PROPER OPTIONAL ATTACHMENT Use only optional attachments designed for and approved by the Manufacturer. Read, understand and follow all instructions in the manual accompanying the optional attachment.

Use of any optional attachment not approved by the Manufacturer in writing, can cause serious injury to personnel, damage to the machine and its components and shorten the life of the machine. Contact your Dealer for optional attachments available for the machine.

F15979

USE PROPER ATTACHMENT

P. PREVENT FIRES Leaking or spilled fuel, lubricants and hydraulic oil are fire hazards. Clean and properly dispose of spills as they occur. Repair or replace all leaking components to prevent fire. Also, clean the machine regularly removing all debris to help prevent fires, pay particular attention to removal of leaves, sticks, paper etc. Keep fire extinguisher in an accessible area and know how to use the fire extinguisher should a fire occur.

F1457

PREVENT FIRES-CLEAN UP SPILLS

1.4 SAFETY DURING OPERATION A. STARTING ENGINE Sit in the operator’s seat.

Sound the horn before starting the engine to alert people the machine is being started. Make sure no one is near the machine.

Do not short circuit the starter circuit or battery to start the machine. This may cause serious injury or cause damage the electrical system.

F15659

SOUND HORN BEFORE STARTING

8

SECTION I - SAFETY PRECAUTIONS B. PASSENGERS This equipment is not intended or designed for the transportation of persons. Never allow persons to ride on the machine. Serious injury or death can result from allowing passengers on or in the machine.

C. TRAVEL Sound horn before moving the machine to inform persons that the machine is travelling. Position the attachment as shown in illustration before beginning travel. Move the machine at slow speeds. Do not turn suddenly on rough terrain.

Avoid travelling over obstacles. Should it become necessary to travel over an obstacle, keep the attachment low to the ground and travel at extremely slow speed.

The incorrect operation of the control levers or of the travel pedals can cause serious injuries or mortal accidents.

Before driving the machine, check for the position of the undercarriage according to the operator’s seat. If the travel motors are located in front of the cab, the machine will move backwards when pushing the travel/pedal control levers forward.

F15980

NO PASSENGERS

F20207

KNOW TRAVEL MOTOR POSITION

D. SWING Make certain the swing area of machine is clear of all persons and obstacles before operating swing controls. Sound horn before swinging machine. If necessary, have a flagman signal operator during operation to help prevent injury to persons or damage to obstacles and equipment.

F14394

SWING SAFETY/USE SWING FLASHERS

E. BOOM, ARM & ATTACHMENTS Give the work you are doing your undivided attention. Make certain the attachment being used is suited for the job at hand. Make certain of obstacles in the work area and operate the machine within those limits. If necessary have a flagman signal the operator to prevent injury to persons or damage to the machine or obstacles in the work area.

ALWAYS PLACE ATTACHMENTS ON THE GROUND AND RAISE THE SAFETY LOCK LEVER BEFORE LEAVING THE CAB.

F20208

SAFETY DURING PARKING

9

SECTION I - SAFETY PRECAUTIONS F. OPERATING ON INCLINES OR SLOPES Operation of this machine on an incline or slope may cause the machine to become unstable or unbalanced. Work up and down inclines or slopes, never across. Never slew/swing or turn machine around on slopes. Build a level area for the machine to operate. Operate controls carefully to prevent sudden movements which may cause the machine to slide or tip over.

G. WORKING AROUND UTILITIES If it is suspected that utility lines such as gas, water, phone or electrical power are in the work area, contact the local utility authority for line location BEFORE beginning work in the area.

Use extreme caution around electrical power lines. Keep a sufficient distance away from electrical lines during operation. See chart below for minimum distances.

Operation Voltage up to 1000 V from 1 kV to 110 kV from 110 kV to 220 kV from 220 kV to 380 kV unknown

Safety distance 1.0 m 3.0 m 4.0 m 5.0 m 5.0 m

F15982

F15983

KEEP A SAFE DISTANCE FROM UTILITIES

H. LIFTING This machine is an excavator. Use extreme caution when lifting or moving heavy loads. Use proper lifting equipment rated at a capacity to handle the load. NEVER USE BUCKET TEETH TO LIFT OR MOVE HEAVY LOADS.

I. FROZEN & SNOW COVERED WORK SITES Use extreme caution when operating the machine on frozen or snow covered work sites.

Operate all controls slowly and cautiously to prevent sudden movements such as start/stop/ turn, that may cause the machine to unexpectedly shift, slide or move. Even on the slightest slope, when snow is present or work area is frozen, it can allow a machine to unexpectedly move. Snow on shoulders or snow drifts can be much deeper than expected. The machine can easily become buried under such conditions. Use extreme caution while operating the machine around or in snow.

Be careful for frozen ground that becomes soft along with the increase of ambient temperature.

10

USE PROPER LIFTING DEVICES

F15984

USE EXTREME CAUTION ON FROZEN OR SNOW

SECTION I - SAFETY PRECAUTIONS J. FILLED OR UNSTABLE GROUND Be certain the condition of the work site is stable and capable of supporting the machine during operation. Do not operate attachment too close to the machine. Operation of the machine on shoulders or filled areas could cause the machine to become unstable presenting a work hazard. Position the travel motors to the rear of the machine, allowing for quick reversal, should the work area become unstable.

F16313

WORK ON STABLE GROUND

K. RESTRICTED WORK AREAS In work sites with limited height and swing areas such as tunnels, bridges, around electrical power lines, other utilities, or inside structures, use extreme caution in keeping the machine and its attachment a safe distance away to prevent personal injury and/or equipment or structure damage. Use a flagman to direct the operator.

F15985

BE AWARE OF OBSTACLES

L. PARKING THE MACHINE Always park the machine on a firm, level surface.

If no firm level surface is available, block the tracks and lower attachment to the ground to help prevent machine movement.

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

120°

CHOCK TRACKS

F16314

PARKING SAFETY

M. STABILIZE ATTACHMENTS Stabilize all attachments removed from the machine to prevent the attachment falling over.

F1463

STABILIZE ATTACHMENTS WHEN REMOVED

11

SECTION I - SAFETY PRECAUTIONS N. SEATBELT The fastening of seatbelt is strictly obliged by the possibility of hard blow inside of cab, being hurled out of the cab, or being crushed under the machine when the machine has tipped over.

It may cause severe personal injury or death.

RELEASE BUTTON (RED)

WARNING • MAKE SURE THAT THE BRACKET AND BELT ARE FREE FROM DAMAGES BEFORE FASTENING SEATBELT. DEFECTIVE ONES MUST BE REPLACED WITH NEW ONES. • BEFORE STARTING MACHINE, TAKE A SEAT AND DON’T FAIL TO FASTEN SEATBELT.

BUCKLE

SEATBELT

1.5 INSPECTION & MAINTENANCE SAFETY A. “TAG-OUT” MACHINE Before performing any inspection or maintenance procedures to the machine, fill out and post to the operator’s controls a “DO NOT OPERATE” tag to warn persons not to start the machine. Also inform the supervisor and all operators that the machine is under inspection or maintenance and they will be informed when the machine is ready for normal operation.

B. TOOLS & EQUIPMENT Use the proper tools and equipment for the task at hand. Know the proper use of the tools and equipment before starting any inspection or maintenance procedures.

F1479

USE PROPER TOOLS

C. PERSONAL EQUIPMENT Wear well fitting work clothes, hard hat, safety shoes and gloves. Confine long hair, loose clothing and remove all jewelry before attempting any inspection or maintenance procedures to this machine or attachments.

F1438

PERSONAL EQUIPMENT

12

SECTION I - SAFETY PRECAUTIONS D. STOP THE ENGINE BE CERTAIN TO TURN ENGINE OFF AND PLACE THE SAFETY LOCK LEVER IN THE “LOCKED” (UP) POSITION before attempting any inspection or maintenance procedures to the machine. Failure to stop engine could result in serious bodily injury or death.

LOCKED (UP) POSITION

F18201

STOP ENGINE / ENGAGE SAFETY LOCK LEVER

E. HYDRAULIC OIL LEVEL CHECK Always set the machine in the hydraulic oil check position on firm level ground before attempting any inspection or maintenance procedures to the machine. If it is not possible to put the machine in this position, secure the boom, arm and attachment to help prevent sudden movement. ALWAYS PLACE ATTACHMENTS ON THE GROUND AND RAISE THE SAFETY LOCK LEVER BEFORE LEAVING THE CAB. F16316

HYDRAULIC OIL LEVEL CHECK POSITION

F. CLEAN THE MACHINE Keep the machine clean and free of debris, excess or spilled lubricants, fuel and fluids. Use approved solvents, detergents and water to clean the machine and its components on a regular basis.

Be careful not to allow water to reach electrical components. Serious damage can occur to the electrical system by allowing water to reach the electrical components. Never clean inside of cab, or electrical components with pressurized water or steam.

F1462

KEEP MACHINE CLEAN

G. PRESSURIZED FLUIDS & LUBRICANTS Always release pressure from hydraulic reservoir, engine coolant, fuel system and all systems containing pressure before removing any caps or components. BE CAUTIOUS OF HOT FLUIDS AND GASSES FROM SYSTEMS ON MACHINES THAT HAVE JUST BEEN STOPPED. ALLOW SUFFICIENT TIME FOR SYSTEMS TO COOL BEFORE PERFORMING ANY INSPECTION OR MAINTENANCE PROCEDURES.

DEPRESS RUBBER CAP TO RELEASE PRESSURE

F16354

RELEASE HYDRAULIC TANK PRESSURE

13

SECTION I - SAFETY PRECAUTIONS H. SUPPORT THE MACHINE If it becomes necessary to raise the machine for inspection or maintenance, always support the machine by positioning the machine as shown in the illustration and use safety supports or blocks, with a sufficient capacity rating to support the machine, under the tracks. NEVER INSPECT OR PERFORM MAINTENANCE PROCEDURES UNDER A RAISED MACHINE THAT IS NOT SUFFICIENTLY SUPPORTED.

90 ~ 110°

SUPPORT

F15989

SUPPORT THE MACHINE

I. REFUELING Move the machine to a well ventilated area for refueling. Use only specified fuel as described in the “MAINTENANCE” section of this manual.

Immediately clean up all spilled fuel and dispose of properly. After refueling is complete, securely tighten fuel cap.

FUEL

F1475

REFUELING

J. HYDRAULIC PRESSURE Under normal conditions, all circuits of the hydraulic system are under extreme pressure.

When inspecting for leaks, use a small piece of cardboard, wood or metal to locate leaks.

SMALL (PINHOLE) LEAKS CAN BE DANGEROUS IF CONTACT WITH SKIN OR EYES IS MADE. Wear approved safety glasses or face shield, gloves, hard hat, safety shoes and work clothes during all inspection and maintenance procedures.

F3636

F1471

CHECKING FOR HIGH PRESSURE LEAKS

K. TRACK SHOE TENSION The grease used to adjust the track shoe tension is under extreme pressure in the cylinder. Use extreme caution when adjusting track shoe tension. KEEP FACE, HANDS AND LEGS AWAY FROM THE GREASE NIPPLE AREA. Carefully and slowly loosen the grease nipple when lessening track shoe tension. Never loosen grease nipple more than one complete turn.

F15990

USE CAUTION WHEN ADJUSTING TRACKS

14

SECTION I - SAFETY PRECAUTIONS L. ELECTRICAL SYSTEM Before performing any inspection or maintenance to the electrical system, or performing any welding procedures, disconnect the negative (–) cables from the battery terminals. Not disconnecting the negative (–) cable could cause extensive damage to the electrical system.

DISCONNECT BATTERY NEGATIVE (-) CABLE WHEN INSPECTING ELECTRICAL OR WELDING

F15692

ELECTRICAL SYSTEM PRECAUTION

M. USE APPROVED WORK LIGHTS Use only approved work lights when performing inspection and maintenance procedures to prevent possible fire or explosion. Certain types of work lights should not be used due to the possibility of ignition of certain flammable gasses and fluids from the machine.

N. DISPOSE OF WASTE PROPERLY Dispose of oils, fuel, coolant, solvents, filters, batteries etc. according to federal, state and local codes and regulations regarding hazardous waste disposal. Contact Local authorities for proper disposal methods of such materials.

F1480

USE APPROVED WORK LIGHTS

1.6 BATTERY SAFETY A. WEAR PROPER PROTECTIVE CLOTHES Wear long sleeve shirt, gloves and approved safety glasses or face shield when working with or around batteries.

F1473

F1474

WEAR PROTECTIVE CLOTHES

B. KEEP AWAY FROM FIRE OR FLAMES Never allow batteries in the vicinity of fire or flames and do not smoke when working with batteries. Explosive hydrogen gas is produced by the electrolyte (acid) in the batteries.E Always work with batteries in a well ventilated area.

F1477

KEEP AWAY FROM FIRE OR FLAMES

15

SECTION I - SAFETY PRECAUTIONS C. CHARGING BATTERY Charge battery off and away from the machine in a well ventilated area. When charging battery, remove cell caps to allow gasses to escape.

Avoid breathing gasses from battery. Wear approved safety equipment when working with batteries.

If you spill acid on yourself: - Flush your skin with water. Apply baking soda or lime to help neutralize the acid.

- Flush your eyes with water for 10-15 minutes.

- Get medical attention immediately.

If acid is swallowed: - Drink large amounts of water of milk. Then drink milk of magnesia, beaten eggs, or vegetable oil.

- Get medical attention immediately.

D. USING BOOSTER CABLES • Wear approved safety equipment when working with batteries.

• If using another machine or vehicle to boost bateries, make certain the machine or vehicle DOES NOT touch the disabled machine.

• Make certain of the positive (+) and negative (-) terminals on the booster battery and the disabled machine before connecting booster cables.

• Connect the positive (+) cable first, then connect negative (-).

• When disconnecting, disconnect the negative (-) cable first, then disconnect the positive (+) cable.

• Refer to “BASIC MACHINE OPERATION” section of this manual for proper procedures for use of booster cables.

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

Connect booster cables using following procedure.

1. Connect booster cable to positive (+) battery terminal of discharged battery. Connect other end of booster cable to positive battery terminal of normal battery.

2. Connect other booster cable to negative (-) battery terminal of normal battery. Connect other end of booster cable to the engine of troubled machine.

3. Start engine and remove booster cables in reverse order.

16

POSITIVE (+) CABLE

NEGATIVE (-) CABLE

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

SECTION I - SAFETY PRECAUTIONS

1.7 WARNING LABELS & TAG A. SPECIFICATIONS Warning labels and decals are affixed to the machine to remind operators and personnel specific safety precautions in certain areas of the machine. The following are illustrated examples of all warning labels and decals along with their locations.

NOTICE FOR WARNING LABELS & TAG • Do not take away the attached warning labels and decals.

• Confirm whether labels can be easily read. If words or illustrations are illegible, clean off or replace the labels.

• Use a cloth, water, and detergent to clean the labels. Never use organic solvents or gasoline.

• If labels are damaged, missing or illegible, replace them with new ones. Contact your Dealer for new labels.

1. TAG, COUNTERWEIGHT SAFE AREA OF OPERATION Located on each side of the rear counterweight.

Make sure that exposed personnel in the area of operation are clear of the machine before moving the machine or its attachments. Sound horn.

Background: yellow Stripe and lettering: black

F14394

2. HYDRAULIC OIL BLEEDING PLATE Located on each hydraulic tank cover.

It indicates that air should be bled from the pumps after every hydraulic oil change.

Danger of pump seizure.

Background: yellow Stripe and graphics: black

F14395

3. TAG ENGINE RUNNER Located on engine cover.

Rotating engine fan, hot engine parts and drive belt can cause severe injury.

Do not open engine cover or service engine with engine running.

F15995

17

SECTION I - SAFETY PRECAUTIONS 4. BOOSTER CABLES TAG Located on fuel tank.

It warns about the danger of starting the motor with booster cables.

Background: yellow Stripe and graphics: black

F14398

5. BATTERY TAG DANGER WARNING Located on fuel tank.

Flammable gas (hydrogen gas) is generated in the battery. Do not produce sparks near the battery, and do not put bare flame close to it to avoid the battery from catching fire and explosion.

Background: yellow Stripe and graphics: black

F14400

6. TAG DO NOT CLIMB Located on engine bonnet.

When servicing or reparing machine, keep surfaces free of oil, water, grease, tools, etc. to avoid possible slipping and/or falling from machine, which can cause personal injury.

F16323

18

SECTION I - SAFETY PRECAUTIONS 7. PRESSURIZED FLUIDS & LUBRICANTS Located on top of engine radiator.

Always release pressure from hydraulic reservoir, engine coolant, fuel system and all systems containing pressure before removing any caps or components. Be cautious of hot fluids and gasses from systems on machines that have just been stopped. allow sufficient time for systems to cool before performing any inspection or maintenance procedures.

Fondo: giallo Filetto e grafica: neri F14397

8. ENGINE STOP TAG Located on engine radiator.

It indicates you have to stop the engine before opening the hood.

Danger of serious injury due to rotating parts such as fans, pulleys and belts.

Background: transparent Stripe and graphics: black

F14407

9. HOT SURFACES TAG Located on engine bonnet.

Immediately after the machine is operated, the temperature and pressure of the engine coolant, engine oil, and hydraulic oil are very high. Burns may result if caps are removed, or oil, water, or filters are changed under these conditions. Wait until the temperature goes down, before attempting to check fluids or change filters.

Background: yellow Stripe and graphics: black F14396

19

SECTION I - SAFETY PRECAUTIONS 10. TAG AIR CLEANER Located on air cleaner.

Check for the O-ring correct location.

Water inside cause engine failure.

F15997

11. STOP ENGINE - WARNING Located on top of engine radiator

F14406

20

SECTION I - SAFETY PRECAUTIONS 12. TRACK ADJUSTER PLATE Located inside cab R.H. It shows that obligation is made to consult the Operation and Maintenance Instruction Manual prior to acting on the track adjust valve.

Danger of severe injuries.

Background: yellow Stripe and graphics: black

F14399

13. TAG , WARNING TO KEEP A SAFETY DISTANCE FROM ELECTRICAL LINES Located inside cab R.H. Always keep a safety distance from electrical lines.

Also in case of work near overhead electrical lines, keep this safety distance.

Background: white and red Edge and lettering: black

F15999

14. TAG , REFERENCE TO MANUALS Located inside cab R.H. Caution: Do not allow anyone to operate the loader without proper instruction.

F16499

21

SECTION I - SAFETY PRECAUTIONS 15. BOOM AND ARM MOVEMENT WARNING PLATE Located inside cab R.H. It shows the danger represented by the bucket hitting the cab.

Pay special attention as no stops are provided to prevent this problem.

Background: yellow Stripe and lettering: black

F14403

16. SAFETY LOCK LEVER Located on the right of the control stand.

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

F16001

17. NIBBLER & BREAKER OPERATION Located on right hand operator console.

Do not set this switch to nibber combined flow operation position when using breaker.

F16000

22

SECTION I - SAFETY PRECAUTIONS 18. TAG FOR WINDOW LOCK Located inside cab front window.

It indicates the danger of injury deriving from incorrect block of front windshield in open position.

Background: yellow Edge and graphics: black F14408

19. TAG , EQUIPMENT SAFE AREA OF OPERATION Located on arm.

Make sure that exposed personnel in the area of operation are clear of the machine before moving the machine or its attachments. Sound horn.

Background: yellow Stripe and lettering: black

F14393

23

SECTION I - SAFETY PRECAUTIONS 20. OPERATION BY FOOT PEDAL Located inside cab R.H.

23. ENGINE AUTO IDLING STOP - NOTICE Located on right hand operator console

CAUTION Attachment operation by foot pedal.

Always check the foot pedal control pattern before operation.

Always read operators manual before operating machine.

YN20T01696P1

F24425

21. SELECTOR VALVE When an auto idling stop switch is ON, after raising a

Located inside cab R.H.

CAUTION

safety lock lever, engine stops after fixed time progress.

F24424

Procedure to change selector valve

MARK

MAINTENANCE

SELECTION

(When using nibbler, breaker or extra) * Contamination and deterioration of hydraulic oil may develop B Breaker malfunctioning of control valves, early E Extra wear and seizure of hydraulic pumps, and consequential damage of entire Please adjust suitable notch to capscrew hydraulic circuit.

Replace filters and hydraulic oil, (some mark may not be indicated). refering to the following table.

Capscrew Notch (1) Hydraulic oil change: every 600

N

Nibbler

24. ENGINE AUTO IDLING STOP - WARNING Located inside cab R.H.

HRS. (2) Hydraulic line filter change First: 50 HRS. Regular: every 250 HRS. Marks

22. BLADE Located inside cab R.H. CAUTION Blade can be operated both with or without leverlock in locked position

24

YN20T01685P1

F24423

SECTION I - SAFETY PRECAUTIONS

WARNING When you do the work which has fear, such as fall of a load, when engine stops, please be sure to turn OFF an auto idling stop switch.

CAUTION The auto idling stop function for cutting down generating of the useless fuel consumption and an exhaust gas at the time of a stop in this machine is carried. When you use it, be careful of the following things. · When you start the engine again after an auto idling stop, please be sure to start after once returning a key switch at ACC or OFF and also returning a throttle potentiometer to Lo. But the engine cannot be again started until a buzzer stops, after engine stops. · When you leave from a cab for a long time, please be sure to turn OFF a starter switch. · When the engine coolant temperature error are displayed with the LCD or lamp, it does not operate, even if the auto idling stop switch is turned on ON. Please read the operator's manual.

F24435

25

SECTION I - SAFETY PRECAUTIONS

1.8 PROHIBITED MACHINE OPERATION The following examples of machine abuse and misuse should never be attempted by even the most experienced operator. Such abuse and misuse of this machine and its attachments can result in serious bodily injury, death, severe equipment damage and shortened service life of the machine.

Under no circumstance should any of these operations be attempted. Use common sense and follow proper operation procedures found in this MANUAL while operating this equipment.

F16318

A. DO NOT USE TRACTIVE FORCE OF THE MACHINE FOR LOADING THE BUCKET ATTACHMENT. Doing so will exert excessive force on the machine structure, front end attachments and could cause severe equipment damage. Use crawlers for normal travel operations only.

B. DO NOT USE SLEWING FORCE OF THE MACHINE FOR OPERATIONS. Doing so will exert excessive forces to the machine structure, front end attachments and shorten life of the swinging system of the machine. Also, serious injury or death could result from such operations.

DO NOT USE TRACTIVE FORCE

F16319

DO NOT USE SLEWING / SWINGING FORCE

C. DO NOT PERFORM “HAMMERING” OPERATIONS WITH THE BUCKET. Performing operations such as hammering and piling will cause extensive damage to the machine and its components. These types of operations can also result in serious injury or death.

F16320

DO NOT HAMMER WITH ATTACHMENT

D. DO NOT USE THIS MACHINE FOR ANYTHING OTHER THAN ITS INTENDED PURPOSE. This machine is designed and manufactured for digging, loading and ground leveling operations only. Any other use can exert excessive force to the machine, its components, its systems and result in serious bodily injury or death to the operators and other personnel working in the vicinity of or with the machine.

USE ONLY FOR INTENDED PURPOSE

26

SECTION I - SAFETY PRECAUTIONS E. DO NOT OPERATE BUCKET AND ARM CYLINDERS TO STROKE END REPEATEDLY. Extending the bucket and arm cylinders to stroke end to clean debris from the bucket, will cause impact to the bucket cylinder causing cylinder damage. Use high pressure water or manually remove stubborn material from the bucket.

ALLOWANCES

F19082

DO NOT OPERATE CYLINDER TO STROKE END

F. DO NOT OVER EXERT THE MACHINE’S CAPACITIES. Know the limitations of the machine and its attachments and operate the machine within those specifications. Do not exceed lift charts.

Never tip or raise the machine to obtain power to move material. This could cause extensive damage to the machine and its components as well as result in serious bodily injury or death F16321

DO NOT OVER EXERT THE MACHINE

1.9 END OF WORK SHIFT SAFETY Perform all of the following procedures after each shift is complete to insure the machine it in optimal operating condition for the next shift or job site.

A. Move the machine to a firm, level surface.

B. Lower attachment to the ground.

C. Refill fuel tank to full mark to reduce air volume and condensation (moisture). This will decrease the possibility of freezing in the fuel tank, rusting due to moisture and other problems associated with start up and operation.

D. Close and secure all windows in place to prevent water or moisture reaching the electrical components of the machine.

E. Thoroughly clean and inspect the machine. Perform lubrication maintenance and repair or replace any problem areas found before restarting the machine.

F. If operating the machine in cold climates, it may be necessary to remove the batteries from the machine and store in a warm well ventilated area. Install the batteries in the machine before next start up. This will help prevent premature battery deterioration.

G. Remove key from key switch and lock all doors and access panels.

F1462

END OF WORK SHIFT SAFETY

27

SECTION I - SAFETY PRECAUTIONS

1.10 USE OF PROTECTIVE STRUCTURES For some particularly dangerous works (for ex. demolitions, tunnel digging, terrace earth moving), it is suggested to use protective structures, such as FOPS (falling object protective structure) and FGPS (front grid protective structure) after evaluating the risk.

If the machine is not equipped with these safety structures, the use in these applications is not allowed.

Consult your Dealer in case of doubt.

FOPS

FRONT GUARD

NOTE FOPS ······ Falling object protective structure.

USE FOPS AND FRONT GUARD

1.11 USE SAFETY VALVE AND OVERLOAD ALARM If your machine is used for lifting application and has a maximum rated lifting capacity bigger than 1 ton or an overturning moment bigger than 40,000 Nm your machine needs safety valves and an overload alarm according to the EN 474 standard.

Please check your local dealer in case of doubt.

28

Section II MACHINE FAMILIARIZATION

SECTION II - MACHINE FAMILIARIZATION

2.1 FOREWORD This manual has been prepared to assist you in the correct safe procedures for driving, operating and servicing the machine.

Only continuous compliance with the norms herein detailed guarantees best performance, economic operation, and durability of your machine and prevents the commonest causes for accidents which might occur during operation or maintenance.

Particularly, as regards safety, we recommend to carefully read the general safety precautions.

Each machine is supplied complete with a copy of this Manual. Descriptions and illustrations herein are not binding. The Manufacturer, provided that the basic characteristics of machine types described and shown in this Manual remain the same, reserves the right to change components, parts and accessories supplied without any commitment to timely update this publication; and this any time it deems it convenient for improvement purposes or due to commercial or manufacturing requirements. For exact information, please consult your Dealer or contact the Manufacturer’s Branch Offices.

DANGER For clarity purposes, some figures in this Manual show the machine with protection panels or covers removed.

Never operate the machine with any protection panels or covers removed.

DANGER It is absolutely forbidden to tamper and/or change the setting of any of the hydraulic system valves to avoid damaging machine components with consequent risks to personal safety.

F19083

30

SECTION II - MACHINE FAMILIARIZATION

2.2 IDENTIFICATION DATA

NOTE: The numbers in the illustrations are for explanation only and differ from actual numbers

• ENGINE No.

EXCAVATOR MARKING DECAL 1. Machine technical type.

2. Identification number.

3. Machine total mass.

4. Machine manufacturing year.

5. Engine power in kW. 6. Frame identification number.

7. Identification decal: diesel engine type and serial number.

31

SECTION II - MACHINE FAMILIARIZATION

2.3 NOISE LEVELS (2000/14/EC) Sound power level Lwa = 101 dB (A) Sound power level guaranteed, determined in compliance with European standard 2000/14/EC. Sound pressure level in the operator’s seat

LWA

101

Lpa = 76 dB (A) Sound pressure level: continuous, equivalent and average (A) measured on an identical machine in compliance with ISO 6396:1992.

VIBRATION TO THE OPERATOR The vibration level to the operator depends mainly on the conditions of the ground where the machine is being operated and on the use conditions of the machine and its equipment.

The exposition to vibrations can be remarkably reduced if the recommendations herebelow are followed: - use equipment suitable for the machine and the type of work to be carried out; - adjust and lock the seat in the correct position; regularly check for the seat suspensions and carry out adjustments or maintenance as required; - operate the equipment evenly, avoiding sudden motion or extreme shocks, if possible; - adjust speed and transfer route. Avoid very irregular routes or the impact with possible obstacles, in order to minimize the vibration level.

• The weighted average quadratic acceleration value to which the operator’s arms are subjected does not exceed 2.5 m/s2.

• The weighted average quadratic acceleration value to which the operator’s body is subjected does not exceed 0.5 m/s2.

NOTE: this machine is equipped with an operator’s seat in compliance with standard ISO 7096:2000. This guarantees that the operator’s body exposures to vibrations respect the requirements for protection against vibrations when the machine is used according to its destination as explained in this manual.

32

F20455

SECTION II - MACHINE FAMILIARIZATION

2.4 BASIC COMPONENTS OF THE EXCAVATOR 1

29

2

28

3 4 5

27

6

24

26

23

7

25

8 22

9

21 20 19

10 18 17

11

16 F16322

12

15 14

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

Arm cylinder Boom Batteries Hydraulic oil tank Swing motor Handrail Main control valve Rear view mirror Hydraulic pump Isuzu BB-4BG1T engine Counterweight Intercooler Travel motor Engine coolant reservoir Swivel joint Engine air cleaner

13

17. Upper roller (1 each side) Upper roller (2 each side) - L 18. Lower roller (6 each side) Lower roller (7 each side) - L 19. Track spring (1 each side) 20. Fuel tank 21. Track idler (1 each side) 22. Track shoe assembly (600 mm STANDARD) Track shoe assembly (800 mm STANDARD) - L 23. Cab 24. Boom cylinder 25. Bucket 26. Bucket link 27. Idler link 28. Bucket cylinder 29. Arm

33

SECTION II - MACHINE FAMILIARIZATION

2.5 OPERATOR CAB NOMENCLATURE The operator cab nomenclature, see Figure below, points out locations of operator controls of the Manufacturer hydraulic excavator operator cab (Typical). Study these areas and locate these components on the machine. Specific information regarding these components are explained on the following pages of this section.

1

5

2

31

6

30

7

4

3

8

29

9

10

28

11 12

27 26

13 14 15

24

23 16 22 21

20

19

17

18 F16009

34

SECTION II - MACHINE FAMILIARIZATION 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

Left travel lever Right travel lever Left travel pedal Right travel pedal Right foot rest Gauge cluster Right hand operator control lever 24 V cigarette lighter Additional working light switch Auto accel switch Auto idling stop select switch Rotary light switch Throttle potentiometer Over load alarm select switch Key switch

16.

17.

18.

19.

20.

21.

22.

23.

24.

26.

27.

28.

29.

30.

31.

Fuse box Swing parking brake release switch Engine emergency stop control KPSS release switch Hour meter Head rest (adjustable) Swinging flasher select switch Breaker and nibbler selector switch (opt.)

12 V power supply Arm rest Air-conditioner panel Operator seat (3 way adjustable) Safety lock lever (for hydraulics) Left hand operator control lever (horn switch) Left foot rest

35

SECTION II - MACHINE FAMILIARIZATION

OF

F

ACC

O

N T AR ST

H

LO

The following information provides a brief description and function of the components and controls of the hydraulic excavator. All personnel associated with this machine should read and understand this information BEFORE beginning any work with or on this equipment.

KEY SWITCH POSITIONS

HE AT

2.6 COMPONENT & CONTROLS NOMENCLATURE

I

A. RIGHT HAND OPERATOR CONSOLE 1. Key Switch The key switch is located on the right hand operator console and has 5 operating functions.

“HEAT” .... This position is used for starting the engine in cold climates. See the section “BASIC MACHINE OPERATION”.

“OFF” ....... When key is turned to this position, the engine stops and electrical power to the machine's electrical systems is stopped after approximately 4 seconds.

“ACC” ...... With key in the “ACC” position only the cigarette lighter, DC to DC converter and horn will have power.

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

“START” .. When key is turned to this position electrical power is supplied to the starter solenoid causing the starter to start the engine. After engine starts key should be released to go back to the “ON” position.

36

AT HE

ACC

ON T AR ST

F16010

PRESS FOR "ON" PRESS FOR "OFF"

LO

2. Auto Accel Switch Press the symbol mark of this switch to turn it “ON”, and the auto accel actuates and switches the speed to the deceleration condition reducing the fuel consumption and the noise, when the accel dial position is set to the decel speed or more, and consequently the remote control pressure of control lever in operation and operating pedal (option) does not operate for 4 seconds.

When the control lever and operating lever are manipulated, the engine revolution rises to the accel dial set position gradually according to the manipulated variable.

And, if the button on which symbol mark is not indicated is pressed during decel rotation, the engine revolution rises to the accel set position.

F OF

H

I

F16011

WARNING When loading or unloading machine on trailer, turn the auto accel switch off. If it is operated keeping the auto accel switch on, the engine speed changes abruptly.

HI

H I

LO

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

LO

SECTION II - MACHINE FAMILIARIZATION

THROTTLE POTENTIOMETER (CONTROL)

F

OF

ACC

ON

HE AT

T AR ST

F16012

4. Rotary Light Switch This switch is located on the right hand control console. Its basic function is to turn the rotary light “ON” and “OFF”.

Depress the icon to turn rotary light “ON”. Depress as shown in the figure to turn rotary light “OFF”.

PRESS FOR "ON"

LO

PRESS FOR "OFF"

H I

F16013

37

SECTION II - MACHINE FAMILIARIZATION

PRESS FOR "ON" H I

LO

5. Over Load Alarm Select Switch The over load alarm select switch is located on the right hand control console. The over load alarm switch is a 2 position rocker switch which is used to turn on the working operations.

“ON” ........ Push the symbol side of switch down to turn over load alarm “ON”.

“OFF” ....... Push the empty side of switch down to turn over load alarm “OFF”.

F

ACC

ON T AR ST

HE AT

OF

PRESS FOR "OFF"

F16016

6. 24 Volt Cigarette Lighter The cigarette lighter is located on the right wall of cab. To use the cigarette lighter the key switch must be in the ON position. Push the lighter in and wait approximately 30 seconds for it to “POP” out. Pull lighter from the socket to use. Replace lighter back into its socket after use.

CAUTION Do not use the cigarette lighter as a power source for 12 Volt accessories. It is 24 Volt outlet.

F16018

38

SECTION II - MACHINE FAMILIARIZATION 7. Auto idling stop select switch Press symbol mark corresponding to this switch to turn “ON”, and the engine in operation stops automatically after a constant elapse of time with safety lock lever (1) remaining locked.

Consequently the fuel consumption is reduced.

And, press the switch no symbol mark is given, and the auto idling stop function is canceled.

2.

PRESS FOR "OFF"

NOTE: Put safety lock lever to “Locked Position”, and the rotation changes to the decel rotation about 4 seconds later.

Buzzer sounds before 5 seconds from engine stop and for 10 seconds after engine stop.

LO

1.

PRESS FOR "ON"

HI

F24431

After auto idling stop, to restart engine; a. Make sure that the buzzer stops sounding. b. Set throttle potentiometer to low idling position. c. Return starter switch to “ACC” or “OFF” once and restart the engine.

(1)

WARNING When you do the work which has fear, such as fall of a load, when engine stops, please be sure to turn off an auto idling stop switch.

F24432

CAUTION Don’t restart the engine while the buzzer is sounding after the engine stops through auto idling stop switch.

The engine starter motor may be damaged.

CAUTION Where being apart from the machine, be sure to switch the key “OFF”. The discharge of battery may occur.

CAUTION In the following cases, the auto idling stop switch can’t be functioned regardless of the idling stop select switch position.

• When the warning of “HIGH E/G COOL TEMP” is given on LCD or by means of lamp.

CAUTION When the following functions are applied to it, turn the auto idling stop select switch “OFF”.

While keeping the safety lock lever on “LOCKED POSITION”.

• When required to warm up the engine; • When required to operate the air-con continuously; • When keeping the working light on;

39

SECTION II - MACHINE FAMILIARIZATION B. SWITCH PANEL The push type switch protected from dust and humidity is attached.

This switch panel is equipped with screen change switch, buzzer stop switch, work mode select switch, wiper switch and working light switch.

1. Screen Change Switch (1) Start the engine, and is appeared on the multidisplay. And then press the screen change is switch once and indicated, and press it one more time and (E/G oil change cumulative time) is indicated.

LOW E/G OIL PRESS

(6) (1)

(5)

(4) 2. Buzzer Stop Switch (2) When the engine coolant temperature is too high, or various sensors of mechatro controller (selfdiagnosis) fail, the alarm sounds intermittently. To stop sounding, press the buzzer stop button.

NOTE: • Buzzer sounding due to engine cooling water temperature rise can not be stopped.

• To stop buzzer sounding due to failures of the preheating, failure of engine oil pressure and the release of hydraulic pressure, turn the key switch off.

3. Working Lights Select Switch (3) Press this switch, and working lights installed on boom and front right side go on.

Press it again, and working lights on boom and front right side go out.

4. Wiper Switch (4) Press this switch, and the front window wiper starts moving. a. Press it once: Wiper moves intermittently. b. Press it again: Wiper moves continuously. c. Press it once more: Wiper stops moving.

40

(2)

(3)

LED LAMP F16019

5. Washer Switch (5) Press this switch, and washer fluid is sprayed while it is pushed.

Also, washer tank is installed in the front of radiator on the rear left side.

CAUTION Make certain the washer reservoir has washer fluid before operating washer.

SECTION II - MACHINE FAMILIARIZATION 6. KPSS Work Mode Switch (KOBELCO Power Sensing System) (6) The mode is set to mode after the engine stops. Select one effective mode from 3 modes depending on the work condition and the aim of work.

The mode is switched in turn every time when the switch is pressed, and the selected work mode indicator lamp lights on. a. Is the machine capable of performing the particular job? b. What attachment (bucket) is best suited for the job? c. What type of material will the machine be excavating? d. What operating mode is best suited for the job?

7. KPSS Work Mode Functions The KPSS work mode switch allows the operation select and control the operation of the machine and the attachment effectively for a particular job by selecting one of three positions. a.“H” mode: Provides maximum speed and power for digging operations. b.“S” mode: Provides standard power and best fuel consumption. c.“FC” mode: Allows fine control of hydraulic functions for attachment.

(7) KPSS WORK MODE FUNCTIONS

LOW E/G OIL PRESS

(6) (1)

(5)

(4) F18203

(2)

(3)

LED LAMP

Select the KPSS work mode best suited for the particular job at hand.

41

SECTION II - MACHINE FAMILIARIZATION C. LEFT HAND OPERATOR CONSOLE 1. 12 Volt Power Supply The 12 Volt power supply is located beside the left hand operator console.

For use of common auto accessories such as a fan or other accessories requiring 12 Volt (DC) power, pull cover away from 12 Volt power supply and insert 12 Volt male socket into power supply. Replace cover after use.

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

MAXIMUM CONTINUOUS OUTPUT - 2.5 Amps

F16020

2. Air Conditioner The climate control-AC provides a comfortable indoor environment and adjustable control of cab temperature. It removes moisture from humid air and reducing window glass fogging.

The climate control-AC is installed behind operator’s seat and sends cold air or hot air into cab.

Air outlet selector Select a preferable air blowout direction moving grille by hand.

(A), (B), (C) ........... Air outlet

(A) (A)

(B)

(C) F16021

42

SECTION II - MACHINE FAMILIARIZATION I. Control Panel Description

AIR OUTLET MODE SELECTOR SWITCH

FRESH AND RECIRCULATE AIR SELECTOR SWITCH

LCD DISPLAY

COMPRESSOR SWITCH

AUTO CONTROL SWITCH

F16022

DEFROSTER SWITCH

TEMPERATURE SETTING SWITCH (°C ↔ °F SELECTOR SWITCH)

FAN SPEED SELECTOR SWITCH

MAIN POWER SWITCH

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

Each switch, FAN mark of blower, and TEMP mark are illuminated green at night.

II. Fundamental use Before turning air-conditioner on, close doors of cab and windows to achieve the best performance 1. Press control switch “AUTO” to control air capacity and blower outlet automatically, and set the temperature in the range from 18.5°C (65.3°F) to 31.5°C (88.7°F).

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

2. Select proper mode manually through recirculate and fresh air capacity selector switch and compressor switch ON - OFF. 3. Select preferable fan speed manually through fan speed selector switch when fan speed, selected through auto control, is not preferable.

The indicator lamp of “AUTO” in LCD display goes out. Press “AUTO” switch to return to automatic climate control.

FRESH AND RECIRCULATE AIR SELECTOR SWITCH

COMPRESSOR SWITCH AUTO CONTROL SWITCH

F16023

FAN SPEED SELECTOR SWITCH

43

SECTION II - MACHINE FAMILIARIZATION III. Control Panel Functions 1. Main power switch and display a. LCD display is illuminated when the climate control-AC is operating.

When the climate control-AC is stopped, LCD will be turned off. b. Press main power switch, and all functions for the climate control-AC switch ON or OFF. Each time when this switch is pressed, the function switches ON and OFF. When switched ON, the climate control-AC starts operating at the point set before switching OFF (when it is set to AUTO, in auto mode; if NORMAL is selected, then in normal mode).

LCD DISPLAY

F16024

MAIN POWER SWITCH

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

2. Auto Control Switch and Display a. Press the main power switch to activate the climate control-AC and the LCD display will illuminate. b. Press control switchI AUTO, and fan speed and air outlet are automatically controlled, and “AUTO” indicator lamp on LCD display is illuminated. c. When the main power switch is OFF, the system will retain the previous setting in memory. Therefore, when the main power switch is pressed again, the climate control AC will come on in the auto control mode.

In the auto mode, the fan speed and air outlet openings are operated automatically.

3. Temperature Setting Switch and Display a. The set temperature is indicated in digits on LCD display. Temperature set range is 18.5°C (65.3°F) to 31.5°C (88.7°F). b. Press the two temperature set switches simultaneously for 5 seconds to change the display from Centigrade (°C) to Fahrenheit (°F) or viceversa in the LCD 77°F or 77°F display (Eg.) 25°C 25°C c. Press temperature set switch DOWN or UP to change the set temperature.

The temperature goes up or down by 0.5°C (0.9°F) in graduation.

The set temperature may be raised or lowered by continued pressing of the switch.

44

LCD DISPLAY

AUTO CONTROL SWITCH

LCD D

F16025

MAIN CONTROL SWITCH

LCD DISPLAY

F16026

TEMPERATURE SETTING SWITCH (°C↔°F SELECTOR SWITCH)

SECTION II - MACHINE FAMILIARIZATION d. The set temperature 18.5°C (65.3°F) is the lowest cooling temperature, and 31.5°C (88.7°F) is the highest heating temperature.

Control beyond either of these limits is not possible.

4. Air outlet mode selector switch and display a. Air outlet position is indicated by the arrow on LCD display. b. Press Air outlet mode switch in the condition where auto display light is on, and the display mode is fixed., “AUTO” indicator lamp on LCD display goes out, and “AUTO” control of air outlet opening is released.

Press it again, and the level is changed BI-LEVEL FOOT. to VENT

AIR OUTLET MODE SELECTOR SWITCH

F16027

LCD DISPLAY

AIR OUTLET OPENING

VENT

BI-LEVEL

FOOT

AIR OUTLET DIRECTION

UPPER HALF OF BODY

UPPER HALF OF BODY, FOOT

FOOT ,FRONT GLASS

5. Defroster switch and display a. Press defroster switch, defroster indicator lamp will be displayed. b. Press air outlet mode selector switch, and it returns to air outlet mode just before pressing defroster switch. c. Press defroster switch in the condition where AUTO display is lighting up, “AUTO” indicator lamp on LCD display goes out and the auto control of air outlet opening is released.

FRESH AND RECIRCULATE AIR SELECTOR SWITCH

LCD DISPLAY

F16028

DEFROSTER SWITCH

AIR OUTLET MODE SELECTOR SWITCH

6. Recirculate and fresh air selector switch and display a. Suction (fresh air intake) mode is indicated on LCD display b. Each time recirculate and fresh air capacity selector switch is pressed, the mode is switched to air recirculate or fresh air intake.

45

SECTION II - MACHINE FAMILIARIZATION 7. Compressor switch and display Press compressor switch in the condition where mark on LCD display is unlit, compressor starts operating and indicator lamp of mark on LCD display goes on.

Press it again, and compressor turns off, and indicator lamp of mark on LCD display goes out.

LCD DISPLAY

FAN SPEED DISPLAY

COMPRESSOR SWITCH

F16029

FAN SPEED SELECTOR SWITCH

8. Fan speed selector switch and display When it is set to MANUAL mode, fan speed on LCD display is as follows.

LCD DISPLAY FAN SPEED

DISPLAY LCD 1 LAMP IS LIT UP

FAN SPEED LOW

LCD 2 LAMPS ARE LIT UP

MEDIUM

LCD 3 LAMPS ARE LIT UP

HIGH

LCD 4 LAMPS ARE LIT UP

MAX

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

46

LOW

MEDIUM

HIGH

MAX

SECTION II - MACHINE FAMILIARIZATION D. REAR PANEL AND OTHERS 1. Swing Parking Brake Release Switch Swing parking brake is usually locked. The swing parking brake is released in swing and arm-in operation. When the swing function becomes inoperable due to a malfunction, turn toggle switch to “RELEASE LOCK” position, and the parking brake is released.

Move machine to a safe area immediately and contact your Dealer for assistance.

Return the toggle switch to “NORMAL” position after repairs are completed.

RELEASE LOCK

NORMAL

F16036

2. KPSS Release Switch The KPSS release switch is located behind a rubber grommet in the panel behind operator seat. It is used when CPU trouble is displayed on the gauge cluster display. Its purpose is to allow operation of the machine if CPU FAIL is displayed and throttle control is still possible. If throttle control is lost, contact your Dealer for service assistance and temporary CPU bypass procedures.

CPU = Central Processing Unit

RELEASE

KPSS

F16037

3. Swing Flasher Switch (Option) The swing flasher switch is located on the rear panel console and is center switch. The swing flasher is a 2 position rocker switch which is used to turn on the swing flashers.

“ON” Push the symbol side of switch down to turn swing flashers “ON”.

“OFF” Push the empty side of switch down to turn swing flashers “OFF”.

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

F16038

47

SECTION II - MACHINE FAMILIARIZATION 4. Fuse Box The fuse box is located behind the right side of the operator’s seat. It contains all necessary fuses for the electrical circuits of the machine. Should it become necessary to inspect or change a fuse, remove the fuse box cover by gently pulling each end away from the box. Should a fuse require replacement, use a replacement fuse of the same type and amperage. Turn key switch to “OFF” and wait approximately 4 seconds for all electrical power to stop before removing or replacing a bad or blown fuse.

The fuse cover incorporates a fuse puller to remove fuses. Refer to the maintenance section of this manual for a detailed diagram and description of fuse box.

COVER

FUSE BOX F16039

5. Hour Meter This indicates the total time the engine has run. Even if the excavator is not moving, the meter continues to count as long as the engine is running.

HOUR METER

F16040

6. Holder This cup holder is located the right front of operator. Place a canned or a bottled drink.

Press lock button .......... cover open.

LOCK BUTTON

COVER

48

SECTION II - MACHINE FAMILIARIZATION 7. Travel Speed Select Switch Select high speed (2nd speed) or low speed (1st speed) with this switch located on the right-hand travel lever. When the starter switch is turned from OFF to ON, the speed is automatically set to LOW. After starting the engine, select the desired speed.

PRESS HERE FOR "FAST" & "SLOW" TRAVEL SPEED SELECT SWITCH

WARNING Do not use speed when performing delicate operations such as pipe laying, fine grading or loading machine onto a trailer.

Do not change travel speed while loading machine could become unstable and cause serious injury, equipment damage and/or death.

F16042

.................. Set to LOW when moving the LOW (1st) machine on a rough or soft road, speed slope, or in a narrow place, or when powerful tractive force is required. .................... Set to HIGH when moving the machine on flat, hard ground.

HIGH (2 nd) speed

E. OPERATING LEVERS & CONTROLS 1. Engine Emergency Stop Control The engine emergency stop control cable is located at the lower right hand side of operator’s seat. It is used only in an emergency situation to stop the engine quickly. It has 2 operating positions. a.“IN” Releases the fuel stop lever on the governor to allow normal starting of the engine. b.“OUT” Activates the fuel stop lever on the engine governor to immediately stop the engine.

ENGINE EMERGENCY STOP CONTROL

F16043

CAUTION Do not suddenly stop the engine when operating at high RPM. Doing so may damage engine.

49

SECTION II - MACHINE FAMILIARIZATION 2. Safety Lock Lever The safety lock lever is located on the front outside of the left hand operator console and is red in color. The safety lock lever is used to lock out the hydraulic controls disallowing the use of any hydraulic function. The safety lock lever has 2 operating positions. a.“UP” When placed in the up position the safety lock lever stops all hydraulic controls from functioning and allows the operator to enter and exit the operator seat. b.“DOWN” When placed in the down position, the safety lock lever allows all operating functions of the hydraulic controls to resume and also locks the left hand operating console in operating position.

SAFETY LOCK LEVER IN LOCKED (UP) POSITION

WARNING Always place the safety lock lever in the locked (up) position before leaving the operator cab.

Never leave the machine unattended with engine running or lever in the down position.

3. Left Hand Operator Control Lever

CAUTION Hydraulic controls are designed for and set to ISO operating pattern for optimum machine performance and safety. Changing the control pattern will effect the performance of the machine.

The left hand operator control lever is located at the top front of the L.H. operator console. Its purpose is to allow the operator to control operations of the swing and arm.

Operating speed of function is variable from stop to full stroke depending on how far lever is operated. The left hand operator control lever has 4 basic operational functions. a.“FORWARD”Variable speed arm out. b.“BACKWARD” Variable speed arm in. c.“LEFT” Variable speed left swing. d.“RIGHT” Variable speed right swing. e.“CENTER” Neutral position.

50

SAFETY LOCK LEVER IN UNLOCKED (DOWN) POSITION F16044

L.H. CONTROL LEVER (ISO PATTERN)

ARM OUT

SWING LEFT

SWING RIGHT

ARM IN

F16045

SECTION II - MACHINE FAMILIARIZATION 4. Right Hand Operator Control Lever The right hand operator control lever is located at the top front of the R.H. operator console. Its purpose is to allow the operator to control operations of the boom and bucket.

Operating speed of function is variable from stop to full stroke depending on how far lever is operated. The right hand operator control has 4 basic operational functions. a.“FORWARD”Variable speed boom down. b.“BACKWARD” Variable speed boom up. c.“LEFT” Variable speed bucket in (Digging). d.“RIGHT” Variable speed bucket out (Dump). e.“CENTER” Neutral position.

BOOM DOWN

R.H. CONTROL LEVER (ISO PATTERN)

BUCKET OUT BUCKET IN

BOOM UP

F16046

5. Left and Right Travel Lever & Pedal The travel lever & pedal are located in front of operator seat. They are used to move the left or right track of the machine either forward or reverse. These controls have 2 basic operational functions. a.“FORWARD”Variable speed forward track movement. b.“BACKWARD” Variable speed reverse track movement c.“CENTER” Neutral position.

These operations are with travel motors at the rear of the machine. If travel motors are positioned in front of the machine the functions of the travel levers will be opposite.

LEFT HAND TRAVEL LEVER

LEFT HAND TRAVEL PEDAL

FOOT REST

RIGHT HAND TRAVEL LEVER

RIGHT HAND TRAVEL PEDAL

FOOT REST

F16047

51

SECTION II - MACHINE FAMILIARIZATION 6. Blade (Option) a. Outline Blade is attached on lower frame with pin, and is used for backfilling and leveling after digging works by operating dozer cylinder through the aid of blade control lever in cab and moving blade up and down.

BLADE CONTROL LEVER

LOWER BLADE

(A)

b. Blade operation (B)

WARNING

LIFT BLADE

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

The blade control lever is located on the right side of the right hand operator console. Its basic function is to lift or lower the blade.

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

2. Move boom, arm and bucket controls set the attachment to desired position.

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

4. Pull the blade control lever to lift up the blade.

5. Push the blade control lever forward to lower the blade.

WARNING Always place attachments on the ground and lock up the safety lever before leaving the cab.

WARNING Blade control function is live at all times. That is, even with the safety lock lever in lock up position.

52

THROTTLE CONTROL

(B)

F16324

(A)

SECTION II - MACHINE FAMILIARIZATION F. GAUGE CLUSTER The monitor displays information sent from sensors positioned at various places on the excavator, making it possible to monitor the excavator's operating working conditions.

KPSS WORK MODE LAMP

WATER TEMPERATURE GAUGE

FUEL LEVEL GAUGE

LCD DISPLAY LCD DISPLAY KPSS WORK MODE SWITCH

WASHER SWITCH SCREEN CHANGE SWITCH WIPER SWITCH

BUZZER STOP SWITCH

WORKING LIGHTS SELECT SWITCH

1. Fuel Level Gauge This indicates the amount of remaining fuel.

F: Full tank is about 168 Liter (44 gal).

E: The remaining fuel oil is about 28 Liter (7.4 gal).

LED LAMP F16048

SUPPLEMENTARY EXPLANATION • For guideline of work mode selector switch see paragraph “SWITCH PANEL” in this section.

2. Water Temperature Gauge This indicates the temperature of the engine coolant, and operates when the starter switch is turned to the “ON” position.

The temperature is normal in the white range. If the needle enters the red range, let the engine idle until the water cools down and the needle moves back into the white range.

3. KPSS Work Mode Lamp Press KPSS work mode selector switches, on switch panel, and the selected work mode indicator is displayed in green.

Machine is usually in S mode after starting engine.

53

SECTION II - MACHINE FAMILIARIZATION 4. LCD Display The LCD display is illustrated below and will display the icons listed on this page. Study these icons and their definitions so that possible problems will be quickly recognized and repairs made in a timely fashion.

b. WARNING DISPLAYS

WARNING The Buzzer will sound the instant #2, #3, #5, #6, #7, #9, #13 and #14 warning icons are displayed.

1. I.T.C.S. CONTROLLER – CPU This icon will display when a problem exists in the I.T.C.S. (Intelligent Total Control System). Turn Key switch 1 CPU “OFF” and back to “ON” to try and reset CPU programming. Should this icon remain on display, stop operation, stop engine call distributor for temporary CPU bypass procedures.

LCD DISPLAY

F16052

a. NORMAL DISPLAYS 1. SYSTEM STATUS This icon will display after key switch is turned “ON” and all machine systems and components are checked

by CPU and found to be in good working order.

OK

2. ENGINE R.P.M. The engine speed (output) 2250 RPM corresponding to the throttle (accel) dial position is displayed.

3. ENGINE LUBRICATION CUMULATIVE TIME 256 hours has elapsed since the 256Hr AFT change of engine oil.

E/G OIL CH This mark shows the total cumulative time on and after the time when the engine oil has been changed.

54

2. SWING PARKING BRAKE RELEASE Turn the “swing parking brake release switch” on the rear side of operator’s seat to the “RELEASE” position, and 2 this warning is displayed. While this warning is displayed, the swing parking brake does not actuates. So this switch should be used only in the event of emergency. Call distributor.

3. KPSS RELEASE Turn the “KPSS work mode release switch” on the rear side of operator’s seat to the “RELEASE” position, and 3 this warning is displayed. While this warning is displayed, the normal electric and hydraulic controls are impossible. So this switch should be used only in the event of emergency.

Call distributor.

SECTION II - MACHINE FAMILIARIZATION 4. ENGINE PRE-HEATING This symbol is displayed when key 4 switch is turned to heat position and the engine preheat circuit is activated.

This display goes out at completion of pre-heating, at which time GLOW is displayed.

5. ENGINE PRE-HEAT COMPLETE When the starter switch is turned to “HEAT” position, if this mark is 5 displayed, buzzer sounds, but it is impossible to stop sounding.

This may introduce the danger of damaging the engine preheat circuit, so stop the preheat operation immediately.

NOTE: Do not operate the preheat position of the key switch for more than 20 seconds at one time.

6. ENGINE OIL PRESSURE This icon will display and the buzzer will sound should the engine oil 6 pressure drop below a safe operating pressure. If this icon is on the display and buzzer is sounding, stop the engine immediately and check engine oil level. Fill engine to proper level with approved motor oil. If engine has LOW OIL PRESSURE, it will automatically go to “LO” idle, and immediately shut down.

This icon will display only if alternator is charging.

7. ENGINE COOLANT TEMPERATURE This icon will display and the buzzer will sound should the engine coolant temperature rise above safe operating 7 temperature. Should this icon display and buzzer sound, reduce engine RPM to idle and stop operation until engine coolant temperature reaches a safe operating temperature range.

8. ENGINE AIR CLEANER This icon will display should the engine 9 air cleaner element(s) (FILTERS) become too dirty to allow proper air flow to the engine. Should this icon display stop engine immediately and clean or replace engine air cleaner element(s) as required. This icon will display only if alternator is charging.

9. OVER LOAD ALARM This icon will display and the buzzer will sound should the boom cylinder circuit 10 pressure exceed the set, specified pressure.

If this happens, the operator should be aware that he is operating the machine in a range of low machine stability.

The operator should reduce the attachment reach in order to increase machine stability for safer operation.

10. BATTERY CHARGING SYSTEM This icon will display the electrical charging system not function properly.

11 Should this icon display has electrical charging system repaired immediately.

Icon displays only when engine is running with normal oil pressure and a problem occurs in the charging system.

11. FUEL LEVEL This icon will display should the fuel level in fuel tank reaches 28 liters (7.4 12 Gal.) or less. Should this icon display refill fuel tank immediately using approved fuel oil.

12. REPLACE ENGINE OIL This icon will display at every 500 hours of machine operation to remind 29 operator of scheduled engine oil change. The recommended oil change interval for ISUZU engines is every 500 hours of operation.

55

SECTION II - MACHINE FAMILIARIZATION 13. PRESSURE RELEASE When the internal pressure of the 32 DRAINING hydraulic pressure system is PR HYD. PRESS required to be released, start the engine and keep the screen change switch ( ) and the buzzer stop ) on the switch panel switch ( pressed for 5 seconds simultaneously, and the “DRAINING HYD. PRESS” is displayed and the buzzer sounds intermittently, consequently the engine speed lowers to the low idling or less.

In this condition, operate the lever for attachment required to be released the pressure, and the internal pressure of the hydraulic pressure system is released.

SUPPLEMENTARY EXPLANATION For the pressure releasing procedure see in the section IV “RELEASING INNER PRESSURE IN HYDRAULIC SYSTEM”.

14. PRESSURE RELEASE FAIL When the pressure release fails, this 33 FAIL “FAIL DRAIN HYD. PRESS” is PR DRAINING HYD. PRESS displayed. Perform the pressure release procedure again.

WARNING When the pressure release fails, don’t disconnect the high pressure line.

15. DISPLAY OF STARTING NUMBER OF ENGINE AUTO IDLING STOP NO.1 MAIN CONT P/N STARTER CHG PROGRAM VER VER 3,00

Recommended number of engine starting

Indicates the appeal of starter change

This indication flickers for 10 seconds on the multi-display each time the starter key is switched ON after the starting number of starter motor for auto idling stop function is raised to the set value.

Replace the starter motor.

SUPPLEMENTARY EXPLANATION The limit number of durable starting times of starter motor varies according to the model of machine.

56

SECTION II - MACHINE FAMILIARIZATION The following chart is aimed at familiarizing personnel with the priority of the gauge cluster display icons. Pay close attention to these icons as they can aid in avoiding unnecessary repairs and expense.

The icon in the chart below are listed in priority from the most serious to least serious.

EXAMPLE: If the engine oil pressure is abnormal and fuel level is low, the engine oil pressure icon will display and buzzer will sound. After the oil pressure is back to safe operating pressure, the low fuel icon will display.

LCD DISPLAY

SERVICE FUNCTION ICON SEQUENCE

BUZZER SOUNDING

Press it once after E/G start.

OK

2250 RPM Press once.

Press once more time.

NORMAL DISPLAY

256Hr AFT E/G OIL CH

No sounding

SUPPLEMENTARY EXPLANATION The screen can be switched into three images by pressing the screen change switch.

1

CPU 2

MECHATRO CONT. FAIL SWINGBRAKE

11

CHARGING PROBLEM

SUPPLEMENTARY EXPLANATION:

12

LOW FUEL LEVEL

DISENGAGED 3

KPSS

29

CHANGE

DISENGAGED 4

E/G

E/G OIL 32

PR

PREHEAT 5

WARNING 6

7

10

HYD. PRESS

33

LOW E/G

NO.1 MAIN CONT P/N S TA R T E R C H G PROGRAM VER V E R 3. 0 0

HIGH E/G COOL TEMP

9

DRAINING

FINISH PREHEAT

OIL PRESS

REST’D AIR CLEANER ATTACHMENT OVER LOAD

• #2, #3, #5, #6, #7, #10, #32, #33, buzzer sounds.

PR

FAIL DRAIN HYD. PRESS

Icon #5, #6, #32 and #33 are displayed and buzzers do not stop sounding even if the buzzer stop switch is pressed.

When icon #6 is displayed, the engine RPM will idle immediately and the engine will shut down after 15 seconds.

Icon #7 is displayed and buzzer stops sounding when the buzzer stop switch is pressed.

Icons 2, #3 and #10 are displayed and buzzers sound intermittently and stop sounding after 5 seconds.

No.1 flickers on the multi-display each time the starter key is switched ON after the starting number of starter motor is raised to the set value.

57

SECTION II - MACHINE FAMILIARIZATION G. OPERATOR CAB AND OPERATOR SEAT 1. Locking/Unlocking Cab Door Use the key switch key to lock or unlock cab door. Insert key into door lock and turn clockwise to unlock or turn counterclockwise to lock cab door.

USE KEY SWITCH KEY TO LOCK & UNLOCK CAB DOOR

2. Cab Door Latch a. The cab door can be latched in an open position by opening door until it is locked open by the door latch located on the cab

CAB DOOR LATCH

CAB DOOR LATCH

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

PUSHING LEVER DOWN TO RELEASE DOOR

F16055

58

SECTION II - MACHINE FAMILIARIZATION c. Pull release lever near side, and door opens from the inside of cab

PULL BACK RELEASE LEVER

F16056

3. Opening & Closing Windshield Front window (upper) can be stored in ceiling.

LEVER (1 EACH SIDE)

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

HANDLE

F16057

FRONT INSIDE OF CAB

a. Pull levers on the right and left sides of front window upper section and levers are unlocked.

b. Hold handles on upper central and lower left sides of front window (upper), remove them up and move front window. Lift the front window up and slide overhead all the way to the back end. Pull down on handles to lock the window in place.

CAUTION Special attention must be paid not to injure hands and others when the front window is closed.

Always, make sure to properly lock the front window in place to avoid injury.

LEVER F16058

REAR INSIDE OF CAB

59

SECTION II - MACHINE FAMILIARIZATION 4. Removing & Storing Lower Front Window a. After placing upper front window in ceiling and locking it in place, remove lower front window by hand from window frame. b. Store the removed lower front window in holder in the rear of cab, behind the operator’s seat. c. To store it, insert the right and left sides of glass in holder, and support it with holder on the lower section of window frame.

5. Opening and Closing Door Glass a. Open cab door glass (upper) sliding it to front side after unlocking it. b. Close the door glass sliding it to LOCK position, then lock it.

HOLDER

HOLDER

HOLDER

F16059

LOCK

F16060

6. Opening and Closing Sunroof Pull locks on right and left sides inward, and sunroof opens through the aid of gas spring.

Close sunroof pulling locks inward, and lock it.

Also the roof can be left slightly open to ventilate air in cab by placing lock (A) section on (B) section.

LOCK (1 EACH SIDE)

(B) (A)

7. Cab Dome Light a. Turn cab dome light “ON” by pushing the dome light switch rightward. b. Turn “OFF” by pushing switch leftward. c. Place dome light switch in the “CENTER” position and the light will be operated by the door switch. When door is opened the light will come “ON” and when the door is closed the light will turn “OFF”.

60

USE THIS SWITCH TO TURN DOME LIGHT "ON" AND "OFF"

F16062

SECTION II - MACHINE FAMILIARIZATION 8. Storage Compartment The operator and parts manual storage compartment is a pouch located on the back of the operators seat. Keep the operator and parts manual for this machine in this location at all times for quick, easy reference.

F15644

9. Operator Seat Adjustments The operator seat incorporates several adjustment mechanisms to insure operator comfort, ease of operation and operator safety. The adjustment areas are as follows:

ROTATE TO SET OPERATOR WEIGHT

a. Operator weight adjustment 1. Rotate the adjustment knob until weight close to the operator weight is at the top end of the dial.

b. Seat height adjustment 1. Pull height adjustment lever up to raise or lower rear of seat.

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

PULL UP TO ADJUST REAR OF SEAT PUSH DOWN TO ADJUST FRONT OF SEAT

c. Seat reclining adjustment 1. Pull reclining adjustment lever up to set desired reclining angle.

2. Release reclining adjustment lever to lock seat in position.

PULL UP ADJUST SEAT RECLINING POSITION

61

SECTION II - MACHINE FAMILIARIZATION d. Seat front to back adjustment 1. Pull up on seat adjustment bail and move seat forward or backward to desired position.

USE BOTTOM BAIL TO ADJUST CONTROL STAND

USE TOP BAIL TO ADJUST OPERATOR SEAT ONLY

e. Arm rest adjustment 1. Lower arm rest and with finger, turn adjustment Swheel until arm rest is in desired position.

TURN WHEEL TO ADJUST ARM REST (1 EACH ARM REST)

f. Head rest adjustment 1. Move head rest forward or backward to desired reclining angle.

2. Raise or lower head rest to desired height.

62

MANUALLY ADJUST HEAT REST HEIGHT AND RECLINING TO DESIRE POSITION

SECTION II - MACHINE FAMILIARIZATION g. Seat belt 1. Sitting in operator seat, bring ends of seat belt around waist and insert L.H. end into latch (R.H. end).

2. Adjust seat belt until snug around waist by pulling loose end of belt on R.H. side.S

ATTACH BELT ENDS AROUND WAIST

TIGHTEN BY PULLING LOOSE END

3. Remove seat belt by pushing red release button on latch end.

F16071

RELASES BY DEPRESSING RED BOTTOM

WARNING Always wear seat belt while sitting in operator seat. always check condition of seat belt and seat belt mounting hardware to make certain seat belt is in good condition and properly secure.

F16072

H. MACHINE ACCESS PANELS AND DOORS 1. Engine Coolant Tank & Engine Air Cleaner Access Doors Located on the L.H. side of the machine the engine coolant tank access door allows access to the engine coolant tank. It also holds the engine air cleaner access door closed.

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

2. Main Pump Access Door Locate on the R.H. side of the machine this door allows access to the main pump.

ENGINE COOLANT TANK ACCESS DOOR

ENGINE AIR CLEANER ACCESS DOOR

RADIATOR SUB TANK ACCESS DOOR

MAIN PUMP ACCESS DOORS

63

SECTION II - MACHINE FAMILIARIZATION 3. Battery Box Access Cover Located on the R.H. front of the upper frame this cover allows access to the batteries and battery relay. This access cover is also locked and unlocked by key switch key.

Use stay to leave the cover open.

4. Fuel Cap Stop engine and remove cap on fuel tank.

Fill to desired level or to full up. See section “MAINTENANCE”.

BATTERY ACCESS COVER

FUEL CAP

FLOAT (RED) F16076

5. Engine Cover Open engine cover with key switch key after stopping engine.

Use stay to support it.

ENGINE BONNET

64

SECTION II - MACHINE FAMILIARIZATION I. How To Correct The Engine Oil Supply Cumulative Time KPSS WORK MODE LAMP

FUEL LEVEL GAUGE

WATER TEMPERATURE GAUGE

LCD DISPLAY LCD DISPLAY

SCREEN CHANGE SWITCH

F16328

BUZZER STOP SWITCH

Procedure

Operating procedure

Display on multidisplay (Normal)

A

Turn the starter switch on.

B

Press the gauge cluster screen change switch once, and the E/G speed (rpm) is displayed.

OK (Normal)

OK

is displayed.

(E/G speed is displayed) Press once 2250 RPM

(E/G speed is displayed) Press once more 2250 RPM

C

Press once more, and the engine oil supply cumulative time screen is displayed.

D

Press the screen change switch for 5 to 10 seconds and release the hand, it returns to the correction mode.

Note: The hourmeter does not flicker.

100Hr AFT E/G OIL CH

OK

100Hr AFT E/G OIL CH

E

Press the work mode selector switch and the cumulative time increases. (once 1Hr)

100Hr AFT E/G OIL CH

Cumulative time increases

101Hr AFT E/G OIL CH

F

Press the buzzer stop switch, the cumulative time decreases. (once 1 Hr)

100Hr AFT E/G OIL CH

The cumulative time decreases

99Hr AFT E/G OIL CH

99Hr AFT E/G OIL CH

Complete the correction

OK

G

Press the gauge cluster screen change switch once the correcting time is stored, and exit from the correction mode and OK symbol is displayed to complete the correction.

100 Hr AFT E/G OIL CH

NOTE: 1. Press the screen change switch once after the procedure D, and the condition is stored and the correction is completed.

2. Even reaching procedure D, the hourmeter does not flicker, and even reaching procedure G, it still does not go on.

65

SECTION II - MACHINE FAMILIARIZATION NOTES:

66

Section III BASIC MACHINE OPERATION

SECTION III - BASIC MACHINE OPERATION

3.1 PRE-START CHECK HI

Perform pre-start inspection and maintenance procedures before starting the machine. Refer to the maintenance section of this manual for specific instructions.

F OF

ACC

ON

T AR ST

HE AT

LO

3.2 STARTING & STOPPING MACHINE ENGINE WITH TEMPERATURE ABOVE 0°C (32°F) A. STARTING ENGINE 1. Move throttle control to “LO” position.

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

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

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

THROTTLE IN “LO” POSITION

KEY SWITCH IN “ON” POSITION

F16081

SOUND HORN

CAUTION Release key after 20 seconds of cranking if engine does not start. Wait at least 2 minutes before attempting to start engine again to allow starter motor to cool.

NOTE: If engine fails to start after 3 attempts, inspect fuel system and correct any problems found. When cranking engine, the absence of “Blue” or “White” smoke from the exhaust indicates no fuel is reaching the engine cylinders.

F16082

WARNING When you do the work which has fear, such as fall of a load, when engine stops, please be sure to turn OFF an auto idling stop switch.

CAUTION The auto idling stop function for cutting down generating of the useless fuel consumption and an exhaust gas at the time of a stop in this machine is carried. When you use it, be careful of the following things: · When you start the engine again after an auto idling stop, please be sure to start after once returning a key switch at ACC or OFF and also returning a throttle potentiometer to Lo. But the engine cannot be again started until a buzzer stops, after engine stops. · When you leave from a cab for a long time, please be sure to turn OFF a starter switch. · When the engine coolant temperature error are displayed with the LCD or lamp, it does not operate, even if the auto idling stop switch is turned on ON. Please read the operator's manual.

F24435

68

SECTION III - BASIC MACHINE OPERATION B. STOPPING ENGINE – NORMAL CONDITIONS 1. Move machine to a firm, level area and place the attachment in the hydraulic oil check position.

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

3. Turn key switch to “OFF”.

MACHINE ON FIRM, LEVEL SURFACE

ATTACHMENT IN HYDRAULIC OIL CHECK POSITION

F16329

C. EMERGENCY ENGINE SHUT DOWN Only in cases of emergency should this method be used.

1. Turn key switch to the “OFF” position.

2. Pull out the engine emergency stop control located on the lower right side of control stand until engine stop.

3. Before restarting engine, push emergency engine stop control in.

USE ONLY IN EMERGENCY

EMERGENCY ENGINE STOP CONTROL

F16084

HI

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

OF

F

ACC

ON

T AR ST

LO

CAUTION

THROTTLE IN “LO” POSITION

HE AT

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

2. Turn the key switch to “HEAT” and preheat for 20 seconds to make start-up easier.

3. Turn key switch “ON” and sound horn to warn personnel that the machine is being started.

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

KEY SWITCH IN “ON” POSITION F16081

KEY IN “HEAT” POSITION FOR 20 SECONDS

Release key after 20 seconds of cranking if engine does not start. Wait at least 2 minutes before attempting to start engine again to allow starter motor to cool.

E/G PREHEAT

F16085

NOTE: If engine fails to start after 3 attempts, inspect fuel system and correct any problems found. When cranking engine, the absence of “Blue” or “White” smoke from the exhaust indicates no fuel is reaching the engine cylinders.

SOUND HORN

F16082

69

SECTION III - BASIC MACHINE OPERATION

WARNING When you do the work which has fear, such as fall of a load, when engine stops, please be sure to turn OFF an auto idling stop switch.

CAUTION The auto idling stop function for cutting down generating of the useless fuel consumption and an exhaust gas at the time of a stop in this machine is carried. When you use it, be careful of the following things: · When you start the engine again after an auto idling stop, please be sure to start after once returning a key switch at ACC or OFF and also returning a throttle potentiometer to Lo. But the engine cannot be again started until a buzzer stops, after engine stops. · When you leave from a cab for a long time, please be sure to turn OFF a starter switch. · When the engine coolant temperature error are displayed with the LCD or lamp, it does not operate, even if the auto idling stop switch is turned on ON. Please read the operator's manual.

F24435

B. STOPPING ENGINE – NORMAL CONDITIONS 1. Move machine to a firm, level area and place the attachment in the hydraulic oil check position.

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

3. Turn key switch to “OFF”.

MACHINE ON FIRM, LEVEL SURFACE

ATTACHMENT IN HYDRAULIC OIL CHECK POSITION

F16329

C. EMERGENCY ENGINE SHUT DOWN Only in cases of emergency should this method be used.

1. Turn key switch to the “OFF” position.

2. Pull out the engine emergency stop control located on the lower R.H. side of control stand until engine stops.

3. Before attempting to restart the engine, push emergency engine stop control in.

USE ONLY IN EMERGENCY EMERGENCY ENGINE STOP CONTROL

F16084

70

SECTION III - BASIC MACHINE OPERATION

3.4 STARTING MACHINE ENGINE WITH BOOSTER CABLES

KEY SWITCH POSITIONS OF

ACC

ON

H EA

RT STA

T

A. CONNECTING BOOSTER CABLES 1. Move vehicle or machine to be used for boosting as close to the battery box of the disabled machine as possible.

F

HI

WARNING T AR ST

F OF

ACC

ON

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

This could short circuit electrical systems and cause extensive damage to the CPU and other components.

HE

AT

LO

CAUTION

F16086

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

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

POSITIVE (+) CABLE

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

NEGATIVE (-) CABLE F19184

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

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

5. Locate and connect second cable to the negative (–) terminal of the battery being used for boosting.

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

WARNING The negative cable, when connected to the upper frame of disabled machine, may arc causing sparks.

Sparks coming in contact with batteries, could trigger an explosion.

Never connect negative cable to Negative (-) terminal of disabled battery.

CABLE CONNECTING ORDER

1

(3)

2

3

4

(1)

(2)

12V

12V

NORMAL BATTERIES

12V

12V

DISCHARGED BATTERIES

(4) UPPER FRAME OF DISABLED MACHINE F16087

71

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

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

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

CABLE DISCONNECTING ORDER

4

(3)

3

2

1

(1)

(2)

12V

12V

NORMAL BATTERIES

12V

12V

DISCHARGED BATTERIES

(4) UPPER FRAME OF DISABLED MACHINE F16087

D. DISCONNECTING BOOSTER CABLES After disabled machine engine is running, first disconnect the negative (-) cable from disabled machine upper frame.

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

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

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

CAUTION When using booster cables remember; 1. Connect positive (+) cable first.

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

72

DISCONNECT NEGATIVE (-) CABLE FROM DISABLED MACHINE

SECTION III - BASIC MACHINE OPERATION

3.5 MACHINE WARM UP

HI

LO

A. ENGINE 1. Allow the engine to run for 5 minutes under no load conditions with throttle control at “LO” idle position.

2. During warm up, visually and audibly inspect engine for abnormal conditions such as unusual exhaust color, excessive vibrations and excessive or unusual noises.

3. Should problem areas be noticed, stop engine, locate and repair problem areas before restarting or operating the machine.

RUN ENGINE 5 MINUTES WITH THROTTLE IN ”LO” IDLE POSITION

NOTE: In warming up the engine, turn auto idling stop select switch “OFF”.

R.H. CONTROL LEVER (ISO PATTERN)

C. HYDRAULIC OIL IN FRIGID TEMPERATURES 1. Perform normal hydraulic oil warm-up procedures.

L.H. CONTROL LEVER (ISO PATTERN)

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

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

ON

F16089

B. HYDRAULIC OIL 1. Move throttle control to “HI” position.

2. Perform bucket dig operation and hold over relief for 10 to 15 seconds, then operate bucket out and hold over relief for 10 to 15 seconds. Repeat this operation for 5 to 10 minutes to help oil to reach operating temperature.

3. Move throttle control to mid position and operate the boom, arm and swing controls for 5 to 10 minutes each.

4. Push and pull the dozer blade control lever on the side of right control stand 4 or 5 times.

NOTE: If machine is operated in frigid temperatures daily, it may be necessary to change the hydraulic oil to an oil designed for operation in frigid climates. Refer to maintenance section for hydraulic oil specifications.

ACC

T AR ST

HE AT

F OF

BOOM DOWN BUCKET OUT BUCKET IN

BOOM UP F16090

ARM OUT

SWING LEFT SWING RIGHT

ARM IN

F16045

73

SECTION III - BASIC MACHINE OPERATION

3.6 CONTROLS DECAL A. OPERATING PATTERN The operating and travel controls of this machine are factory set to ISO standard operating patterns for optimum performance of the machine and its systems.

B. OPERATING PATTERN DECAL Figure is a representation of the “CONTROLS” decal located on the R.H. side window inside the operator cab. Study this decal and understand the directions each control can be operated and the functions associated with each movement of particular control. Detailed instructions for each control and its functions are explained on the following pages of this section.

HYDRAULIC CONTROL LEVERS

LEFT CONTROL LEVER

LEFT TRAVEL LEVER AND PEDAL

RIGHT TRAVEL LEVER AND PEDAL

RIGHT CONTROL LEVER

NOTE: Travel motors are positioned behind the operator’s cab.

(A) LOWER BLADE DOZER BLADE CONTROL LEVER (OPT.)

(B) LIFT BLADE

74

SECTION III - BASIC MACHINE OPERATION

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

Each operator must read, understand and follow these basic instructions along with all safety precautions found in this manual and on the machine before operating this equipment.

TRAVEL MOTOR AT REAR MACHINE

WARNING Normal positioning of the machine for the purpose of determining front, rear, forward and reverse are with the travel motors located behind the operator’s cab.

Always know the location of travel motors before operating any hydraulic controls.

A. SAFETY LOCK LEVER 1. Unlocked Position Before any hydraulic operation is possible the safety lock lever must be placed in the “UNLOCKED” (DOWN) position. Placing the safety lock lever in the UNLOCKED (DOWN) position also positions the L.H. operator’s console in its operating and locked position.

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

SAFETY LOCK LEVER IN UNILOCKED (DOWN) POSITION

SAFETY LOCK LEVER IN LOCKED (UP) POSITION

WARNING Always place the safety lock lever in the “locked” (up) position before leaving cab to prevent any operation of hydraulic controls.

Failure to place safety lock lever in the locked (up) position could result in serious injury or death as well as serious damage to the machine and its components.

F16530

WARNING Dozer blade control function is live at all times. That is, even with the safety lock lever in locked position.

75

SECTION III - BASIC MACHINE OPERATION B. KPSS WORK MODE SWITCH The mode is switched in turn every time when the switch is pressed, and the selected work mode indicator lamp lights on.

Before selecting a machine work mode, the operator should always study each job site to answer some basic questions.

1. Is the machine capable of performing the particular job?

2. What attachment (bucket) is best suited for the job?

3. What type of material will the machine be excavating?

4. What operating mode is best suited for the job?

CHARGING PROBLEM

F16093

2. KPSS WORK MODE SELECTION TABLE The KPSS work mode selection table gives examples of work types, work requirements and materials being excavated. Use this table when deciding the KPSS work mode best suited for the specific job at hand.

1. KPSS WORK MODE FUNCTIONS The KPSS work mode switch allows the operation select and control the operation of the machine and the attachment effectively for a particular job by selecting one of three positions. a. “H” Mode ...... Provides maximum speed and power for digging operations. b. “S” Mode ... Provides standard power and best fuel consumption. c. “FC” Mode .... Allows fine control of hydraulic functions for attachment.

KPSS WORK MODE SELECTION TABLE WORK TYPE WORK REQUIREMENTS

DIGGING

LOADING

1

2

3

1

2

SOFT VISCOUS SOIL

H

S

FC

H

S

LOOSE SANDY SOIL

H

S

FC

H

TIGHT SANDY SOIL

H

S

FC

GRAVEL & STONE

H

H

TIGHT GRAVEL/MIXED SOIL

H

SOFT STONE

H

MATERIAL

3

CORRECTION 1

2

3

REFILLING & CRUSHING CORRECTION

TRANSFER

1

2

3

FC FC FC FC

H

S

FC

Flat Land "S"

S

FC FC FC FC

H

S

FC

H

S

FC

S

Slope & Long Distance Travel "H"

S

H

H

S

S

S

FC

H

S

H

H

S

H

H

S

H

H

H

H

H

H

H

H

1

2

FC FC H

3

1

2

3

Loading & Unloading etc. "FC"

Work Requirements – 1=large volumes at fast speed • 2=normal work, less fuel • 3=fine control of attachment F17902gb

76

SECTION III - BASIC MACHINE OPERATION C. MACHINE TRAVEL CONTROLS This machine incorporates several travel controls for the convenience of the operator.

Each track can be operated independently to turn the machine or simultaneously to counter rotate the machine or to travel straight.

1. Operating Both Travel Levers Together a. Push both travel levers or press the pedals toward front of machine and machine will travel “FORWARD”. b. Pull both travel levers or press the pedals toward operator seat and machine will travel “REVERSE”. c. Return both travel levers to “NEUTRAL” (center) position and machine will stop.

Parking brakes are automatically applied when travel levers are in neutral position.

FORWARD TRAVEL

F16092

REVERSE TRAVEL

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

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

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

2. Use of Travel Speed Select Switch a. For fast travel speed, depress and release the travel speed select switch once before operating the travel controls.

This puts the travel motors in “FAST” ( ) travel speed and the lamp for “FAST” ( ), on the gauge cluster display, will come on. b. To return to “SLOW” travel speed, depress and release travel speed select switch once.

F16094

PRESS HERE FOR “FAST” & “SLOW”

TRAVEL SPEED SELECT SWITCH

CAUTION Use “FAST” ( )travel speed on firm, level surfaces only.

Do not travel continuously for more than two hours.

Stop for a period of 10 min. at low idle speed before resuming travel.

F16042

77

SECTION III - BASIC MACHINE OPERATION 3. Turning Machine a. Push the L.H. travel lever toward front of machine to turn machine RIGHT in forward motion. b. Pull the L.H. travel lever back toward operator seat to turn machine to the LEFT in reverse motion. c. Push the R.H. travel lever toward front of machine to turn machine to the LEFT in forward motion. d. Pull R.H. travel lever toward operator seat to turn machine to the RIGHT in reverse motion.

LEFT FORWARD TRAVEL

4. Counter Rotating Machine a. Pull L.H. travel lever BACK and push R.H. travel lever FORWARD to counter rotate machine to the LEFT. b. Pull R.H. travel lever BACK and push L.H. travel lever FORWARD to counter rotate machine to the RIGHT.

RIGHT FORWARD TRAVEL

F16095

NOTE: All the functions explained with use of travel levers can also be performed using the travel pedals.

F16096

CAUTION 1. Depending on shoe type and ground conditions this machine has a maximum climbing ability of 35˚ (70%) maximum, limited by engine lubrication.

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

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

4. The travel operation for 2 hours or more may cause the failure of travel motor due to the rise of operating temperature. Don’t travel countinuously for more than 2 hours. Stop for 10 min. at low idle before resuming travel.

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

COUNTER ROTATING TO THE LEFT

F16097

COUNTER ROTATING TO THE RIGHT

F16098

78

SECTION III - BASIC MACHINE OPERATION 5. Travel Safety a. Make certain travel motor location is known before performing any travel operation. b. Travel on firm, level surfaces as much as possible. c. When traveling on rough terrain, travel in ) speed with engine at a low SLOW ( idle. d. Travel with the travel motors in back of the machine for long distance travel. e. When traveling or operating machine on snow or icy surfaces, clean track shoes frequently to prevent clogging. This will help keep the machine from sliding unexpectedly. f. Keep a safe distance from stationary objects and electrical power lines. g. Be aware of load capacities of bridges and road shoulders. Reinforce if necessary. h. Use decking or plating to protect road surfaces as much as possible. Be careful when turning or spinning machine on asphalt pavement. i. Do not allow large or heavy objects to strike travel motors. j. Do not travel over large objects such as boulders rocks etc. k. If necessary to travel or operate machine in a river or other water, the bed must be firm and water current slow. Water must not be deeper than indicated in the chart in Figure.

WATER DEPTH WATER MUST NOT BE OVER

BED MUST BE FIRM & STABLE F16333

MODEL E115SR E115SRL

MAXIMUM WATER DEPTH 620 mm 730 mm

NOTE: If the machine is operated while the slewing bearing is submerged in water, then the slewing bearing, slewing pinion, and the swivel joint may wear out prematurely.

Immediate replacement of grease in grease bath and overhaul of the slewing bearing is required. See maintenance section.

l. On soft ground or mud the machine can sink.

Stay constantly aware of undercarriage position.

79

SECTION III - BASIC MACHINE OPERATION D. MACHINE ATTACHMENT & SWING CONTROLS The following operation instructions are to be used with hoe bucket attachment only. If other attachments are being used, consult the operator’s manual for the particular attachment.

WARNING Be careful when operating certain attachments close to the cab.

Certain attachments can hit and damage cab.

Stop attachment a safe distance away from cab to avoid damage or injury.

WARNING Read, understand and follow all safety precautions during all operations of this machine and its attachment(s).

1. Boom Operation Operation of the boom is performed by pushing and pulling the R.H. control lever forward and backward. Boom speed is determined by how far the lever is activated. a. Pulling R.H. control lever BACK raises boom. b. Pushing R.H. control lever FORWARD lowers boom. c. Returning R.H. control lever to the neutral (center) position stops operation of the boom.

PULL BACKBOOM UP

2. Arm Operation Operation of the arm is performed by pushing or pulling the L.H. control lever forward and backward. Arm speed is determined by how far the lever is activated. a. Pushing the L.H. control lever FORWARD moves the arm out. b. Pulling the L.H. control lever BACK moves the arm in. c. Returning the L.H. control lever to the neutral (center) position, stops operation of the arm.

PULL BACKARM IN

3. Bucket Operation Operation of the bucket is performed by moving the R.H. control lever to the right or left. a. Moving the R.H. control lever to the LEFT operates the bucket in (digging). b. Moving the R.H. control lever to the RIGHT operates the bucket out (dumping).

PULL LEFTBUCKET IN (DIGGING)

PUSH FORWARDBOOM DOWN

F16100

PUSH FORWARDARM OUT

F16101

PUSH RIGHTBUCKET OUT (DUMPING)

F16102

80

SECTION III - BASIC MACHINE OPERATION 4. Swing Operation

PUSH LEFT SWING LEFT

PUSH RIGHT SWING RIGHT

NOTE: Use rotary light during swing operations.

Swing operation is performed by moving the L.H. control lever to the right and left. Swing speed is determined by the amount the lever is moved. a. Moving the L.H. control lever to the LEFT swings the machine to the left. b. Moving the L.H. control lever to the RIGHT swings the machine to the right. c. Returning control to the neutral (center) position stops swing.

F16103

DOZER BLADE CONTROL LEVER

WARNING

LOWER BLADE

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

Sound horn before beginning swing operations

(A)

(B) LIFT BLADE

5. Dozer Blade Control Lever (Opt.) NOTE: Read, understand and follow all safety precautions and operation procedures found in this manual before operating the machine or any attachment.

TROTTLE CONTROL

The dozer blade control lever is located on the right side of the right hand operator console basic function is to lift or lower the dozer blade. a. Start machine and place the safety lock lever in the “UNLOCKED” (down) position. b. Move throttle control to the “HI” idle position. c. Using boom, arm and bucket controls set the attachment to desired position. d. Pull the blade control lever to lift up the blade. e. Push the blade control lever forward to lower the blade.

NOTE: Always place attachments on the ground and lock up the safety lock lever before leaving the cab.

(B)

F16324

(A)

NOTE: Dozer blade control function is live at all times. That is, even with the safety lock lever in locked position.

81

SECTION III - BASIC MACHINE OPERATION E. USING AUTO-ACCELERATION

Depress this side of switch to turn auto accel “ON”.

Depress back side of switch to turn auto accel “OFF”.

WARNING When loading or unloading machine on trailer, turn the auto accel switch off. if it is operated keeping the auto accel switch on, the engine speed changes abruptly.

WARNING Automatic two speed travel system changes travel speed automatically and can adversely affect machine control when descending a slope and loading or unloading on a trailer.

Personal injury can occur from sudden change in machine control.

Put travel speed select switch in low speed position when descending a slope and loading or unloading on a trailer.

WARNING Blade control lever is unavailable for auto accel releasing.

82

PRESS HERE FOR “ON” PRESS HERE FOR “OFF”

LO

1. Auto Accel Switch The auto accel switch is located to the right hand operator console.

The auto accel switch is a 2 position rocker switch and when “ON” will automatically decrease engine RPM approximately 4 seconds after all hydraulic controls have been placed in their neutral positions then, upon operation of any hydraulic control, will automatically increase engine RPM to match throttle control setting.

HI

THROTTLE POTENTIOMETER F16105

SECTION III - BASIC MACHINE OPERATION

3.8 PRACTICES TO IMPROVE EFFICIENCY

USE ARM HORIZONTALLY AS MUCH AS POSSIBLE

A. USE ARM HORIZONTALLY Operate the bucket at shallow depths and use the arm horizontally to fill the bucket. Setting the bucket too deep will decrease the machine’s efficiency.

F16334

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

OPERATE BOOOM SMOOTHLY DURING ALL BOOM OPERATIONS

F16335

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

ALWAYS POINT BUCKET TEETH IN DIRECTION OF DIGGING

F16336

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

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

90°~ 110°

F16337

83

SECTION III - BASIC MACHINE OPERATION E. CLEANING SAND & SOIL FROM BUCKET Operate arm to a near level position and bring the bucket to a dumping position. If sand and soil do not fall out, move the bucket lever right and left a few times.

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

CAUTION Avoid shaking out soil using shocks at the end of the bucket cylinder stroke.

F16338

F. STOP SWING MOTION EARLY To stop slewing action, release the swing lever before you get to your final point of digging or dumping.

RELEASE SWING BEFORE REACHING DESIRED DIGGING POSITION

G. BACK FILLING & LEVELING For back filling and leveling work after digging, move the bucket back and forth horizontally.

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

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

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

3. ln the above operation, bucket motion may be used together with the boom. By controlling the action of the boom work lever, you can dig a slope- like, slope facing operation.

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

84

F16339

USE ARM TO MOVE BUCKET HORIZONTALLY FOR LEVELING

F16340

SECTION III - BASIC MACHINE OPERATION H. OPERATING THE SHOVEL Digging with the shovel differs slightly from digging with backhoe.

1. Using the arm cylinder, scrape the ground.

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

3. Be careful not to bump the reversed bucket into the cab.

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

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

GRADE AT 2~3’ SLOPE FOR DRAINAGE

EYE 2°~ 3° F16341

I. MACHINE OPERATION IN ADVERSE WEATHER CONDITIONS 1. Operation in Extreme Cold a. Follow procedures to the section III “STARTING & STOPPING MACHINE ENGINE WITH TEMPERATURE BELOW 0°C (32°F)” as starting engine may be difficult due to extremely cold temperatures. b. Use an engine oil, hydraulic oil and diesel fuel designed for use in cold climates. See maintenance section, for reference. Also, keep battery fully charged. c. Make certain to perform machine warm-up procedures as described to the section III “MACHINE WARM-UP” to prevent premature wear or damage to pumps, motors and other components.

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

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

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

85

SECTION III - BASIC MACHINE OPERATION e. Keep battery terminals free of ice and snow.

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

2. Operation in Extreme Heat a. Use an engine oil, hydraulic oil and fuel oil designed for use in hot climates. See maintenance section, for reference. Also, keep battery fully charged. b. Clean radiator, oil cooler and debris screen often to prevent damage or overheating of the machine.

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

c. Keep all belts properly tensioned. d. Make certain that the engine coolant mixture is sufficient to keep the machine safe. e. If the machine becomes overheated, idle the machine to help cool the engine, turn engine “OFF” and check coolant level. After filling to proper level the machine continues to over heat, stop engine, allow to cool, drain and flush entire cooling system and refill with the proper mixture of fresh, clean coolant. f. Check the battery electrolyte (acid) level frequently and fill as necessary with distilled water. g. Keep a close watch on the gauge cluster for warning icons during operation. Avoid unnecessary low speed running of the engine during operation. During slow, or no work periods, place throttle (accel) dial in “LO” idle position.

86

3. Operation in High Altitudes a. Due to low atmospheric pressure at high altitudes, a decrease in engine power will be experienced. Be aware of this fact when placing machine under heavy load in high altitude climates. b. Keep close watch on the engine temperature gauge to avoid overheating of the engine.

4. Operation in Sandy and Dusty Areas a. Check the engine air cleaner elements frequently in sandy or dusty conditions. b. When air cleaner restriction lamp is lit, change filters immediately regardless of time intervals. c. Service fuel filter, water separator, and all hydraulic filters frequently.

5. Operation at Seashore or Salty Climate a. Thoroughly wash machine daily to help avoid corrosion of machined areas, electrical components and cylinder rods. b. Frequently check all mounting hardware for proper tightness. Torque to proper value to aid in preventing salt from entering the machine systems.

6. Operation in Humid Climate a. In climates with high humidity, thoroughly wash the machine daily and coat all bare surfaces with an oil based lubricant to help prevent corrosion.

SECTION III - BASIC MACHINE OPERATION

3.9 FLAGMAN HAND SIGNALS All personnel associated with the operation of the excavator should know these signals and their meaning before attempting to operate this machine.

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

F16116

B. LOWER LOAD VERTICALLY Face machine operator, extend right arm down, point index finger down and move hand in a small circular motion.

F16117

C. MOVE LOAD IN HORIZONTALLY Face machine operator, extend right arm toward operator with hand facing operator and move hand in direction of movement required.

F16118

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

F16119

87

SECTION III - BASIC MACHINE OPERATION E. RAISE BOOM Face machine operator, extend right arm out horizontally from shoulder, make a fist with thumb up.

F16120

F. LOWER BOOM Face machine operator, extend right arm out horizontally from shoulder, make a fist with thumb down.

F16121

G. SWING LEFT Face machine operator, extend right arm out horizontally from shoulder, make a fist with index finger pointing in swing direction.

F16122

H. SWING RIGHT Face machine operator, extend left arm out horizontally from shoulder, make a fist with index finger pointing in swing direction.

F16123

88

SECTION III - BASIC MACHINE OPERATION I. ARM IN Face machine operator, bend at elbows with arms facing operator, make fists and point thumbs in toward each other.

F16124

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

F16125

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

F16134

L. EMERGENCY STOP Face machine operator, raise both arms out horizontally from shoulders with hands open and facing down, move arms in a horizontal motion back and forth.

F16137

89

SECTION III - BASIC MACHINE OPERATION NOTES:

90

Section IV MAINTENANCE

SECTION IV - MAINTENANCE

4.1

GENERAL INFORMATION WARNING

Read, understand and follow all safety precautions contained in this manual before performing any inspection or maintenance procedures on this machine, its systems or components.

A. It is recommended by the Manufacturer, that an inspection and maintenance schedule be developed and maintained on a regular basis for this machine. Developing and maintaining such a schedule, helps to keep the machine in optimum operating condition.

B. The information contained in this section gives the proper procedures for performing inspection and maintenance functions for this machine. Use these procedures when performing inspection and maintenance as they will guide the technician step by step for each procedure. Also, refer to the Inspection and maintenance charts for general service interval recommendations.

NOTE: The inspection and maintenance charts provided in this section give only general time intervals. It may be necessary to develop a custom schedule to perform machine maintenance at more frequent intervals based on the work conditions such as severe applications, work in dusty or humid circumstances, etc.

C. Use only the Manufacturer oils, fluids, lubricants, filters and replacement parts to keep machine in optimum operating condition.

Furthermore, use the oils and greases with the specified viscosity depending on the ambient temperature.

• Store the vessels and containers indoor for the oils, fluids and greases, taking suitable measures to prevent them from invading dust, water, etc.

NOTE: Make sure to consult with your Dealer for the adjustment, disassembling and repair.

92

SECTION IV - MAINTENANCE

4.2

GENERAL SAFETY & PRECAUTIONS A. DISPOSAL OF HAZARDOUS WASTE Dispose of waste oils, fluids, lubricants, filters and other hazardous waste properly.

CAUTION Dispose of all hazardous waste in accordance with government environmental regulations, laws and codes.

F1478

B. KEEP MACHINE CLEAN Thoroughly clean machine before performing inspection and maintenance procedures. It is easier and safer to locate problems, perform maintenance and also reduce the risk of hydraulic system contamination when machine is clean.

F1462

C. HOT SURFACES & FLUIDS Use cautions and wear the proper safety equipment when working around hot areas.

Never change oils, engine coolant or filters immediately after machine has been stopped.

Allow machine to cool down before performing maintenance procedures.

D. WARM ENGINE OIL Engine oil should have a temperature of between 20~40˚C (68~104˚F) before the oil is changed.

If necessary run engine until the oil is warm within the recommended oil change temperature.

DO NOT OPERATE

E. “TAG-OUT” MACHINE Before beginning any inspection or maintenance procedures, secure a “ DO NOT OPERATE” tag to the operator’s console to inform the operator that the machine will be inoperable for inspection and maintenance.

This tag will help prevent accidental starting of the machine.

93

SECTION IV - MAINTENANCE F. INSPECT WASTE OILS AND FILTERS Before disposal, inspect all waste oils, fluids and filters for debris and foreign material. It is recommended to cut open the oil filters to determine any abnormal wear.

CHECK FOR DEBRIS

G. PREVENT CONTAMINATION Always cap or plug lines when hydraulic components are removed to prevent hydraulic system contamination that can be caused by dirt, dust and debris entering a line or port.

F16139

CAUTION Never allow a hydraulic line or component to become contaminated. This could cause severe system damage. Contact an authorized distributor to obtain the proper caps and plugs to be used on this machine.

H. SEALS AND “O”-RINGS Always replace seals and “O”-rings with new parts. Never reuse a seal or “O”-ring during reassembly of components. Make sure to lubricate all new seals with the appropriate oil before installation.

F16140

I. STOP ENGINE Never attempt any MAINTENANCE with engine running. Always stop the engine and allow machine to cool.

J. WEAR SAFETY EQUIPMENT Wear hard hat, safety goggles or face shield, work gloves, safety shoes and well fitting work clothes when performing inspection and maintenance procedures on this machine.

K. CLEANING PARTS Use only approved cleaning solvents and proper equipment to clean parts.

F1438

WARNING Never use gasoline, diesel fuel or other flammable solvents to clean parts.

Always clean parts in a well ventilated area.

94

SECTION IV - MAINTENANCE L. HYDRAULIC TANK PRESSURE Always release the internal pressure of the hydraulic tank before performing inspection or maintenance procedures.

DEPRESS RUBBER CAP TO RELEASE PRESSURE

1. Push rubber cap “DOWN” to release air pressure in the reservoir.

HYDRAULIC TANK

CAUTION Gasses from hydraulic tank may be hot.

Wear safety equipment.

F16354

HI

LO

M. WELDING SAFETY 1. Turn key switch to “OFF” position. Wait 4 seconds for electrical power to disconnect.

KEY SWITCH IN “OFF” POSITION

HE

F

ACC

ON T AR ST

AT

OF

F16141

2. Remove negative (-) cable from battery terminal.

3. Attach welder ground cable with 1 m (3´-3˝) away from component being welded.

4. Make certain welder ground is not located at a seal or bearing.

5. Make certain that no bearings nor seals separates the welder ground and the weld area.

F16142

95

SECTION IV - MAINTENANCE N. RELEASING INNER PRESSURE IN HYDRAULIC SYSTEM

WARNING Never change oils or filters on a machine that has just finished working. Allow machine to cool first until oils and fluids are warm not hot.

Release hydraulic tank pressure before working with any hydraulic component.

1. Select the hard and flat area and place the machine in the position shown in Figure.

2. Start the engine.

3. Keep the screen change switch and buzzer stop switch on the switch panel pressed for 5 seconds simultaneously, and the “DRAINING HYD. PRESS” is displayed on the multidisplay and the buzzer sounds intermittently.

4. In this condition, operate the lever for attachment required to be released the pressure, and the internal pressure of the hydraulic pressure system is released.

Special attention must be given to operate because the attachment moves a little by its own weight.

5. After releasing the pressure, if the pressure release fails, the symbol “FAIL DRAIN HYD. PRESS” is displayed on the multidisplay.

6. At the same time, buzzer sounds continuously. Turn the starter key “OFF”, and the buzzer stops sounding.

7. Release the pressure again.

8. Stop the dozer operating at the position where the blade reaches close to the ground, and after the engine stops, move the dozer lever forward and rearward several times, and the blade contacts the ground, consequently the inner pressure is released.

9. Stop the engine. Pressure release available.

96

F16316

DRAINING HYD. PRESS

F16143

SECTION IV - MAINTENANCE

4.3 INSPECTION AND MAINTENANCE CHART

WARNING

Follow the chart below for recommended intervals of regular inspection and maintenance procedures.

SYSTEM

ENGINE

MAINTENANCE TO PERFORM

Read, understand and follow all safety precautions found in this manual before performing inspection & maintenance.

COMPONENT LOCATION

CHECK OIL LEVEL

REAR SIDE OF ENGINE

CHECK COOLANT LEVEL

RESERVOIR

CHECK FOR FLUID LEAKS

COMPLETE ENGINE

CHECK BELT TENSION

FRONT OF ENGINE

CHECK FUEL LEVEL

GAUGE CLUSTER

CHECK AIR CLEANER

AIR CLEANER

CHECK ENGINE ELECTRICAL

COMPLETE ENGINE

DRAIN WATER FROM FUEL

FUEL TANK BOTTOM

CHANGE ENGINE OIL

OIL PAN

CHANGE OIL FILTER

REAR SIDE OF ENGINE

CHANGE FUEL FILTER

L.H. SIDE OF ENGINE

FUEL PRE-FILTER

R.H. SIDE OF ENGINE

DRAIN WATER SEPARATOR

L.H. SIDE OF ENGINE

CHECK AIR INTAKE SYSTEM

HOSES & CLAMPS

CHECK FAN ASSEMBLY

FRONT OF ENGINE

CHECK BELT TENSIONER

FRONT OF ENGINE

CLEAN RADIATOR

RADIATOR

CLEAN DEBRIS SCREEN

BETWEEN RADIATOR AND OIL COOLER

CHANGE ENGINE COOLANT

RADIATOR

CHANGE AIR CLEANER ELEMENTS

AIR CLEANER

ADJUST VALVE CLEARANCE

ENGINE TOP

CHECK ENGINE COMPRESSION

ENGINE

CHECK INJECTION PRESSURE

ENGINE

HYDRAULIC OIL LEVEL

SIDE OF HYD TANK

CHECK HYD FUNCTIONS

CAB

CHECK FOR OIL LEAKS

HYDRAULIC SYSTEM

CHECK HOSES / LINES

HYDRAULIC SYSTEM

CLEAN SUCTION SCREEN

HYDRAULIC TANK

CHANGE RETURN FILTERS

HYDRAULIC TANK

CHANGE HYDRAULIC TANK BREATHER

HYDRAULIC TANK

CHANGE HYDRAULIC OIL

HYDRAULIC TANK

CLEAN HYDRAULIC TANK

HYDRAULIC TANK

INSPECT ALL WIRING

COMPLETE MACHINE

INTERVAL (HOURS ON HOURMETER) 8 50 100 250 500 1000 2000

HYDRAULIC

ELECTRICAL BATTERY ELECTROLYTE BATTERY SERVICE

(BREAKER)

BATTERIES BATTERIES

• • • Regular inspection & maintenance required.

F19177gb

• • • Break-in (after first 50 hours) inspection & maintenance required.

97

SECTION IV - MAINTENANCE

SYSTEM

UPPER FRAME

LOWER FRAME

ATTACHMENT

MAINTENANCE TO PERFORM

COMPONENT LOCATION

HYD. FUNCTION OPERATION

OPERATOR'S CONTROLS

CHECK SWITCHES

CONTROL PANEL

CHECK TRAVEL ALARM

OPERATOR'S CONTROLS PANEL

CHECK SWING BRAKE

OPERATOR'S CONTROLS

CHECK WARNING LIGHTS

CAB / FRAME / BOOM

CHECK BUZZER

OPERATOR'S CONTROLS

CHECK GAUGES

GAUGE CLUSTER

CHECK HORN

HORN SWITCH

CHECK GAUGE CLUSTER

GAUGE CLUSTER

CHECK SWING REDUCTION OIL LEVEL & FILL

UPPER FRAME

CHECK BOLTS / TORQUE

SLEWING RING

CHECK SLEWING RING & PINION GEAR

SIGHT WINDOW IN CENTER SECTION

CHECK SLEWING RING SEAL

SLEWING RING

CHECK SWIVEL JOINT SEALS

SWIVEL JOINT

DRAIN WATER FROM SLEWING RING GREASE BATH

LOWER FRAME CAVITY DRAIN PORT

GREASE SLEWING RING

SLEWING RING

CHANGE GREASE IN SLEWING RING GREASE BATH

REMOVE UPPER FRAME

CHANGE SWING REDUCTION UNIT OIL

SWING MOTOR

CHECK BOLTS / TORQUE

COUNTERWEIGHT

CHECK FOR OIL LEAKS

COMPLETE SYSTEM

CHECK LINES FOR DAMAGE

FRAME CAVITY

CHECK STEPS

FRAME RAILS

CHECK FRAME STRUCTURE

ENTIRE FRAME

CHECK TRACKS & LINKS

TRACKS

CHECK SPROCKET WEAR

FRONT OF TRACKS

CHECK IDLER WEAR

REAR OF TRACKS

CHECK ROLLER WEAR

TRACKS

CHECK TRACK TENSION

RAISE TRACKS

ADJUST TRACK TENSION

FRAME RAILS

CHECK TRAVEL REDUCTION UNIT OIL LEVEL & FILL

TRAVEL MOTORS

CHANGE TRAVEL REDUCTION UNIT OIL

TRAVEL MOTORS

CHECK BOLTS / HARDWARE

ENTIRE MACHINE

CHECK BOOM & ARM STRUCTURE

BOOM & ARM

CHECK BUCKET TEETH & SIDE CUTTERS

BUCKET & BLADE

GREASE BOOM PINS

BOOM

GREASE ARM PINS

ARM

GREASE BUCKET PINS & DOZER BLADE

ARM & BUCKET LINK

INTERVAL (HOURS ON HOURMETER) 8

• • • Regular inspection & maintenance required.

• • • Break-in (after first 50 hours) inspection & maintenance required.

98

50

100

250

500

1000

2000

(100 h) F18209gb

SECTION IV - MAINTENANCE

4.4

FLUIDS AND FILTERS

The following charts list all the necessary lubricants, oils, greases, fuels, coolants and filters required for the hydraulic excavator. Also a chart is provided giving specific information for the proper lubricants, oils, greases, fuels and coolants to be used in certain climates. Contact Manufacturer distributor to order the required filters, fluids and lubricants.

A. FLUIDS TYPE OF FLUID HYDRAULIC OIL

ENGINE OIL

B. FILTERS LOCATION OF USE HYDRAULIC TANK

94 Liters (25 GAL)

HYDRAULIC SYSTEM

140 Liters (37 GAL)

ENGINE OIL PAN (H LEVEL)

13 Liters (3.4 GAL)

ENGINE OIL PAN (L LEVEL)

11 Liters (2.9 GAL) 0.02 Liters X 4 (1.2cu.in X 4) 0.05 Liters X 4 (3cu.in X 4)-L 0.15 Liters X 12 (9cu.in X 12) 0.16 Liters X 14 (9.8cu.in X 14)-L 0.20 Liters X 2 (12.2cu.in X 2) 1.7 Liter (0.4 GAL)

UPPER ROLLER

LOWER ROLLER

IDLER

GEAR OIL

SWING MOTOR REDUCTION UNIT TRAVEL MOTOR REDUCTION UNIT

"U" JOINT EACH SIDE

ATTACHMENT PINS

12 PLACES

SLEWING RING GEAR

ENGINE COOLANT

FUEL

2.5 Liter X 2 (0.7 GAL X 2) 3.0 Liter X 2 (0.8 GAL X 2)-L

OPERATING LEVER JOINT

GREASE

WITH LITHIUM BASE MoS2 GREASE

QUANTITIES REQUIRED

1 PLACE 90° X 4

TRACK TENSION ADJUSTMENT

2 PLACES AS REQ'D

SLEWING GEAR SUMP (BATH)

6.4 kg (14.1 lb)

RADIATOR

8.5 Liters (2.2 GAL)

COOLING SYSTEM TOTAL VOLUME

18 Liters (4.8 GAL)

FUEL TANK

168 Liters (44 GAL)

LOCATION OF FILTER USE

SYSTEM

RETURN FILTER ELEMENT KIT (STD AND BREAKER) HYDRAULIC

TANK SUCTION STRAINER TANK BREATHER FILTER ELEMENT

ENGINE

ENGINE OIL FILTER CARTRIDGE (BYPASS)

*

ENGINE OIL FILTER CARTRIDGE (FULL FLOW)

*

AIR CLEANER INNER ELEMENT AIR CLEANER OUTER ELEMENT

FUEL

OPERATOR CAB

ENGINE FUEL FILTER CARTRIDGE ENGINE FEED PUMP GAUGE FILTER AIR-CON FILTER (OUTER) AIR-CON FILTER (INNER)

*AVAILABLE FROM ISUZU DEALER ONLY. F19179gb

C. FLUIDS AND LUBRICANTS DESCRIPTION ENGINE OIL-SAE 15W/40 (1 GALLON) HYDRAULIC OIL-AW 46 (5 GALLON) GREASE EP/2-14 OUNCE GEAR OIL 80W90-5 GALLONS F20151gb

99

SECTION IV - MAINTENANCE D. LUBRICANT, FUEL & COOLANT SPECIFICATIONS The following information is designed to allow usage of the proper oils, grease, fuels and coolants in various climates and certain working conditions.

LUBRICANT HYDRAULIC OIL (ANTI-WEAR, ANTIOXIDANT AND NON-FOAMING) *Note: Machines are shipped from factory with SHELL TELLUS 32S hydraulic oil

CLIMATE ZONE FRIGID -30°C ~ 15°C (-22°F ~ 59°F)

FRIGID -20°C ~ 30°C (-4°F ~ 86°F)

NORMAL -25°C ~ 40°C (-13°F ~ 104°F)

WARM -5°C ~ 40°C (23°F ~ 104°F)

VERY HOT 5°C ~ 55°C (41°F ~ 131°F)

ISO VG22

ISO VG32

ISO VG32S*

ISO VG46

ISO VG68

LUBRICANT ENGINE OIL* A.P.I. CLASSIFICATION FOR "SERVICE CD" *ALL ENGINES SHIPPED FROM FACTORY WITH SAE30 OR SAE15W40 OIL ACCORDING TO AMBIENT TEMPERATURE IN ENGINE OIL PAN.

CLIMATE ZONE FRIGID -30°C ~ 30°C (-22°F ~ 86°F)

NORMAL -5°C ~ 40°C (23°F ~ 104°F)

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

SAE10W30

SAE15W40

SAE15W50

LUBRICANT

FUEL

LUBRICANT ENGINE OIL (FOR GENERAL PURPOSE LUBRICATION)

LUBRICANT GEAR OIL

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

WARM -5°C ~ -15°C (23°F ~ 5°F)

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

ASTM D975 No.2

ASTM D975 No.2

FOR ROLLERS AND IDLERS ON ALL MODELS. A.P.I. Classification for "Service CD"-SAE30

FOR SWING MOTOR REDUCTION UNIT AND TRAVEL MOTOR REDUCTION UNIT ON THE FOLLOWING MODEL: E115SR EXTREME PRESSURE GEAR OIL #90 GRADE GL-4 BY A.P.I. CLASSIFICATION

LUBRICANT

GENERAL LUBRICATION

SLEWING GEAR SUMP (BATH)

GREASE

EXTREME PRESSURE MULTIPURPOSE GREASE No.2

N.L.G.I. No.2 LITHIUM BASE WITH MoS2 GREASE

LUBRICANT ENGINE COOLANT (50% MIXTURE)

ANTIFREEZE (LLC) -34°C (-29.2°F) MIXTURE RATIO SHOULD PROSPECT TO 5°C (9°F) LOWER THAN THE COLDEST TEMPERATURE THE MACHINE WILL EXPERIENCE. TAKE INTO CONSIDERATION WIND CHILL FACTORS. F18212gb

NOTE: USE OF BIO-DEGRADABLE OILS When you use Bio-degradable Oil (BIO OIL), refer to the following information.

1. There are two types of BIO OIL available; vegetable-based and synthetic-based. You are recommended to use the synthetic-based type, because the vegetable-based oil has a maximum usage temperature of 80˚C (176˚F). Because of this, the degradation of vegetable-based oil occurs more rapidly, and causes reduced service life.

2. Do not mix either type of BIO OIL with the original factory-filled mineral oil. In case that you do use BIO OIL, it is required to flush the hydraulic system that was filled with mineral oil three times.

3. If you use BIO OIL, slewing and propel travel brake performance will be reduced, because of the lower friction factor of BIO OIL compared to that of mineral oil.

4. For further information about recommended Bio-degradable oil, please contact your Dealer.

100

SECTION IV - MAINTENANCE

4.5 PRE-START INSPECTION & MAINTENANCE The following procedures are to be performed every day, before the machine is started.

ENGINE OIL DIPSTICK REAR SIDE OF ENGINE

WARNING Be cautious of hot fluids and surfaces. Wear goggles, safety shoes, hard hat, work clothes and work gloves to perform inspection and maintenance on this machine.

A. ENGINE OIL LEVEL 1. Stop engine and raise engine bonnet.

2. Locate and pull engine dipstick. Clean it with a clean, dry, lint free cloth. Reinsert into engine. Pull out again and visually inspect the engine oil level on dipstick.

3. If necessary to add oil, remove oil filler cap and fill engine oil to proper level.

BETWEEN LOW & HIGH: 2 LITER

H-MAX

ENGINE OIL FILLER CAP

L-MIN F16342

NOTE After adding oil, check oil level again, replace oil filler cap, replace dipstick and close engine cover.

B. ENGINE COOLANT LEVEL 1. Open radiator access cover and inspect coolant level in engine coolant reservoir.

2. Proper coolant level is between “FULL” and “LOW” marks.

3. If necessary to add coolant, remove reservoir cap and fill to proper level with fresh coolant mixture. Refer to the section IV “LUBRIFICANT, FUEL & COOLANT SPECIFICATIONS” for proper coolant specifications.

4. If no coolant is in reservoir, check coolant level in radiator. Fill radiator with proper coolant mixture and replace cap. Then fill reservoir to proper level.

ENGINE COOLANT RESERVOIR FULL

PROPER LEVEL

LOW

F16343

RADIATOR CAP

WARNING Never remove radiator cap when engine is hot. Allow engine to cool before removing radiator cap.

DO NOT REMOVE WHEN ENGINE IS HOT

F16344

101

SECTION IV - MAINTENANCE C. ENGINE FLUID LEAKS 1. Inspect complete engine for signs of fluid leaks.

2. When inspecting around pressure lines and hoses use a stiff piece of cardboard.

USE CARDBOARD TO CHECK FOR PRESSURE LEAKS

CAUTION Never use hands to check for leaks. High pressure fluid leaks will penetrate the skin and cause severe injury.

D. FAN BELT WEAR AND TENSION 1. Inspect fan belt for excessive wear or damage.

2. Measure belt tension on the span of belt.

Belt deflection should be 8 mm ~ 12 mm (0.3˝ ~ 0.5˝).

3. Loosen attaching nut and adjusting nut, and adjust tension of belt.

4. Loosen adjusting bolt, adjust fan belt to the specified tension, and tighten attaching nut and adjusting nut.

5. After adjustment, rotate engine at low idling for 5 minutes, then check the tension of belt.

NOTE When moving the alternator, try not to damage the stater coil section between the front and rear brackets or the bolts.

Force : Approx.

98N (22Ibf/10 kgf)

ALTERNATOR FAN PULLEY

COMPRESSOR CRAN PULLEY

F16346

ATTACHING NUT

7.7±1.5 kgf·m (56±11Ibf·ft)

ATTACHING NUT

8.4±1.0 kgf·m (61±7Ibf·ft)

102

ADJUST BOLT F16149

SECTION IV - MAINTENANCE E FUEL LEVEL 1. Turn key switch to “ON” position.

2. Visually watch fuel level gauge on gauge cluster panel.

3. The fuel tank can be filled through the fuel filler cap located on top of the fuel tank or by using the auxiliary fuel pump located the cab rear side. a. Filling tank through fuel filler cap 1. Open fuel filler cap with key switch key and fill tank to proper level with diesel fuel.

Refer to the section IV “LUBRIFICANT, FUEL & COOLANT SPECIFICATIONS” for proper coolant specifications. b. Filling tank using auxiliary fuel pump.

The fuel pump and suction hose are located in the fuel box on the rear side of the cab.

Use it in the following procedure.

1. Put the bucket on the ground, and stop the engine.

2. Open the fuel pump access cover with the key switch.

3. Place the suction hose in the drum and turn the switch ON, and the fuel pump actuates regardless of the key switch and starts fueling.

After filling up the fuel tank, turn the switch OFF. Make certain the fuel level with a level gauge installed on the side of fuel tank.

NOTE: • Do not use in volatile liquid, e.g. gasoline, etc.

• Do not operate more than 60 minutes continuously, and more 5 minutes in the dry operation.

• After the switch is turned ON, if the fuel pump does not actuate, check the fuse in the switch box for possible damage. The fuse is 15 A (tubular fuse).

F16347

LOCK OF FUEL PUMP ACCESS COVER

FUEL PUMP SWITCH FUEL PUMP SUCTION HOSE

4. After removing fuel delivery hose from fuel supply reservoir, coil hose and place filter into its storage housing. Replace fuel strainer and fuel filler cap.

103

SECTION IV - MAINTENANCE F. AIR CLEANER 1. Open engine air cleaner access door with starter switch key.

2. Release clamp from the air cleaner cover.

ENGINE AIR CLEANER ACCESS COVER

3. Remove the air cleaner outer element from the housing.

4. Remove the air cleaner inner element from the housing.

5. Cover air intake port of the housing (to prevent entry of dust).

6. Clean the inside of the housing using a clean, lint free cloth dampened with water.

7. Thoroughly dry the inside of the housing with a clean, dry lint free cloth.

8. Remove the cover attached to protect it from dust.

9. Reinstall air cleaner element in reverse order.

RELEASE CLAMP AND COVER

REMOVE AIR CLEANER OUTER ELEMENT

REMOVE AIR CLEANER INNER ELEMENT

CAUTION Carefully hold the O-ring, water inside cause engine failure.

NOTE: For machines equipped with W (double) element and the inner element must be replaced together with the outer element. Don’t fail to replace the inner element with new one.

REST’D AIR CLEANER

F15988

104

SECTION IV - MAINTENANCE G. ENGINE ELECTRICAL 1. Visually and manually inspect all engine electrical wiring, connectors and components for signs of damage and malfunction.

2. Repair or replace all damaged or malfunctioning wiring, connectors and components before resuming operation of the machine.

POSITIVE (+) CABLE

NEGATIVE (-) CABLE

WARNING Operating the machine with damaged or malfunctioning electrical components can cause serious damage to the machine and serious injury to personnel. Repair or replace faulty components immediately.

105

SECTION IV - MAINTENANCE H. HYDRAULIC OIL LEVEL 1. Place the machine in the oil check position on a firm surface.

2. Right hand hydraulic oil tank side cover and view the hydraulic oil level in the sight glass on side of hydraulic oil tank.

HYDRAULIC OIL CHECK POSITION

WARNING

F16316

For safe operation on inclines, the hydraulic oil level must be maintained between “proper level” and “upper limit” mark.

3. Use the following instructions to add hydraulic oil: a. Release hydraulic tank pressure.

CAUTION

UPPER LIMIT

Gasses from hydraulic tank may be hot. Wear safety equipment.

PROPER LEVEL LOW (ADD OIL)

b. Remove the six mounting bolts from the hydraulic suction screen cover plate. c. Add hydraulic oil through the suction screen, filling hydraulic tank to the proper level. d. Before replacing filter cover, replace “O”-ring. e. Place new “O”-ring in seat. Place cover over opening and install mounting bolts with lockwashers. f. Torque mounting bolts to proper value. Refer to torque specifications table.

DEPRESS RUBBER CAP TO RELEASE PRESSURE

HYDRAULIC TANK

F16354

WARNING Clean up all spilled oil to prevent fires. Dispose of hazardous waste according to environmental laws and regulations.

SLOWLY REMOVE BOLTS & COVER

ADD CLEAN OIL

REPLACE “O”-RING F16358

106

SECTION IV - MAINTENANCE I. HYDRAULIC FUNCTIONS 1. Check all hydraulic controls for proper function before operating the machine.

CHECK ALL CONTROLS FOR PROPER FUNCTION

WARNING Never operate the machine with a faulty control or function. Make all necessary repairs before allowing any operation.

F16161

J. HYDRAULIC OIL LEAKS 1. Check complete hydraulic system for leaks.

Use a small piece of cardboard when checking areas with high pressure.

USE CARDBOARD TO CHECK FOR PRESSURE LEAKS

CAUTION Never use hands to check for leaks. High pressure fluid leaks will penetrate the skin and cause severe injury.

2. Check all hoses and lines for signs of damage.

3. Repair or replace damaged hoses and lines before allowing any operation.

WARNING Clean up all spilled oil to prevent fires. Dispose of hazardous waste according to environmental laws and regulations.

K. MACHINE ELECTRICAL 1. Check all switches for proper operation.

2. Visually check all wiring and connectors for signs of damage, corrosion etc..

3. Repair or replace all damaged or faulty electrical components before allowing any operation of the machine.

4. Check all gauges and LCD display on the gauge cluster panel for proper operation.

CHECK ALL GAUGES AND LCD DISPLAY

WARNING Damaged or faulty electrical components can cause severe damage to the machine and cause serious personal injury or death.

F16359

107

SECTION IV - MAINTENANCE L. STEPS AND HANDRAILS 1. Inspect daily all mounting steps and handrails on the machine to make sure they are clean and in safe working condition.

2. Repair or replace all areas before allowing any operation of the machine.

USE GRIP BARS AND STEP RAILS KEEP STEP CLEAN AND IN GOOD CONDITION

CAUTION Use steps, and handrails when mounting and dismounting the machine. Keep steps, handrails and step rails clean and in safe working condition.

M. FRAME STRUCTURE 1. Carefully inspect the entire frame structure for signs of damage, broken welds etc..

2. Repair or replace all frame components found to be damaged before allowing any operation of the machine.

3. In cases where welding repair is required, consult the Manufacturer for proper procedures concerning weld repairs. Use only certified welding personnel familiar with structural welding methods to perform repairs requiring welding.

DISCONNECT BATTERY NEGATIVE (-) CABLE WHEN INSPECTING ELECTRICAL OR WELDING

F16164

WARNING Disconnect batteries before welding on this machine.

Connect welder ground cable 1m (3´-3˝) away from area to be welded.

N. TRACKS AND COMPONENTS 1. Track Shoes a. Visually inspect track shoes for signs of excessive wear or damage. b. Have all repair or replacement work done by the Manufacturer. c. Check tightness of shoe attaching bolts and nuts. If loose, remove bolt, clean thread, apply engine oil and torque: E115SR = 41~45 kgf·m (296~325 lbf·ft) E115SRL = 87~89 kgf·m (628~643 lbf·ft)

108

CHECK SHOE WEAR CHECK FOR BEND

TORQUE BOLTS

SECTION IV - MAINTENANCE 2. Track Links a. Inspect links for signs of excessive wear or damage. b. Have all repair or replacement work done by the Manufacturer.

INSPECT TRACK LINK ASSEMBLIES

3. Sprockets a. Inspect sprockets for excessive wear and damage. b. Should the sprockets require service, contact the Manufacturer. c. Check and make sure all sprocket bolts are properly tightened.

INSPECT THESE SURFACES

4. Idlers a. Inspect idlers for excessive wear and damage. b. Should the idlers require service, contact the Manufacturer.

INSPECT THESE SURFACES

5. Rollers a. Inspect rollers for excessive wear and damage. b. Should the rollers require service, contact the Manufacturer distributor.

LOWER ROLLER

UPPER ROLLER INSPECT THESE SURFACES

INSPECT THESE SURFACES

109

SECTION IV - MAINTENANCE O. TRACK TENSION 1. Operate swing, arm, bucket and boom controls until machine is set up.

MACHINE POSITION

WARNING Support lower frame with suitable blocks.

2. In center of track, measure the distance between the bottom of frame rails and surface of shoe.

3. Perform steps 1 and 2 on right track.

4. To increase track tension, set machine and with grease gun inject extreme pressure No.2 grease into idler adjustment grease fitting until proper tension is reached.

Perform this procedure on both tracks.

270~300 mm (10.6”~11.8”)

NOTE: After injecting grease, operate the travel control forward and reverse for the track being adjusted. This will balance the tension between the idler and the sprocket.

5. To decrease track tension, set machine up.

6. Carefully loosen the adjusting grease nipple to allow grease to escape.

WARNING Grease in track tensioning mechanism is under extreme pressure and can penetrate skin causing severe injury. Keep face and body away from grease nipple area. Never loosen grease nipple more than one complete turn. If grease does not release after one turn of the nipple, call an dealer for assistance.

7. Tighten grease nipple, measure track tension.

8. If necessary, perform steps 5 through 7 on other track.

110

TRACK ADJUSTING GREASE NIPPLE FRAME OPENING TO GREASE NIPPLE

SECTION IV - MAINTENANCE P. BOOM AND ARM 1. Inspect boom and arm structures for signs of excessive wear and damage.

2. Should repair or replacement be necessary, contact the Manufacturer.

INSPECT BOOM & ARM FOR DAMAGE

WARNING Disconnect batteries before welding on this machine.

Connect welder ground cable 1m (3´-3˝) away from area to be welded.

DISCONNECT BATTERY NEGATIVE (-) CABLE WHEN INSPECTING ELECTRICAL OR WELDING

F16164

Q. BUCKET TEETH AND SIDE CUTTERS 1. Inspect bucket teeth and side cutters for signs of excessive wear and damage.

2. Should repair or replacement be required, follow bucket manufactures recommendations.

INSPECT TEETH AND SIDE CUTTERS FOR DAMAGE

CAUTION Wear goggles, safety shoes, hard hat, work clothes and work gloves to perform inspection and maintenance on this machine.

111

SECTION IV - MAINTENANCE

4.6 50 HOUR & NEW MACHINE BREAK-IN INSPECTION & MAINTENANCE PROCEDURES

REMOVE BOLTS AND LOWER COVER

Change the engine oil and filter on a new machine after the first 50 hours of operation.

Then change the engine oil at every 500 hours of operation.

A. ENGINE OIL AND FILTER ELEMENT 1. Move the machine to a firm, level surface and run engine for 5 minutes to warm the oil.

LOOSEN BOLTS TO LOWER COVER

WARNING Do not change oil on a machine that has just stopped working. The oil will be extremely hot. Allow the engine to cool until oil is just warm before changing.

NOTE: • Check the waste oil. If there are metal chips or powder mixed in the oil, contact your Dealer.

• Do not reuse the oil filter.

F16177

FULL FLOW

BYPASS

2. Remove the six mounting bolts from the engine lower cover plates.

3. Place the oil container under the filter.

4. Remove the oil filter by turning counterclockwise.

5. To install the oil filter, apply a thin coat of engine oil to the gasket of the oil filter, and then secure the filter by tightening prescribed number of rotations after the gasket comes in contact with the oil filter head.

6. When replacing the element only, and not the engine oil, the amount of oil to be added is shown below. Partially fill filter with oil before installing.

Bypass: Approx. 1.5 Liters (0.39 GAL) Full flow: Approx. 0.8 Liters (0.21 GAL) 7. Start engine, operate it at idling operation for several minutes. Then check filter fitting section for oil leakage.

8. Install cover just below the engine to the regular position.

112

APPLY CLEAN ENGINE OIL

F16178

SECTION IV - MAINTENANCE B. ENGINE OIL Change the engine oil on a new machine after the first 50 hours of operation. Then change the engine oil at every 500 hours of operation.

REMOVE BOLTS AND LOWER COVER

NOTE: Do not change oil on a machine that has just stopped working. The oil will be extremely hot. Allow the engine to cool until oil is just warm before changing.

LOOSEN BOLTS TO LOWER COVER

1. Move the machine to a firm, level surface and run engine for 5 minutes to warm the oil.

ENGINE OIL FILLER CAP

WARNING Do not change oil on a machine that has just stopped working. The oil will be extremely hot. Allow the engine to cool until oil is just warm before changing.

2. Remove the six retaining bolts from the oil pan access cover on the bottom, rear center of machine.

3. Raise engine bonnet and remove oil filler cap.

4. Remove cap from engine oil drain by hand.

Place a 15 liter (3.9 Gal) capacity container under oil pan.

5. Install engine oil drain plug.

6. Refer to the section IV “LUBRIFICANT, FUEL & COOLANT SPECIFICATIONS” for the proper oil to use and fill engine oil to proper level.

• Total oil volume to be replaced: 13 liters (3.4 Gal) 7. Install oil filler cap. Clean up all spilled oil.

8. Start engine, run for 5 minutes. While running, check for oil leaks.

9. Should any oil leaks be found, repair immediately and refill with proper oil.

10. Check oil level and close cover.

ENGINE OIL DRAIN PLUG

F16379

113

SECTION IV - MAINTENANCE C. FUEL TANK DRAIN 1. Locate and open fuel tank drain valve on bottom of fuel tank.

2. Allow all water and sediment to drain from fuel tank into a waste container, then close the drain valve.

FUEL TANK DRAIN VALVE

D. WATER SEPARATOR The water separator isolates water that mixes in with the fuel. The case is equipped with a float. When water accumulates, the float rises.

When the float rises to the level line, drain the water.

1. Loosen the drain plug to drain the water.

2. When the float comes down to the bottom, close the drain plug.

3. Check that fuel is not leaking.

Drain water whenever the float rises to the level line, regardless of inspection time.

F16181

LEVEL LINE (RED)

FLOAT

DRAIN PLUG F16380

CAUTION

GAUGE FILTER

Clean up all spilled fuel to avoid a fire.

OUT

NOTE: The gauze filter is contained in the OUT side of water separator. Remove the gauge filter and clean it with light oil.

Cleaning interval is every 1,000 hours of operation.

IN

F16381

E. AIR INTAKE SYSTEM Inspect all hoses and clamps of the air intake system on a new machine after the first 50 hours of operation. Then at every 500 hours of engine operation.

1. Inspect all hoses for damage and tighten all hose clamps.

2. Replace any hose found to be damaged before allowing any operation of the machine.

114

HOSE & CLAMPS FROM AIR CLEANER

HOSE & CLAMPS FROM AIR CLEANER

SECTION IV - MAINTENANCE F. RADIATOR, OIL COOLER AND DEBRIS SCREEN 1. Clean radiator after every 50 hours of operation using water.

ENGINE BONNET

ENGINE RADIATOR ACCESS DOOR

CAUTION Do not use high pressure water as it will bend the radiator fins. Use standard water pressure.

2. Open engine air cleaner access door and engine bonnet for cleaning the radiator and oil cooler.

3. Open engine bonnet and remove the wing bolts retaining the debris screen. Carefully remove debris screen and clean with water.

SCREEN (REAR)

SCREEN (FRONT)

WING BOLTS

4. Remove wash out access cover from bottom of machine.

5. Rinse all dirt and debris from engine compartment. Reinstall debris screen and wash out access cover.

DEBRIS SCREEN WASH OUT COVER

CAUTION Be careful not to bend or damage cooling fins of the radiator or oil cooler. Replace debris screen if damage is found. Repair damaged cooling fins of radiator and oil cooler.

REMOVE BOLTS

NOTE: To remove or install the screen, remove three wing bolts on the upper section of radiator, and pull out the screen on the front side then pull the rear screen frontward and remove. After cleaning it, install it by the reverse procedure.

115

SECTION IV - MAINTENANCE G. HYDRAULIC RETURN FILTERS Change the hydraulic tank return filter on a new machine after the first 50 hours of engine operation then change every 500 hours.

DEPRESS RUBBER CAP TO RELEASE PRESSURE

NOTE: Move machine to firm leveled ground and place attachment in oil level check position.

HYDRAULIC TANK

F16354

1. Release hydraulic tank pressure.

WARNING Never change oils or filters on a machine that has just finished working. Allow machine to cool first until oils and fluids are warm not hot. Release hydraulic tank pressure before working with any hydraulic component.

SLOWLY REMOVE BOLTS & COVER

2. Remove the four mounting bolts (1) and spring washer (2) from the hydraulic return cover (3).

CAUTION Slowly remove the mounting bolts. The filter cover plate is under spring tension.

3. Remove “O”-ring (5) and spring (4).

4. Disassemble element assy (A) while turning the handle.

Disassembling parts ...(B), (C), (D), (E), (F) 5. Replace “O”-ring (C) of check valve (B).

6. Replace packing (F) of plate (E).

7. Replace element, and assemble element assy (A) disassembled in procedure (4) again.

8. Attach element in reverse procedure of the (3) and (4) above-mentioned.

9. Install cover (3).

Tightening torque: 46.1 ± 4.9 N·m {4.7 ± 0.5 kgf·m} 10. Start engine, put the machine on hydraulic oil level check position while moving each operating lever, and check hydraulic oil level.

NOTE: Long-life return filter is used.

Place an order of return filter element kit.

116

(1) (2)

(5) (C)

(4)

(D)

(3) (5)

(F)

(B) (C)

ELEMENT KIT ELEMENT ASSY

(D) (E) (F)

(A)

SECTION IV - MAINTENANCE H. BATTERIES Perform complete battery service on a new machine after the first 50 hours of engine operation. Then, check electrolyte (acid) every 50 hours.

WARNING 1. Wear safety clothes, goggles or face shield, gloves and safety shoes when working with batteries.

2. Work in a well ventilated area.

3. Battery electrolyte (acid) is corrosive. If it comes in contact with skin, eyes or clothing, flush with large amounts of water and seek immediate medical attention.

4. Battery electrolyte (acid) produces hydrogen gas that is highly explosive. Do not allow near sparks, fire or flames and do not smoke when working with batteries.

F1474

F1477

1. Open battery access cover.

2. Remove battery cell caps and visually inspect electrolyte (acid) level. Proper level is 10~15 mm (0.4˝ ~ 0.6˝) above cell plates.

3. If necessary, fill each cell to proper level with distilled water only.

4. Remove cables from terminals and clean with hot water. Coat each terminal with a thin layer of petroleum jelly. Clean cables in the same manner and reinstall onto battery.

5. If cables are found to be in poor condition, replace with new parts immediately.

WARNING PREVENT BATTERY EXPLOSION • Batteries give off hydrogen gasses that can explode and cause personal injury.

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

• Keep metallic articles away from batteries.

• Keep all ventilation caps tightly secured.

• Never check charge by placing metal articles across battery terminals.

• Leave battery box open to improve ventilation when charging.

BATTERY ACCESS COVER

ELECTROLYTE LEVEL 10~15 MM (0.4~0.6)

CELL PLATES

REMOVE CELL CAPS

117

SECTION IV - MAINTENANCE 6. Use a hydrometer to check the specific gravity of each cell. Compare readings to the chart below.

NOTE: Use hydrometer according to its manufacturer’s instructions.

DISCONNEC T BATTERY NEGATIVE (-) CABLE WHEN INSPECTING ELECTRICAL OR WELDING

F16164

CHARGE % 100% 90% 80% 75%

AMBIENT TEMPERATURE 20° C 0°C -10°C (68°F) (32°F) (14°F) 1.26 1.27 1.28 1.24 1.25 1.26 1.22 1.23 1.24 1.21 1.22 1.23

7. When disconnecting batteries, remove the negative (-) cable first. When connecting batteries, connect the negative (-) cable last.

8. When the battery requires charging: a. Disconnect battery cables from terminals. b. Remove all cell caps. c. Check for proper electrolyte (acid) level. d. Connect charger leads to the proper battery terminals.

CAUTION Make certain not to cross positive and negative terminals when connecting charger.

e. Stop charge if battery overheats. f. Periodically check the specific gravity of the batteries with a hydrometer. Stop charging batteries when 100% charged.

NOTE: Battery life can be shortened by over discharging of the battery. Replace any batte o charge.

118

SECTION IV - MAINTENANCE

4.7 100 HOUR INSPECTION & MAINTENANCE PROCEDURES

ATTACHMENT LUBRICATION POSITION

NOTE: Perform all pre-start (Every 8 hour and 50 hour) inspection & maintenance procedures along with the following 100 hour inspection and maintenance procedures.

A. ATTACHMENT LUBRICATION Use extreme pressure multi-purpose grease No.2 type grease. Lubricate all points until grease oozes.

NOTE: If attachment is sank in water, it is recommended to lubricate it every 8 hours.

F16388

BUCKET CYLINDER ROD END

TO BUCKET LINK PIN IDLER LINK TO ARM PIN ARM TOP PIN

1.

2.

3.

4.

Idler link and bucket pin.

Bucket cylinder rod end.

Arm top pin.

Bucket link pins.

BOTTOM BUCKET LINK PIN F16389

B. DOZER BLADE LUBRICATION Use extreme pressure multi-purpose grease No.2 type grease. Lubricate all points until grease oozes.

1. Dozer cylinder rod and head.

2. Dozer blade link pin.

C. REPLACEMENT OF CUTTING EDGE (OPT.) Check cutting edge of the blade for damage. If severe damage or wear is detected, replace it.

1. Remove sand and soil adhered around mounting capscrews, and then cut capscrews by means of gas cutting and remove cutting edge.

2. Clean contact surface of it and install new cutting edge.

Don’t fail to replace capscrews and nuts with new ones at the same time when the cutting edge is replaced.

Torque value : 28 ± 3 kgf·m {203 ± 22 lbf·ft} Apply loctite #262 or equivalent.

F16390

F24443

NOTE: The delay of replacement may cause damage of blade.

We recommend to replace it a little ahead of schedule.

119

SECTION IV - MAINTENANCE D. SWING MOTOR REDUCTION OIL Check the oil level of the swing motor reduction unit on a new machine after the first 50 hours of engine operation. Then check every 100 hours.

1. Locate the dipstick on the side of the swing motor. Pull dipstick, wipe clean and reinsert all the way in.

2. Pull dipstick and read oil level.

3. If necessary to add oil, remove plug from oil fill port and fill to full level with proper oil.

Refer to the section IV “LUBRIFICANT, FUEL & COOLANT SPECIFICATIONS” for oil specifications.

DIPSTICK

FILL PLUG

F16391

DRAIN PORT

CAUTION Reduction unit may be under pressure.

Remove plug slowly.

4. To drain oil from swing motor reduction unit. a. Locate drain port under rear of machine. b. Place a 2 liter 0.5 gallon) container under drain port and remove plug allowing oil to drain into container. c. Replace plug and tighten securely after all oil is drained. d. Fill through fill port using proper oil. Refer to the section IV “LUBRIFICANT, FUEL & COOLANT SPECIFICATIONS” for oil specifications.

WARNING Never change oils or filters on a machine that has just finished working. Allow machine to cool first until oils and fluids are warm not hot.

120

F16392

SECTION IV - MAINTENANCE E. TRAVEL MOTORS REDUCTION OIL Inspect oil level of travel motor reduction unit on a new machine after the first 50 hours of engine operation. Then check every 100 hours.

1. Move machine to a firm, level surface. Operate travel until “FILL/LEVEL” plugs on travel motors are at top.

2. Stop engine and remove the travel motor reduction unit oil “LEVEL” plug. If oil just seeps from the port, oil level is correct.

FILL/ LEVEL

DRAIN

F16393

CAUTION Travel reduction unit could be under pressure. Carefully loosen plug and remove slowly fill air pressure is released.

3. To add oil, remove the oil “FILL” plug and add extreme pressure gear oil #90 grade GL-4 until oil just begins to flow from this plug.

4. Use teflon tape on the plug for better sealing.

Install plug and tighten securely.

NOTE: Capacity of each travel motor reduction unit is 2,5 liters (0.7 Gallons).

FILL PLUG

F. TRAVEL MOTORS REDUCTION OIL E115SRL Inspect oil level of travel motor reduction unit on a new machine after the first 50 hours of engine operation. Then check every 100 hours.

1. Move machine to a firm, level surface. Operate travel until “FILL” plugs on travel motors are at top.

2. Stop engine and remove the travel motor reduction unit oil level plug. If oil just seeps from level port, oil level is correct.

LEVEL PLUG

DRAIN PLUG F24588

CAUTION Reduction unit may be under pressure. Remove plug slowly.

3. To add oil, remove the oil “FILL” plug and add extreme pressure gear oil #90 grade GL-4 until oil just begins to flow from this plug.

4. Use teflon tape on the plug for better sealing.

Install plug and tighten securely.

NOTE: Capacity of each travel motor reduction unit is 3,0 liters (0.8 Gallons).

121

SECTION IV - MAINTENANCE

4.8 250 HOUR INSPECTION & MAINTENANCE PROCEDURE

ATTACHMENT LUBRICATION POSITION

NOTE: Perform all pre-start inspection & maintenance procedures along with the following 250 hour inspection and maintenance procedures.

A. ATTACHMENT LUBRICATION Lubricate attachment pins every 250 hours of engine operation. Use extreme pressure multi-purpose No. 2 type grease. Lubricate all points until grease oozes.

F16388

1. Boom cylinder head and rod pins.

BOOM CYLINDER HEAD PINS F16394

2. Boom foot pin.

BOOM FOOT PIN EACH END

CENTRALIZED GREASE NIPPLES ON BOOM F16395

3. Boom cylinder rod pins.

4. Arm cylinder head pin.

ARM CYLINDER HEAD END

BOOM CYLINDER ROD ENDS

CENTRALIZED GREASE NIPPLES ON BOOM F16396

122

SECTION IV - MAINTENANCE 5. Arm cylinder rod end.

6. Arm to boom pin.

7. Bucket cylinder head end.

ARM TO BOOM PIN

ARM CYLINDER ROD END F16397

BUCKET CYLINDER HEAD END

B. AIR CONDITIONER FILTERS Cleaning recirculate and fresh air filters.

Recirculate air filter ....... Every 500 hours Fresh air filter ................ Every 250 hours

COVER

1. Cleaning Fresh Air Filter a. Loosen 3 bolts under operator’s seat, and remove cover. b. Remove cover, and take fresh air filter out. c. Blow compressed air to clean fresh air filter.

F16200

NOTE: Water washing is not allowed to clean air filter because it is paper filter.

RECIRCULATE AIR FILTER

FRESH AIR FILTER

d. Cleaning about 10 times is allowed, or replace it with new one every two years.

2. Cleaning Recirculate Air Filter a. Raise recirculate air filter slightly, and pull it out. b. Clean it with water or compressed air blow.

COVER

MACHINE FRONT

NOTE: Washing with organic solvent (gasoline, trichlene, thinner, etc.) is strictly prohibited.

F16201

c. When frequently clogged, or damage is serious, replace it with new one. d. After drying, set outside and recirculate air filters and install cover.

123

SECTION IV - MAINTENANCE C. INSPECTING COUNTERWEIGHT ATTACHING BOLTS FOR LOOSENING Check bolts and nuts for loosening.

CAUTION Striking counterweight against obstruction may cause loosening of bolts. Check bolts for loosening after 50 hours the first time, and every 250 hours after that.

MODEL E115SR

COUNTERWEIGTH ATTACHING BOLT

TORQUE SPECIFICATION (Apply loctite#262) 105± 50 {760 ± 036 } kgf·m (Ibf·ft)

D. BELT TENSIONER (FAN & AIR CONDITIONER) Inspect belts and tensioner assembly on a new machine after the first 50 hours of operation.

Then at every 250 hours of engine operation.

Force: Approx.

98 N (22 lbf, 10 kgf) ALTERNATOR FAN PULLEY

1. Measure belt tension on longest span of belt.

Belt deflection should be 8 mm to 12 mm.

COMPRESSOR

BELT Fan Belt Air Conditioner

DEFLECTION 8 mm to 12 mm (0.3” to 0.5”) 10 mm to 12 mm (0.4” to 0.5”)

CRANK PULLEY

2. Loosen attaching nuts and adjusting nut, and adjust tension of belt.

3. Loosen or tighten adjusting bolt to adjust fan belt to the specified tension, and tighten attaching nut and adjusting nut properly.

4. After adjustment, start engine and run it at low idle for about 5 minutes. Then recheck belt tension.

5. Adjust the tension of belt of air conditioner turning adjusting bolt of idle pulley.

F16399

ATTACHING NUT 7.7 ± 1.5 kgf·m (56 ± 11· Ibf·ft)

ATTACHING NUT 8.4 ± 1.0 kgf·m (61 ± 7· Ibf·ft)

124

ADUSTING BOLT

ADJUSTING BOLT F16149

SECTION IV - MAINTENANCE

4.9

500,1000 HOURS INSPECTION & MAINTENANCE PROCEDURES Perform all other inspection & maintenance procedures as previously described in this section.

A. ENGINE FUEL FILTER

WARNING Clean up all spilled fuel.

Fuel oil is highly flammable. Spilled fuel can cause fires.

REMOVAL

1. Use the filter wrench to remove the fuel filter and replace it with a new one.

FUEL FILTER

INSTALLATION

F16400

NOTE: The fuel filter is cartridge type, and so cannot be reused.

2. Clean the seal face of the filter base. Before installing the fuel filter, apply clean fuel oil to the sealing face.

3. Install the fuel filter and screw it by hand until it contacts the filter base. Then use the filter wrench to tighten the filter 2/3 turn.

125

SECTION IV - MAINTENANCE B. BLEEDING AIR FROM THE FUEL SYSTEM AIR PLUG LEVEL LINE (RED)

WARNING Clean up all spilled fuel.

Fuel oil is highly flammable. Spilled fuel can cause fires.

FLOAT

If air contaminates the fuel system, the engine may become hard to start or it malfunction.

Bleed the air whenever the fuel tank is empty, the water separator is drained, or the fuel filter element is replaced.

DRAIN PLUG

F16401

1. Air Bleeding Procedure a. Fill fuel tank with fuel. b. Check that air bleed plug on upper part of water separator and drain plug are tightened. c. Loosen air bleed screw, turn upper section of pump counterclockwise, and move priming pump up and down until fuel mixed without bubbles flows out.

BLEED SCREW

FEED PUMP

F16206

C. GREASING THE SLEWING RING - 500 HOURS 1. Locate the grease nipple at the front of the slewing ring.

2. Using grease gun filled with general purpose grease, lubricate slewing ring with several shots from grease gun.

3. Swing machine 90° right, and repeat step 2. See label on frame.

4. Continue to swing machine at 90° increments and lubricating slewing ring until ring has been completely greased.

SLEWING RING GREASE NIPPLE

F16403

BALL

D. CHECKING SLEWING RING FITTING BOLTS FOR LOOSENING Check that bolts securing slewing ring are not loosened. If loosened, remove bolts once, apply Loctite #262 or equivalent, and tighten them again.

Torque specification 28.5 ± 3 kgf·m (206 ± 22 lbf·ft) Alternately tighten bolts facing each other in order.

SLEWING RING

BOLTS

LOWER FRAME

NOTE: Since the tightening of slewing ring requires special tools, contact your Dealer for assistance.

126

F16208

SECTION IV - MAINTENANCE E. FUEL SYSTEM INJECTION PRESSURE AND NOZZLE CONDITION (ATOMIZATION) Perform this inspection and adjustment every 500 hours of engine operation. Contact your Dealer for assistance.

Initial injection pressure: 185 kgf/cm2 (2,631 psi)

F. CHECKING THE AIR CONDITIONER REFRIGERANT 1. Start the engine. Set the engine speed to the middle speed position.

2. Set the machine to the conditions shown below when checking the refrigerant.

• Air conditioner switch: ON • Fan switch: HI position (Maximum ) • Temp. adjustment switch: Lower temp position ( ) • Door / Window: Close lamp lit up) • Compressor switch: ON (The

3. Follow the procedure below and check the refrigerant volume by looking through the sight glass (inspection window) on the upper part of the receiver dryer. See right table for better reference. a. Figure (A) shows that the refrigerant volume is proper. b. Figure (B) shows that the refrigerant is over charged. This will make both high and low pressure extreme and exert a bad influence on the pressure switch operation and the air conditioning system. c. Figure (C) shows that the refrigerant is insufficient. Have the refrigerant recharged at your Dealer.

NOTE: • New refrigerant (HFC-134a), whose characteristics are different from conventional CFC-12, is used in this machine. Do not mix HFC-134a with CFC-12.

• Keep the air conditioner ready for use all year round.

Operate the air conditioner at least once every week for several minutes to rotate the compressor regardless of the season. This will prevent the refrigerant gas from leaking from the compressor sealing.

AIR CAPACITY SELECTOR SWITCH

COMPRESSOR SWITCH

F16209

TEMPERATURE SETTING SWITCH (°C ↔ °F SELECTOR SWITCH)

Refrigerant volume

MAIN POWER SWITCH

Description

(A) Proper

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

(B) Overcharged

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

(C) Insufficient

After the air conditioner is turned ON, bubbles appear continuously.

Bubbles:

Refrigerant gas is mixed with refrigerant fluid.

No Bubbles: Whole refrigerant becomes fluid and transparent.

Cloudy:

Refrigerant is separated from oil.

The fluid becomes a light milky white.

F18229gb

127

SECTION IV - MAINTENANCE

4.10 2000 HOUR INSPECTION & MAINTENANCE PROCEDURES

REMOVE CAP SLOWLY

Perform all other inspection & maintenance procedures as previously described in this section.

A. ENGINE COOLANT CHANGE

WARNING Be cautious of hot fluids and surfaces. Wear goggles, safety shoes, hard hat, work clothes and work gloves to perform inspection and maintenance on this machine. Allow engine to cool before changing fluids.

ALLOW ENGINE TO COOL BEFORE OPENING

F16344

REMOVE ACCESS COVER

1. Raise engine bonnet and slowly remove radiator cap.

2. Locate coolant drain access cover under L.H. rear of machine. Remove the four retaining bolts.

3. Locate radiator drain valve, place a 18 liter (4.8 Gal) capacity container under drain tube and turn drain valve counterclockwise to open.

4. After drainage, close drain valve and drain plug, and feed water in it.

5. Open drain valve and drain plug. And clean it with flowing water for 10 minutes in low idling state. Be careful that water hose is not disconnected from water feeding port of radiator while cleaning and flowing water.

6. After cleaning, stop engine, and also stop water feeding. Then after draining water, close drain valve and drain plug.

7. After draining, clean it with radiator flush.

Clean it following instruction manual for flush in use.

8. After cleaning, open drain valve and drain plug, then close them after completely draining water, and fill it with water and clean out radiator flush material completely.

ENGINE DRAIN PLUG RADIATOR DRAIN VALVE

F16406

NOTE: NOTE: Never spill the coolant on the ground that can cause the environmental pollution.

Expected minimum temperature -14.5°C (5.9°F) -34°C (-29.2°F)

Long life coolant 30% mixed 50% mixed

Change contaminated and foamy coolant with new one as soon as possible.

Cooling water other than long life coolant should be changed two times a year, in spring and autumn.

128

SECTION IV - MAINTENANCE 9. Fill radiator with water, open drain valve and drain plug, and clean it flowing water with engine in a low idling state until clean water flowing out. Adjust water feeding and draining so as to keep radiator in full condition.

10. After clean water has drained out, stop engine and close drain valve and drain plug.

Fill with “long life coolant” in appropriate concentration.

Refer to the section IV “LUBRIFICANT, FUEL & COOLANT SPECIFICATIONS” for oil specifications.

11. Run engine at low idling for 5 minutes and high idling for 5 minutes to bleed air contaminated in coolant (with cap of radiator removed).

12. Drain coolant in reservoir, clean inside of reservoir and fill it up with long life coolant in appropriate concentration to of FULL and LOW. 13. Stop engine, fill it with water to the top of radiator about 3 minutes later, and tighten cap.

14. Return engine bonnet and radiator access door to the closed position respectively.

ENGINE DRAIN PLUG RADIATOR DRAIN VALVE

F16406

ENGINE COOLANT RESERVOIR FULL

LOW

F16408

NOTE: Total cooling system volume is approximately 18 liters (4.8 Gal).

129

SECTION IV - MAINTENANCE B. HYDRAULIC OIL CHANGE

HYDRAULIC OIL CHECK POSITION

NOTE: The following procedures are to be used for normal changing of the hydraulic oil only.

If necessary to change the hydraulic oil viscosity, change hydraulic oil due to hydraulic component failure or changing main pump, contact your Dealer for assistance.

F16316

DEPRESS RUBBER CAP TO RELEASE PRESSURE

WARNING Be cautious of hot fluids and surfaces. Wear goggles, safety shoes, hard hat, work clothes and work gloves to perform inspection and maintenance on this machine. Allow hydraulic oil to cool before changing.

HYDRAULIC TANK

F16354

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

SLOWLY REMOVE BOLTS & COVER

NOTE: If machine is cold, warm the hydraulic oil by operating attachment controls before placing machine in the hydraulic oil check position.

2. Release hydraulic tank pressure. Clear area around cover of dirt and debris.

3. Slowly remove the retaining bolts from the suction strainer cover plate.

4. Remove “O”-ring, and suction strainer from hydraulic tank.

NOTE: Never spill the hydraulic oil on the ground, that can cause the environmental pollution.

BOLTS SPRING WASHER

COVER

O-RING

SUCTION STRAINER

130

SECTION IV - MAINTENANCE 5. Install special suction stopper, over suction tube inside hydraulic tank.

6. Remove cover plate under hydraulic tank and locate the hydraulic drain plug on bottom of hydraulic tank.

7. Place a 94 liter (25 Gal) capacity container under drain plug. Remove plug and allow oil from hydraulic tank to drain onto container.

8. After all oil has drained, carefully and thoroughly clean inside of hydraulic tank.

9. Replace drain plug and tighten securely.

10. Remove suction stopper and clean outside of suction tube with a clean, dry cloth.

11. Carefully inspect suction strainer for damage. In any damage is found, replace strainer with new part.

12. Install strainer assembly onto suction tube.

13. Install new “O”-ring in cover plate mounting surface groove and install suction strainer cover plate onto hydraulic tank. Make certain plate boss is inside suction strainer holder.

14. Torque retaining bolts to proper value. Refer to specifications section.

HYDRAULIC TANK

SUCTION STOPPER ASSEMBLY

SUCTION TUBE F16214

REMOVE COVER PLATE TO REMOVE HYDRAULIC TANK DRAIN PLUG

BOLTS SPRING WASHER

COVER

O-RING

SUCTION STRAINER

131

SECTION IV - MAINTENANCE 15. Fill hydraulic tank to proper level with fresh, clean hydraulic oil through hydraulic return filter.

CAUTION Use same viscosity oil in hydraulic tank as was drained.

Refer to the section IV “LUBRIFICANT, FUEL & COOLANT SPECIFICATIONS”.

UPPER LIMIT

PROPER LEVEL LOW (ADD OIL)

NOTE: This machine was shipped from the factory with ISO VG32S viscosity hydraulic oil in hydraulic system.

C. CHANGE OIL IN TRAVEL MOTOR REDUCTION UNITS - 2000 HOURS Change the travel reduction units oil on a new machine after the first 500 hours of engine operation then change every 2000 hours.

FILL / LEVEL

WARNING Never change oils or filters on a machine that has just finished working. Allow machine to cool first until oils and fluids are warm not hot.

1. Move machine to a firm, level surface. Operate travel until “FILL / LEVEL” plugs on travel motors are at top.

2. Stop engine and remove the travel motor reduction unit oil “DRAIN” plug.

3. To add oil, remove the oil plug and add gear oil #90 grade GL-4 until oil just begins to flow from level plug.

4. To drain oil, remove “FILL / LEVEL” plug and drain plug. Allow oil to drain into a 3 liter (0.8 Gal) capacity container. Replace drain plug, remove level plug and fill through fill port using gear oil #90 grade GL-4.

NOTE: Capacity of each travel motor reduction unit is 3.0 liters (0.7 Gallons).

5. Replace all plugs and tighten securely.

132

DRAIN

F16393

SECTION IV - MAINTENANCE D. CHANGE OIL IN TRAVEL MOTOR REDUCTION UNITS - 2000 HOURS E115SRL Change the travel reduction units oil on a new machine after the first 500 hours of engine operation then change every 2000 hours.

FILL PLUG

LEVEL PLUG

WARNING Never change oils or filters on a machine that has just finished working. Allow machine to cool first until oils and fluids are warm not hot.

DRAIN

DRAIN PLUG F24588

1. Move machine to a firm, level surface. Operate travel until “FILL” plugs on travel motors are at top.

2. Stop engine and remove the travel motor reduction unit oil level plug. If oil just seeps from Level port, oil level is correct.

3. To add oil, remove the oil plug and add gear oil #90 grade GL-4 until oil just begins to flow from level plug.

4. To drain oil, remove “FILL” plug and drain plug. Allow oil to drain into a 8 liter (2.1 Gal) capacity container. Fill port using extreme pressure gear oil #90 grade GL-4.

NOTE: Capacity of each travel motor reduction unit is 3.0 liters (0.8 Gallons).

5. Use teflon tape on the drain plug for better sealing. Install plug and tighten securely.

133

SECTION IV - MAINTENANCE E. CHANGE OIL IN SWING REDUCTION UNIT Change the swing reduction unit oil on a new machine after the first 500 hours of engine operation then change every 2000 hours.

DIPSTICK

FILL PLUG

WARNING Never change oils or filters on a machine that has just finished working. Allow machine to cool first until oils and fluids are warm not hot.

F16391

1. Remove the drain plug on the rear lower side of the swing reduction unit to drain oil to the container.

2. Clean the drain plug seal it with teflon tape.

Install plug and tighten securely.

3. Remove the oil filler plug and fill with extreme pressure gear oil grade GL-4.

4. Using the dipstick, confirm that the extreme pressure gear oil grade GL-4 levels is within the designated range.

5. Clean the fill plug and use teflon tape on plug and install. Tighten it securely.

DRAIN PORT

F16392

NOTE: Capacity of each swing reduction unit is 1.7 liters (0.4 Gallons).

F. CHANGE GREASE IN SLEWING RING 1. Drain water by removing drain plate located in lower frame cavity.

SUMP BATH DRAIN PLATE

CAUTION If the slewing ring ever becomes submerged in water, it is mandatory that the sump bath grease be changed.

2. To replace the slewing bath grease it is necessary to remove the upper frame.

Contact your dealer to do it.

SUMP BATH GREASE QUANTITIES CHART

GREASE TYPE N.L.G.I.LITHIUM BASE W/MoS2

134

QUANTITIES 6.4 kg (14 Ib)

CLEAN & FILL WITH MoS2 GREASE

SECTION IV - MAINTENANCE G. HYDRAULIC TANK BREATHER - FILTER REPLACEMENT 1. Release hydraulic tank pressure.

DEPRESS RUBBER CAP TO RELEASE PRESSURE

WARNING The temperature of hydraulic oil is high immediately after stopping the operation. Special attention must be paid when releasing the pressure because hot gases may erupt.

HYDRAULIC TANK

F16354

2. Remove rubber cap and nut.

3. Remove breather housing.

RUBBER CAP

NUT

FILTER

BREATHER HOUSING

F16219

4. Remove old filter, clean mounting surfaces and install new filter.

5. Install breather housing.

6. Install retaining nut and tighten securely.

Torque : 1.0 ~ 1.4 kgf·m (7.2 ~ 10 lbf·ft) 7. Install rubber cap.

REMOVE FILTER

F16220

135

SECTION IV - MAINTENANCE H. ATTACHMENT & DUST SEALS 1. Bucket Clearance a. Inspect bucket clearance frequently for wear. If clearance between bucket and bucket link and / or between arm and bucket is greater than 1.2 mm (0.05˝) adjust clearance according to instructions.

BUCKET CLEARANCE ADJUSTING MECHANISM

CAUTION

F16416

Set the safety lock lever to the locked position and stop the engine when adjusting the clearance of the bucket.

O-RING

STANDARD CLEARANCE OF THE BUCKET (A) = 1.2 mm (0.05”) or less b. Lower the bucket onto the ground to stabilize, as shown in the right figure. c. Move the O-ring (1) from its normal position to the bucket boss. d. Slightly rotate in the left direction to slightly push the arm end to the bucket left side (where no clearance adjusting mechanism is equipped). e. Set the safety lock lever to the locked position; then stop the engine. f. Measure the clearance (A) between the arm and bucket boss. If the measurement value is 1.0 mm (0.04˝) or more, adjust the clearance. g. Five shims (3) 1.0 mm (0.04˝) on the average are inser ted in the three capscrews (2) at the clearance adjusting part. Loosen every capscrews (2) and remove shims (3) corresponding the clearance. h. Tighten the capscrews equally to the specified tightening torque.

Tightening torque: 18 ± 2 kgf·m (130 ± 14 lbf·ft) i. Return the O-ring to the normal position.

136

F16417

BUCKET BOSS

(3) (2)

(A)

(1)

F16418

SECTION IV - MAINTENANCE 2. Reversing Backhoe Bucket a. Move the machine to a firm, level surface and rest the bucket on the ground, making certain the bucket is stable. b. Roll “O”-rings onto bucket boss. c. Remove jam nuts, nuts and pin retaining bolts. d. Carefully remove main pins mounting arm and bucket link to bucket. e. Rotate bucket 180° or move machine, install arm and bucket link in their respective positions.

STABILIZE BUCKET ON GROUND

NOTE: Make certain “O”-rings are on bucket boss for reinstallation.

ROLL “O”-RING ONTO BUCKET BOSS

f. Install pins, retaining bolts and nuts.

Torque to proper value. Install jam nuts and torque to proper value. g. Roll “O”-rings into grooves between bucket/arm and bucket/bucket link.

NOTE: Inspect “O”-rings for damage or excessive wear. If worn or damaged replace with new parts to protect seals, pins and surfaces from dirt and debris which can cause premature failure.

BOLT (2) NUT

JAM NUT

MAIN PINS

BUCKET LINK HERE

ARM HERE

137

SECTION IV - MAINTENANCE 3. Dust Seals a. The attachment incorporates several dust seals that should be periodically checked for damage and excessive wear. b. If excessive wear or damage is found, remove seal and replace with new parts.

LOCATION OF ATTACHMENT SEALS

8 1

8 7 2

NOTE: Order the following parts for replacement seals: 1. Boom foot (2 req’d) 2. Arm to boom (2 req’d) 3. Arm to idler link (2 req’d) 4. Bkt cylinder to bkt link (4 req’d) 5. Arm to bucket (4 req’d) 6. Boom cylinder head (4 req’d) 7. Boom cylinder rod (4 req’d) 8. Arm cylinder head and rod (4 req’d) 9. Bkt cylinder head (2 req’d).

9

5

5

6

3 4

F16423

LIP OUT

.

BOSS

c. Install replacement seals. d. Make certain pin surface and tapered end are smooth and free from all burrs or imperfections. Rough pin surfaces can cause damage to the new seals.

BUSHING SEAL

138

F16226

SECTION IV - MAINTENANCE I. WINDSHIELD WASHER RESERVOIR Fill the windshield washer fluid reservoir as required using approved windshield washing fluid.

1. Open engine radiator access door to locate washer fluid reservoir.

2. Pull cap off and fill with proper windshield washing fluid.

3. Replace cap and reposition engine radiator access door.

OPEN ENGINE RADIATOR ACCESS DOOR

WINDSHIELD WASHER RESERVOIR CAP

F16424

139

SECTION IV - MAINTENANCE

4.11 MISCELLANEOUS A. FUSES Follow the procedures below to replace “blown” or faulty fuses.

1. Move seat and seat base completely forward.

2. Remove fuse box cover from fuse box.

3. Locate and remove faulty fuse. Replace fuse with same amperage fuse as removed.

FUSE BOX

F16230

WARNING Never replace a faulty fuse with a higher amp fuse.

Never use a “jumper” in place of a fuse. Never splice accessories directly into fuse terminals.

20 20 10 20

20

10

10 10 10

10

10

20

19

17

15

10 10

20

20

18

16

20

4. Refer to fuse box cover or figure for fuse amperage and their functions.

13

14

11

12

20

NOTE: When ordering replacement fuses, order the following amperages: 10 and 20 AMPS.

10 20

10

No. AMPS 1 20 A 2 10 A 10 A 3 4 10 A 10 A 5 6 NONE 10 A 7 8 20 A 9 10 A 10 20 A 11 20 A 12 20 A 13 10 A 14 20 A 15 10 A 16 20 A 17 10 A 18 20 A 19 10 A 20 20 A

9

7

8

6

5

4

3

2

1

F16231

FUNCTION Mechatro Controller (CPU) Wiper, Washer Relay Cigarette Lighter 24V DC to DC Converter Horn None Controller (Back Up) Fuel Supply Pump DC to DC Converter, Dome Lamp Starter Switch Cab light Swing Flasher Gauge Cluster Windshield wiper, washer Solenoid Valve (Lever Lock) Working Light Resistor Air Conditioner Controller (A/C) Spare 24V F16414gb

140

SECTION IV - MAINTENANCE B. TOWING THE MACHINE Where you can not get the machine out of soft soil, place with slings as shown on the right and pull it by an other machine. Always place wire slings around the frame section and put pads between the wire and the frame on each corner to prevent the wire slings from being damaged.

NOTE: Do not pull the machine utilizing the brackets welded on the lower plates of the car body. These brackets are provided for pulling lightweight objects.

F16106

C. PERIODICAL INSPECTION ITEMS Since there is no definite time table for the replacement of hydraulic lines, tubes and hoses, inspect the following periodically for tightness and signs of damage. Replace all damaged lines, tubes and hoses with new parts. Refer to the parts manual for correct part numbers when ordering.

HEATER HOSES

WARNING Do not bend, strike or damage high pressure lines.

Do not install bent or damaged lines, tubes or hoses.

Replace all damaged lines, tubes and hoses immediately.

Tighten all loose fittings and connections to the proper torque value.

Clean up all fuel and oil spills immediately to help prevent fires.

Never use hands to check for leaks Carefully inspect all lines, tubes and hoses for: 1.Fittings & connections damaged or leaking.

2.Outer covering of hoses worn, cut or damaged exposing wire reinforcement.

3.Hose swelling or “ballooning”.

4.Evidence of hose being kinked or collapsed.

5.Steel protective covering worn or damaged.

6.Loose fittings and connections.

Make certain all clamps, guards and heat shields are in place and secure. This will help prevent vibration, excessive wear of components and excessive heat during operation.

BOOM HOSES AND TUBES

ARM HOSES AND TUBES

1. Heater Hoses Inspect the heater hoses between heater and engine for signs of damage and wear.

2. Boom Hoses & Tubes Inspect boom head and rod hoses and tubes for damage, wear and loose connections.

3. Arm Hoses & Tubes Inspect arm head and rod hoses and tubes for damage, wear and loose connections.

141

SECTION IV - MAINTENANCE 4. Bucket Hoses & Tubes Inspect bucket head and rod hoses and tubes for damage, wear and loose connections.

5. Fuel Lines and Hoses Inspect fuel lines and hoses for damage, wear and loose connections. Repair or replace fuel lines and hoses before operating the machine.

BUCKET HOSES AND LINES

6. Hydraulic Suction Tubes and Hoses Inspect all hydraulic tubes and hoses for damage, wear and loose connections.

HOSE

7. Radiator Hoses and Cap Inspect the radiator hoses for signs of damage or deterioration. Replace hoses if found to be in bad condition. Inspect the radiator cap seal for signs of damage and deterioration and replace with new part if found to be in bad condition.

RADIATOR HOSES AND LINES

8. Foam Seals Inspect the foam rubber seals around the radiator, oil cooler and on the engine cover.

Make certain they are in place and secure to prevent overheating of the engine.

FOAM SEALS

142

SECTION IV - MAINTENANCE 9. Fuel Filler Strainer (with red float) Inspect the fuel filler strainer beneath fuel filler cap for damage, dirt and debris. Make certain the strainer is clean and in place before fueling the machine. If the strainer is damaged, replace with a new part.

FUEL FILLER STRAINER

NOTE: Do not remove this strainer to refuel machine. To do so may allow dirt and debris to enter fuel tank.

10. Fuel Lines and Hoses Inspect fuel lines and hoses for damage, wear and loose connections. Repair or replace fuel lines and hoses before operating the machine.

F24466

11. Rear View Mirrors Inspect the rear view mirrors. Make certain both sides rear view mirrors are in place, properly adjusted, clean, and in good condition. Secure them tight to prevent them from breaking.

MAKE SURE REAR VIEW MIRRORS ARE CLEAN AND IN GOOD CONDITION F24467

143

SECTION IV - MAINTENANCE D. MACHINE STORAGE Perform the following procedure to prepare the machine for long term storage.

1. Perform all inspection and maintenance procedures as previously described in this section.

2. Thoroughly clean the machine, inspect for damaged or worn parts and components and replace or repair all damaged or worn parts.

CAUTION

E. CARE DURING STORAGE 1. Every 30 days during storage, it will be necessary to start and run the machine to circulate the fluids through the systems.

Before starting clean cylinder rods and after running re-grease cylinder rods.

NOTE: Run and operate machine for approximately 1 hour to allow all fluids to circulate well and reach normal operating temperatures.

Protect CPU and all electrical components from water and steam when cleaning the machine.

3. Completely fill fuel tank with fresh, clean fuel to aid in preventing condensation of moisture inside the fuel tank.

4. Move machine to an indoor location for storage.

5. Operate bucket and arm completely “IN” extending cylinders. Then lower boom until attachment is resting on the floor.

6. Coat cylinder rods with a heavy coat of grease to prevent corrosion during storage.

7. Remove batteries and store in a well ventilated, warm area.

F. REMOVING MACHINE FROM STORAGE 1. Perform all inspection and maintenance procedures as described in this section before bringing machine out of storage for normal operation.

2. Remove drain plugs from travel motor and slewing gear reduction units to drain off any moisture which may have accumulated during storage.

3. Carefully and closely inspect all hydraulic hoses after long periods of storage for signs of deterioration. Replace all hoses showing these signs.

POSITION MACHINE AS SHOWN INSIDE A STORAGE BUILDING

F16433

HEAVILY GREASE ALL CYLINDER RODS TO PREVENT CORROSION

144

Section V TRANSPORTATION

SECTION V - TRANSPORTATION

5.1 GROUND TRANSPORTATION

d. Use only a trailer with a rated capacity sufficient to transport the machine. e. Make certain trailer has ramps or a ramp is available for loading and unloading the machine.

3,490 mm (11´-5˝) 3,690 mm (12´-1˝)-L

750 mm (2´-6˝)

1. MACHINE PREPARATION a. Know the total weight, length, width and height of the machine being transported. b. Know route to be traveled. Investigate bridges, overpasses, trusses and traffic flow on route. c. Obtain any permits required from proper government agencies for transport of machine.

6,880 mm (22´-7˝) 7,090 mm (23´-3˝)-L

Dimensions and weights are with 2.2 m (7´-3˝) Arm, 0.45 m3 (0.59 cu.yd.) Bucket and 4.26 m (14') Boom

MACHINE MODEL

WEIGHT 600 mm SHOE

800 mm SHOE

E115SR

11,900 kg

----------

E115SRL

----------

14,500 kg

2. LOADING THE MACHINE

THROTTLE CONTROL TRAVEL SPEED SELECT SWITH

a. Apply parking brakes on tractor and trailer and chock trailer wheels before attempting to load or unload machine. b. Lower ramps of trailer. c. Place travel speed select switch on travel lever in 1st ( ) speed position and move throttle control to the “LO” idle position. d. Slowly travel machine up trailer ramps and over rear axles, stop travel.

HI

Never attempt to load or unload machine without ramps.

Never use attachment as an aid in loading or unloading the machine.

LO

WARNING

F16241

STOP MACHINE OVER TRAILER AXLES

TRAILER RAMPS

F16435

WARNING To prevent the arm and bucket cylinder (s) from any damage, you are advised to follow the following instructions. Do not have the arm and/or bucket cylinder fully extended to a “ramp over center” situation.

This allows sudden and abrupt contact of the arm or bucket to a trailer deck, ramp or the ground. This can result in internal mechanical contact, which can stretch the cylinder rod(s).

SLOWLY SWING MACHINE UNTIL ATTACHMENT IS TOWARD REAR OF TRAILER

F16436

146

SECTION V - TRANSPORTATION e. Slowly swing machine 180° until attachment is toward rear of trailer. f. Slowly travel machine completely onto trailer until in proper transport position. g. Slowly lower boom and dozer blade until attachment rests on trailer bed.

SLOWLY SWING MACHINE UNTIL ATTACHMENT IS TOWARD REAR OF TRAILER

F16436

h. Place safety lock lever in the up “LOCKED” position. i. Turn machine “OFF”, remove key and lock all doors, filler caps and access panels.

SAFETY LOCK LEVER IN LOCKED (UP) POSITION

CAUTION Place a cover over the exhaust pipe of the machine and secure to avoid water entering the engine.

F16243

3. SECURING MACHINE TO TRAILER a. Use cable or wire rope with sufficient capacity to secure front and rear of the machine to trailer. b. Secure attachment to trailer as shown in figure. c. Secure all loose components to trailer.

CAUTION Do not excavate with the machine in transport position.

Such operation can cause attachment damage and cab interference. (Only long arm machine.)

SECURE FRONT & REAR OF EACH TRACK

SECURE ATTACHMENT

F16437

147

SECTION V - TRANSPORTATION

5.2 LIFTING MACHINE

4. Slowly lift and move machine to desired location.

The following procedures are for lifting the machine, as built by your Dealer. These procedures do not take into account modifications made to the machine that affect machine weight or center of gravity.

1. Locate lifting locations at the front and rear of each crawler frame.

2. Attach cables or wire rope with a capacity rating sufficient to lift the machine, at lifting locations.

WARNING Always use proper lifting equipment and devices. Use of improper lifting equipment could allow the load to shift or fall causing severe damage, serious injury or death.

WARNING Do not use counterweight lifting eyes to lift whole machine.

Lifting eyes can fall under this load resulting in personal injury. Refer to operators manual for proper way of lifting machine.

CAUTION Place a hardwood or steel block between cables and crawler frame to prevent damage to the tracks from cables during lifting.

3. Bring loose ends of cables together at machine center of gravity and attach to an overhead lifting device with a rated lifting capacity sufficient to lift the machine.

TOOLS

(A)

(7 °)

Q'TY

CABLE (A)

Ø25 X 13.6 m

1

CABLE (B)

Ø25 X 13.7 m

1

3.67 m

2

SPREADER BARS (C)

0°

(1

)

1900 mm (6´-3˝)

WEIGHT: 11,900 kg (26,230 lbs) ARM: 2.2 m (7’-3”) SHOE: 600 mm (23,6”) MODEL: E115SR

SIZE

ITEM

NOTE: It may be necessary to place reinforced spreader bars between lifting cables to prevent damage to the machine during lifting.

(B)

(44

°) (44°)

3670 mm (12˝)

3100 mm (10´-2˝)

CENTER OF GRAVITY

(C)

632 mm (24.9˝) NOTE:

148

Lifting machine with wider track shoes will tend to shift the Center of Gravity slightly forward, toward the center of the slewing ring.

586 mm (23˝)

PLACE BLOCK BETWEEN EACH CABLE AND FRAME

F16438gb

WARNING Do not use the counterweight lifting eyes to lift machine.

SECTION V - TRANSPORTATION TOOLS ITEM CABLE (A) CABLE (B) SPREADER BARS (C)

(8.

3˚)

Q.TY 1 1 2

(B)

(10

.8˚

2,100mm (6´-11˝)

(A)

WEIGHT: 14500 kg (31,973 lbs) ARM: 2.2 m (7’-3”) SHOE: 800 mm (31.5”) MODEL: E115SRL

SIZE Ø 28 X 13,6 m Ø 28 X 13,6 m 4.2 m

)

(45

˚) (45˚

)

4,200mm (13´-9˝)

3,100mm (10´-2˝)

CENTER OF GRAVITY

(C)

660mm (26.0˝)

NOTE:

Lifting machine with wider track shoes will tend to shift the Center of Gravity slightly forward, toward the center of the slewing ring.

660mm (26.0˝)

PLACE BLOCK BETWEEN EACH CABLE AND FRAME

WARNING Do not use the counterweight lifting eyes to lift machine.

149

SECTION V - TRANSPORTATION

Lift up machine without attachment is the procedure described below.

WEIGHT: 10,100 kg (22,270 lbs) SHOE: 600 mm (23,6”) MODEL: E115SR (13

°)

) (5°

(B)

CENTER OF GRAVITY

(44 ) °) (44°

Lifting machine with wider track shoes will tend to shift the Center of Gravity slightly forward, toward the center of the slewing ring.

(C)

F16439gb

PLACE BLOCK BETWEEN EACH CABLE AND FRAME

WARNING Do not use the counterweight lifting eyes to lift machine.

WEIGHT: 12,900 kg (28,440 lbs) SHOE: 800 mm (31,5”) MODEL: E115SRL

(A) (12

(B)

.4˚

462mm (18.2˝)

7˚)

(6.

247mm (9.7˝)

SIZE Ø 28 X 13.7 m Ø 25 X 13.6 m 4.2 m

(45 ˚)

660mm 626mm (26.0˝) (24.6˝)

150

Lifting machine with wider track shoes will tend to shift the Center of Gravity slightly forward, toward the center of the slewing ring.

4,200mm (13´-9˝º)

334mm660mm (13.1˝) (26.0˝)

PLACE BLOCK BETWEEN EACH CABLE AND FRAME

Q’TY 1 1 2

(C) ˚) (45

3,100mm (10´-2˝)

CENTER OF GRAVITY

)

2,100mm (6´-11˝)

TOOLS ITEM CABLE (A) CABLE (B) SPREADER BARS (C)

NOTE:

Q’TY 1 1 2

3670 mm (12'')

586 mm (23˝)

632 mm (24.9˝)

NOTE:

SIZE Ø 25 X 13.7 m Ø 25 X 13.7 m 3.67 m

3100 mm (10´-2˝)

(A)

TOOLS ITEM CABLE (A) CABLE (B) SPREADER BARS (C)

1900 mm (6´-3˝)

5.3 LIFTING MACHINE (WITHOUT ATTACHMENT)

WARNING Do not use the counterweight lifting eyes to lift machine.

SECTION V - TRANSPORTATION

5.4 SHIPPING DIMENSIONS A. E115SR a. Machine with standard attachments Refer to Figure for reference in regards to the machine basic dimensions, with standard attachments:

a.1. Standard boom ................ 4.26m (14´-0˝) a.2. Standard arm ...................... 2.2 m (7´-3˝) a.3. Bucket ..................... 0.45 m3 (0.59 cu yd)

* Marked dimensions do not include height of shoe lug.

3320 mm (10´-11˝)

600 mm (23.6˝) 2590 mm (8´-6˝)

6880 mm (22´-7˝) F16440gb

*455 mm (17.9")

2740 mm (9´) 2810 mm (9´-3˝)

2410 mm (7´-11˝)

*910 mm (3´)

2690 mm (8´-10˝)

1385 mm (4´-7˝)

B. E115SRL a.1. Standard boom ................ 4.26m (14´-0˝) a.2. Standard arm ...................... 2.2 m (7´-3˝) a.3. Bucket ..................... 0.45 m3 (0.59 cu yd)

a. Machine with standard attachments Refer to Figure for reference in regards to the machine basic dimensions, with standard attachments:

* Marked dimensions do not include height of shoe lug.

800 mm (31.5˝) 2,840 mm (9´-4˝)

*600mm (23´-6˝)

3,800 mm (12´-6˝) 7,090 mm (23´-3˝)

2,940mm (9´-8˝)

2,410 mm (7´-11˝)

*1,100mm (3´-7˝)

2,740 mm (9´-0˝)

1,385 mm (4´-7˝)

151

SECTION V - TRANSPORTATION b. Boom with arm cylinder

Boom mm (ft-in)

4260 (14´-0˝)

LXHXW mm (ft-in) Weight With Arm Cylinder kg (lbs)

4420 X 1330 X 570 (14´-6˝ X 4´-4˝ X 1´-10˝) 790 (1740)

H

F19708gb

L

F16441

c. Arm with bucket cylinder

Arm

1.9 m (6´-3˝)

2.2 m (7´-3˝)

2.7 m (8´-10˝)

LXHXW mm (ft-in)

2640 X 650 X 350 (8´-8˝ X 2´-2˝ X 1´-2˝)

2930 X 590 X 350 (9´-7˝ X 1´-11˝ X 1´-2˝)

3500 X 590 X 350 (11´-6˝ X 1´-11˝ X 1´-2˝)

Weight With Bucket Cylinder kg (lb)

460 (1.010)

480 (1.060)

560 (1.230)

H

F19709gb

L

152

F16442

SECTION V - TRANSPORTATION d. Arm with bucket cylinder and bucket

Combination LXHXW mm (ft-in) Weight kg (lb)

Arm 1.9 m (6´-3˝) Bucket 0.51 m3 (0.66 cu yd) 3780 X 790 X 1000 (12´-5˝ X 2´-7˝ X 3´-3˝)

Arm 2.2 m (7´-3˝) Arm 2.7 m (8´-10˝) Bucket 0.45 m3 (0.59 cu yd) Bucket 0.37 m3 (0.48 cu yd) 4070 X 790 X 950 4640 X 790 X 800 (13´-4˝ X 2´-7˝ X 3´-3˝) (15´-3˝ X 2´-7˝ X 2´-7˝)

820 (1.810)

820 (1.810)

860 (1.900) F19710gb

I

L

F16443

B

e. Bucket Standard bucket is 0.45 m3 (0.59 cu yd) A. Length is 1190 mm (3´-11˝) B. Height is 1070 mm (3´-6˝) C. Width without side cutters is 850 mm (2´-9˝) D. Width with side cutter is 950 mm (3´-1˝) E. Bucket weight is 340 kg (750 lb) A

C D F16444

153

SECTION V - TRANSPORTATION NOTES:

154

Section VI SPECIFICATIONS

SECTION VI - SPECIFICATIONS

6.1 GENERAL SPECIFICATIONS The specifications found in this section are given on the E115SR and hydraulic excavator. No modifications or options are taken into consideration in regard to these specifications.

A. MACHINE DIMENSIONS These dimensions consider the following: a. Standard boom .................. 4.26 m (14´-0˝) b. Standard arm ........................ 2.2 m (7´-3˝) c. Bucket ....................... 0.45 m3 (0.59 cu yd) d. Standard shoe .................. 600 mm (23.6˝)

* Dimension does not include height of grouser.

3320 mm (10´-11˝)

600 mm (23.6˝) 2590 mm (8´-6˝)

6880 mm (22´-7˝) F16440gb

B. WORKING RANGES a. Boom ...................................... 4.26 m (14´) b. Arm ........................................ 2.2 m (7´-3˝) c. Bucket SAE heaped .................. 0.45 m3 (0.59 cu yd) Struck ............................ 0.35 m3 (0.46 cu yd) Width with side cutters .......... 950 mm (3´-1˝) Width without side cutters ..... 850 mm (2´-9˝) Weight ................................... 340 kg (750 lb)

A B H

D ITEM

FUNCTION

mm

E

SAE

A

Maximum digging reach

7710

25´-4˝

B

Maximum digging reach at ground

7560

24´-10˝

C

Maximum digging depth

5060

16´-7˝

D

Maximum digging height

8160

26´-9˝

E

Maximum dumping height

5780

19´-0˝

F

Minimum dumping height

2170

7´-1˝

G

Max. vertical wall digging depth

4500

14´-9˝

H

Minimum swing radius

2330

7´-8˝

F

C G

F18234gb

F16445

156

*455 mm (17.9")

2740 mm (9´) 2810 mm (9´-3˝)

2410 mm (7´-11˝)

*910 mm (3´)

2690 mm (8´-10˝)

1385 mm (4´-7˝)

SECTION VI - SPECIFICATIONS C. BOOM Standard boom is 4.26 m (14´).

A. Length is 4.26 m (14’) Center line to center line of pins.

B. Height is 1038 mm (3´-5˝) From centerline of boom end to centerline of arm cylinder boss.

C. Width is 574 mm (22.6˝) From edge to edge of boom foot.

Weight - Approximately 630 kg (1390 lb)

D. ARM Standard arm is 2.2 m (7´-3˝).

A. Length is 2.2 m (7´-3˝) Center line to center line of pins.

B. Width is 216 mm (8´-5˝) From edge to edge of arm end.

Weight - Approximately 300 kg (660 lb)

C ARM CYLINDER BOSS

B

GROUND LEVEL F16446

A

B

F16447

A

B

E. BUCKET Standard arm is 0.45 m3 (0.59 cu yd).

A. Length is 1.19 m (3´-11˝) B. Height is 1.07 m (3´-6˝) C. Width without side cutters is 850 mm (2´-9˝) D. Width with side cutters is 950 mm (3´-1˝) E. Bucket weight is 340 kg (750 lb) A

C D F16444

157

SECTION VI - SPECIFICATIONS F. SHOES 1. Standard shoes for the E115SR are 600 mm (23.6˝) triple grouser.

2. Quantity of shoes .................. 41 per track.

TRIPLE GROUSER SHOE

158

SECTION VI - SPECIFICATIONS G. PERFORMANCE SPECIFICATIONS The following performance specifications are based on the machine with standard attachment.

1. Travel speed, swing speed & gradeability DESCRIPTION

SPECIFICATION

TRAVEL SPEED

6.0 km per hr (3.7 mph) in 3.5 km per hr (2.2 mph) in

mode. mode.

SWING SPEED

11.4 RPM IN M-Mode / "HI" idle.

GRADEABILITY

70% (35°)

2. Engine Major engine specifications Engine maker

ISUZU

Model

BB-4BG1T

Type

4-cycle, water cooled, direct injection with

Number of cylinders-Bore X Stroke

4-105 mm X 125 mm (4.13˝ X 4.92˝)

Displacement

4329 cm3 (264 cu in.)

Compression ratio

18.0: 1

Output rating

58.8 kW / 2050rpm

Maximum torque

294 N·m / 1600rpm

turbocharger, diesel

Ignition order

1 - 3 - 4 - 2 clockwise rotation

Injection timing

9°±1° Before top dead point

Intake valve clearance Cold

0.4 mm (0.0157˝)

Exhaust valve clearance Cold

0.4 mm (0.0157˝)

Electrical system

D.C. 24 V

Starting motor

24 V – 4.5 kW

Alternator

24 V – 30 A

Batteries

2–12 V - 80Ah

Engine dry weight*

363 kg (800 lb)

Thermostat

Begin to open at 82°C (180°F). Full open at 95°C (203°C)

Cooling fan drive method

Ø550 (Ø21.7˝) suction type belt drive, pulley ratio: 0.98

Air cleaner

Dry type with safety elemen

*Less flywheel and electrics.

3. Hydraulic components COMPONENT Hydraulic Pumps Swing Motor Travel Motor Control Valves Cylinders Return Filter Oil Cooler

TYPE Tandem, variable displacement, axial piston with pilot gear pump Axial piston Axial piston 6 spool multiple control Double acting Safety valve containing filter type Air cooled

4. Operating pressure Unit: kgf/cm2 (psi) Pilot System Implement (Attachment) Swing Travel

50 (710) 330 (4700) 265 (3770) 330 (4700)

159

SECTION VI - SPECIFICATIONS H. MACHINE AND COMPONENT WEIGHTS The following weight specifications are based on the machine with standard attachment.

1. Component weight.

Unit: kg (lb)

Complete Machine (Standard)

11,900 (26,230)

Upper Frame Assembly

6,080 (13,400)

Counterweight

2,340 (5,160)

Cab

210 (460)

Boom cylinder*

84 (235)x 2

Engine*

363 (800)

Radiator

65 (143)

Pump assembly

95 (210)

Control valve

114 (251)

Fuel tank*

53 (116)

Hydraulic tank*

91(200)

Swing motor& reduction unit

110 (240)

Lower Frame Assembly

4140 (9,130)

Slewing ring

149 (330)

Travel motor & reduction unit

144 (320) x 2

Idler assembly

70 (150) x 2

Lower roller assembly

27 (60) x 12

Upper roller assembly

8 (18) x 2

Track tension assembly

57 (125) x 2

Sprocket

36 (79) x 2

Swivel Joint

30 (66)

Dozer blade (Opt.)

470 (1,040)

Dozer blade cylinders*(Opt.)

57 (125) x 2

Track link w/600mm (23.6˝) shoes

760 (1,670) x 2

Track link

270 (590) x 2

Attachment (Standard)

1,680 (3,700)

Bucket assembly [0.45 m3 (0.59 cu yd)]

340 (750)

Arm assembly [2.2 m (7´-3˝)]

490 (1,080)

Arm [2.2 m (7´-3˝)]

300 (660)

Bucket cylinder*

87 (190)

Idler link

12 (26) x 2

Bucket link

35 (77)

Pin (2pcs for mtg bucket cyl. & bucket)

24 (52)

Boom assembly

850 (1,870)

Boom

680 (1,500)

Arm cylinder*

128 (280)

Pin (mounting the arm)

27 (59)

Fluids

310 (680)

Hyd oil, engine oil

HYD 138 (304) / ENG 11 (24)

Fuel

139 (310)

Water

18 (40) *Dry weight

WARNING Use only lifting devices and equipment with rated capacities sufficient to lift the specific component(s) being removed or installed.

160

SECTION VI - SPECIFICATIONS I. LIFTING CAPACITIES RATED CAPACITIES TABLE WORKING CONDITIONS: • With no tool (bucket, clamshell..).

If objet handling is performed with tool installed, the weight of the tool shall be deducted from the values of this table.

SHOE WIDTH 600 mm

LIFT POINT (AXIS)

8

AXIS ARM (See the following table)

HEIGHT (m)

• With extended bucket cylinder.

• On a compact or horizontal, level ground.

• In complete swing of the upper structure.

7

BOOM (See the following table)

6 LD

COUNTERWEIGHT 2340 kg

5

Z2

4 3 2 1 0 Z1 1 2

WORKING CIRCUIT PRESSURE 32362 kPa

3 4 Z3

HOLDING CIRCUIT PRESSURE 32362 kPa

AXIS OF ROTATION

0

1

2

3

4

5

6

5 7 8

F16449

OUTREACH (m)

THESE LOADS ARE VALID FOR THE HEIGHT OF THE CONSIDERED ZONE (Z.) FOR THE INTENDED OUTREACH BOOM LENGTH 4.26 m

ARM LENGTH OUTREACH (m) (m) Z2 2.20

LD = 2.47

LD = 2.96

–

3460 2140 1400

MAX REACH –

Z1

3420 3680 1900 1210 1090 (6.58 m)

Z3

7350 3290 1930

Z2 2.70

OUTREACH IN mLOADS IN kg 1.5 3.0 4.5 6.0

–

–

–

2130 1530

– –

Z1

3130 3860 2010 1300 1060 (7.06 m)

Z3

6250 3420 2020

–

LD : BOOM POINT TO HOOK POINT DISTANCE

– F19189gb

161

SECTION VI - SPECIFICATIONS

6.2 SPECIFICATIONS – OPTIONAL ATTACHMENTS

A B

The following working range is based on the standard machine with optional attachments.

A.WORKING RANGES 1. Attachment with: a. Boom ................................. 4.26 m (14´-0˝) b. Arm ...................................... 2.7 m (8´-10˝) c. Bucket SAE heaped .................. 0.37 m3 (0.48 cu yd) Struck ............................ 0.27 m3 (0.35 cu yd) Width with side cutters .......... 800 mm (2´-7˝) Width without side cutters ..... 700 mm (2´-4˝) Weight ................................... 310 kg (680 lb) ITEM

FUNCTION

mm

H

D E

F

SAE

A

Maximum digging reach

8180 26´-10˝

B

Maximum digging reach at ground

8050 26´-5˝

C

Maximum digging depth

5560 18´-3˝

D

Maximum digging height

8490 27´-10˝

E

Maximum dumping height

6100 20´-0˝

F

Minimum dumping height

1720

G

Max. vertical wall digging depth

4860 15´-11˝

H

Minimum swing radius

2590

C G

F16445

5´-8˝ 8´-6˝ F20766gb

2. Attachment with: a. Boom ................................. 4.26 m (14´-0˝) b. Arm ........................................ 1.9 m (6´-3˝) c. Bucket SAE heaped .................. 0.51 m3 (0.65 cu yd) Struck ............................ 0.39 m3 (0.51 cu yd) Width with side cutters ........ 1000 mm (3´-3˝) Width without side cutters ... 900 mm (2´-11˝) Weight ................................... 360 kg (790 lb) ITEM

FUNCTION

mm

SAE

A

Maximum digging reach

7430

24´-5˝

B

Maximum digging reach at ground

7290

23´-11˝

C

Maximum digging depth

4760

15´-7˝

D

Maximum digging height

7960

26´-1˝

E

Maximum dumping height

5570

18´-3˝

F

Minimum dumping height

2510

8´-3˝

G

Max. vertical wall digging depth

3960

13´-0˝

H

Minimum swing radius

2440

8´-0˝ F20767gb

162

CAUTION Do not excavate with the machine in transport position.

Such operation can cause attachment damage and cab interference.

SECTION VI - SPECIFICATIONS

6.1 GENERAL SPECIFICATIONS The specifications found in this section are given on the E115SRL and hydraulic excavator. No modifications or options are taken into consideration in regard to these specifications.

A. MACHINE DIMENSIONS These dimensions consider the following: a. Standard boom .................. 4.26 m (14´-0˝) b. Standard arm ........................ 2.2 m (7´-3˝) c. Bucket ....................... 0.45 m3 (0.59 cu yd) d. Standard shoe .................. 800 mm (31.5˝)

* Dimension does not include height of grouser.

1,385 mm (4´-7˝)

*600mm (23´-6˝)

2,940mm (9´-8˝)

*1,100mm (3´-7˝)

2,740 mm (9´-0˝)

2,410 mm (7´-11˝)

800 mm (31.5˝)

3,800 mm (12´-6˝) 7,090 mm (23´-3˝)

2,840 mm (9´-4˝)

B. WORKING RANGES a. Boom ...................................... 4.26 m (14´) b. Arm ........................................ 2.2 m (7´-3˝) c. Bucket SAE heaped .................. 0.45 m3 (0.59 cu yd) Struck ............................ 0.35 m3 (0.46 cu yd) Width with side cutters .......... 950 mm (3´-1˝) Width without side cutters ..... 850 mm (2´-9˝) Weight ................................... 340 kg (750 lb)

A B H

D E Item

FUNCTION

mm

SAE

A B

Maximum digging reach Maximum digging reach at ground

7,710 25’-4” 7,520 24’-8”

C D

Maximum digging depth Maximum digging height

4,860 15’-11” 8,350 27’-5”

E F

Maximum dumping clearance Minimum dumping clearance

5,970 19’-7” 2,370 7’-9”

G H

Max. vertical wall digging depth Minimum swing radius

4,310 14’-2” 2,330 7’-8”

F

C G

F16445

163

SECTION VI - SPECIFICATIONS C. BOOM Standard boom is 4.26 m (14´).

A. Length is 4.26 m (14’) Center line to center line of pins.

B. Height is 1,038 mm (3´-5˝) From centerline of boom end to centerline of arm cylinder boss.

C. Width is 574 mm (22.6˝) From edge to edge of boom foot.

Weight - Approximately 630 kg (1,390 lb)

D. ARM Standard arm is 2.2 m (7´-3˝).

A. Length is 2.2 m (7´-3˝) Center line to center line of pins.

B. Width is 216 mm (8´-5˝) From edge to edge of arm end.

Weight - Approximately 300 kg (660 lb)

C ARM CYLINDER BOSS

B

GROUND LEVEL

F16446

A

B

F16447

A

B

E. BUCKET Standard arm is 0.45 m3 (0.59 cu yd).

A. Length is 1.19 m (3´-11˝) B. Height is 1.07 m (3´-6˝) C. Width without side cutters is 850 mm (2´-9˝) D. Width with side cutters is 950 mm (3´-1˝) E. Bucket weight is 340 kg (750 lb) A

C D F16444

164

SECTION VI - SPECIFICATIONS F. SHOES 1. Standard shoes for the E115SRL are 800 mm (31.5˝) triple grouser.

2. Quantity of shoes .................. 42 per track.

TRIPLE GROUSER SHOE

165

SECTION VI - SPECIFICATIONS G. PERFORMANCE SPECIFICATIONS The following performance specifications are based on the machine with standard attachment.

1. Travel speed, swing speed & gradeability DESCRIPTION

SPECIFICATION

TRAVEL SPEED

5.1 km per hr (3.7 mph) in 2.8 km per hr (2.2 mph) in

mode. mode.

SWING SPEED

11.4 RPM IN M-Mode / "HI" idle.

GRADEABILITY

70% (35°)

2. Engine Major engine specifications Engine maker

ISUZU

Model

BB-4BG1T

Type

4-cycle, water cooled, direct injection with

Number of cylinders-Bore X Stroke

4-105 mm X 125 mm (4.13˝ X 4.92˝)

Displacement

4329 cm3 (264 cu in.)

Compression ratio

18.0: 1

Output rating

58.7 kW / 2050rpm

Maximum torque

300 N·m / 1600rpm

turbocharger, diesel

Ignition order

1 - 3 - 4 - 2 clockwise rotation

Injection timing

9°±1° Before top dead point

Intake valve clearance Cold

0.4 mm (0.0157˝)

Exhaust valve clearance Cold

0.4 mm (0.0157˝)

Electrical system

D.C. 24 V

Starting motor

24 V – 4.5 kW

Alternator

24 V – 30 A

Batteries

2–12 V - 80Ah

Engine dry weight*

363 kg (800 lb)

Thermostat

Begin to open at 82°C (180°F). Full open at 95°C (203°C)

Cooling fan drive method

Ø550 (Ø21.7˝) suction type belt drive, pulley ratio: 0.98

Air cleaner

Dry type with safety elemen

*Less flywheel and electrics.

3. Hydraulic components COMPONENT Hydraulic Pumps Swing Motor Travel Motor Control Valves Cylinders Return Filter Oil Cooler

TYPE Tandem, variable displacement, axial piston with pilot gear pump Axial piston Axial piston 6 spool multiple control Double acting Safety valve containing filter type Air cooled

4. Operating pressure Unit: kgf/cm2 (psi) Pilot System Implement (Attachment) Swing Travel

166

50 (710) 330 (4700) 265 (3770) 330 (4700)

SECTION VI - SPECIFICATIONS H. MACHINE AND COMPONENT WEIGHTS The following weight specifications are based on the machine with standard attachment.

1. Component weight.

Unit: kg (lb)

Complete Machine (Standard)

14,500 (31,970)

Upper Frame Assembly

6,080 (13,400)

Counterweight

2,340 (5,160)

Cab

210 (460)

Boom cylinder*

84 (235)x 2

Engine*

363 (800)

Radiator

65 (143)

Pump assembly

95 (210)

Control valve

114 (251)

Fuel tank*

53 (116)

Hydraulic tank*

91 (200)

Swing motor& reduction unit

110 (240)

Lower Frame Assembly

6,770 (14,920)

Slewing ring

149 (330)

Travel motor & reduction unit

240 (530) x 2

Idler assembly

106 (230) x 2

Lower roller assembly

35 (77) x 14

Upper roller assembly

17 (37) x 4

Track tension assembly

102 (225) x 2

Sprocket

65 (143) x 2

Swivel Joint

30 (66)

Track link w/800mm (31.5˝) shoes

1,460 (3,220) x 2

Track link

465 (1,025) x 2

Attachment (Standard)

1,680 (3,700) 3

Bucket assembly [0.45 m (0.59 cu yd)]

340 (750)

Arm assembly [2.2 m (7´-3˝)]

490 (1,080)

Arm [2.2 m (7´-3˝)]

300 (660)

Bucket cylinder*

87 (190)

Idler link

12 (26) x 2

Bucket link

35 (77)

Pin (2pcs for mtg bucket cyl. & bucket)

24 (52)

Boom assembly

850 (1,870)

Boom

680 (1,500)

Arm cylinder*

128 (280)

Pin (mounting the arm)

27 (59)

Fluids

300 (660)

Hyd oil, engine oil

HYD 138 (304) / ENG 11 (24)

Fuel

139 (310)

Water

18 (40) *Dry weight

WARNING Use only lifting devices and equipment with rated capacities sufficient to lift the specific component(s) being removed or installed.

167

SECTION VI - SPECIFICATIONS

6.4 SPECIFICATIONS – OPTIONAL ATTACHMENTS

A B

The following working range is based on the standard machine with optional attachments.

A.WORKING RANGES 1. Attachment with: a. Boom ................................. 4.26 m (14´-0˝) b. Arm ...................................... 2.7 m (8´-10˝) c. Bucket SAE heaped .................. 0.37 m3 (0.48 cu yd) Struck ............................ 0.27 m3 (0.35 cu yd) Width with side cutters .......... 800 mm (2´-7˝) Width without side cutters ..... 700 mm (2´-4˝) Weight ................................... 310 kg (680 lb)

H

D E

F

C G Item

FUNCTION

mm

SAE

A B

Maximum digging reach Maximum digging reach at ground

8,180 26’-10” 8,000 26’-3”

C D

Maximum digging depth Maximum digging height

5,360 17’-7” 8,680 28’-6”

E F

Maximum dumping clearance Minimum dumping clearance

6,300 20’-8” 1,920 6’-4”

G H

Max. vertical wall digging depth Minimum swing radius

4,680 15’-4” 2,590 8’-6”

168

F16445

CAUTION Do not excavate with the machine in transport position.

Such operation can cause attachment damage and cab interference.

SECTION VI - SPECIFICATIONS

6.5 BUCKET AND ARM COMBINATIONS BUCKET m3 (cu yd) SAE (HEAPED)

SAE (STRUCK)

0.17 (0.22)

0.13 (0.17)

0.23 (0.30)

0.19 (0.24)

0.30 (0.39)

0.22 (0.28)

0.37 (0.48)

0.27 (0.35)

0.45 (0.58)

0.35 (0.46)

0.51 (0.69)

0.39 (1.51)

ARM 1.9 m (6´-3˝)

2.2 m (7´-3˝)

2.7 m (8´-10˝) ····· ····· ····· ·····

Normal working Standard Light duty only Do not use this combination

F20768gb

6.6 TORQUE SPECIFICATIONS The following torque specifications are provided for use when actual torque value of a fastener is not known.

A. CAPSCREWS AND NUTS 1. Metric coarse thread standard tightening torque values. Make certain to tighten all capscrews & nuts to proper torque values.

Torque value unit - kgf·m (lbf·ft) Classification

4.8 T

7T

10.9 T

NOMINAL SIZE NO LUBRICATION OIL LUBRICATION NO LUBRICATION OIL LUBRICATION NO LUBRICATION OIL LUBRICATION 0.45 ± 0.05 (3.2 ± 0.4) 0.38 ± 0.04 (2.7 ± 0.3) 0.98 ± 0.1 (7.1 ± 0.7) 0.83 ± 0.08 (6.0 ± 0.6) 1.77 ± 0.18 (12.8 ± 1.3) 1.5 ± 0.15 (10.8 ± 1.1)

M6

P=1

M8

P=1.25 1.09 ± 0.11 (7.9 ± 0.8) 0.92 ± 0.09 (6.6 ± 0.7) 2.4 ± 0.2 (17.3 ± 1.4)

M10 P=1.5

2.2 ± 0.2 (15.9 ± 1.4) 1.83 ± 0.18 (13.2 ± 1.3) 4.7 ± 0.5 (33.9 ± 3.6)

M12 P=1.75 3.7 ± 0.4 (26.7 ± 2.9)

3.2 ± 0.3 (23.1 ± 2.2)

2.0 ± 0.2 (14.4 ± 1.4)

4.3 ± 0.4 (31.0 ± 2.9)

3.6 ± 0.4 (26.0 ± 2.9)

4.0 ± 0.4 (28.9 ± 2.9)

8.5 ± 0.9 (61.3 ± 6.5)

7.2 ± 0.7 (52.0 ± 5.1)

6.8 ± 0.7 (49.1 ± 5.1) 14.6 ± 1.5 (105 ± 10.8) 12.3 ± 1.2 (88.8 ± 8.7)

8.1 ± 0.8 (58.5 ± 5.8)

M14 P=2

5.9 ± 0.6 (42.6 ± 4.3)

5.0 ± 0.5 (36.1 ± 3.6) 12.8 ± 1.3 (92.5 ± 9.4) 10.8 ± 1.1 (78.0 ± 7.9)

23 ± 2 (166 ± 14)

19.5 ± 1.9 (140 ± 14)

M16 P=2

9.0 ± 0.9 (64.9 ± 6.5)

7.6 ± 0.7 (54.8 ± 5.1) 19.5 ± 2.0 (140 ± 14.4) 16.4 ± 1.6 (118 ± 11.5)

35 ± 4 (252 ± 28.9)

29 ± 3 (209 ± 21.6) 41 ± 4 (296 ± 29)

M18 P=2.5

12.4 ± 1.2 (89.6 ± 8.7) 10.5 ± 1.0 (75.8 ± 7.2)

27 ± 3 (195 ± 22)

23 ± 2 (166 ± 14)

49 ± 5 (354 ± 36)

M20 P=2.5

17.5 ± 1.7 (126 ± 12.3) 14.7 ± 1.4 (106 ± 10.1)

38 ± 4 (274 ± 29)

32 ± 3 (231 ± 22)

68 ± 7 (491 ± 51)

57 ± 6 (412 ± 43)

51 ± 5 (368 ± 36)

43 ± 4 (310 ± 29)

92 ± 9 (663 ± 65)

77 ± 7 (555 ± 58)

118 ± 12 (852 ± 87)

96 ± 10 (693 ± 72)

23 ± 2 (166 ± 14)

19.6 ± 2.0 (142 ± 14)

M24 P=3

30 ± 3 (217 ± 22)

24 ± 3 (173 ± 22)

65 ± 7 (469 ± 51)

53 ± 5 (383 ± 36)

M27 P=3

44 ± 4 (318 ± 29)

36 ± 3 (260 ± 22)

96 ± 10 (693 ± 72)

78 ± 8 (563 ± 58)

173 ± 17 (1250 ± 120) 140 ± 14 (1010 ± 100)

M30 P=3.5

60 ± 6 (433 ± 43)

50 ± 5 (361 ± 36)

131 ± 13 (946 ± 94)

110 ± 11 (794 ± 79)

235 ± 24 (1700 ± 170) 198 ± 20 (1430 ± 140)

M33 P=3.5

81 ± 8 (585 ± 58)

68 ± 7 (491 ± 51)

176 ± 18 (1270 ± 130) 148 ± 15 (1070 ± 110) 317 ± 32 (2290 ± 200) 266 ± 27 (1920 ± 200)

105 ± 10 (758 ± 72)

88 ± 9 (636 ± 65)

227 ± 23 (1640 ± 170) 190 ± 19 (1370 ± 140) 409 ± 41 (2960 ± 300) 343 ± 34 (2480 ± 250)

M22 P=2.5

M36 P=4

F18238gb

2. Metric fine thread standard tightening torque values. Make certain to tighten all capscrews & nuts to proper torque values.

Torque value unit - kgf·m (lbf·ft)

Classification

4.8 T

7T

10.9 T

NOMINAL SIZE NO LUBRICATION OIL LUBRICATION NO LUBRICATION OIL LUBRICATION NO LUBRICATION OIL LUBRICATION 2.5 ± 0.2 (18.0 ± 1.4)

2.1 ± 0.2 (15.2 ± 1.4)

4.5 ± 0.4 (32.5 ± 2.9)

3.8 ± 0.4 (27.4 ± 2.9)

M10 P=1.25 2.3 ± 0.2 (16.6 ± 1.4) 1.91 ± 0.19 (13.8 ± 1.4) 4.9 ± 0.5 (35.4 ± 3.6)

4.2 ± 0.4 (30.3 ± 2.9)

8.9 ± 0.9 (64.2 ± 6.5)

7.5 ± 0.7 (54.2 ± 5.1)

M12 P=1.25 4.0 ± 0.4 (28.9 ± 2.9)

15.7 ± 1.6 (113 ± 13) 13.2 ± 1.3 (95.3 ± 9.4)

M8

P=1.0

1.15 ± 0.11 (8.3 ± 0.8) 0.97 ± 0.1 (7.0 ± 0.7) 3.4 ± 0.3 (24.5 ± 2.2)

8.7 ± 0.9 (62.8 ± 6.5)

7.3 ± 0.7 (52.7 ± 5.1)

M16 P=1.5

9.4 ± 0.9 (67.9 ± 6.5)

7.9 ± 0.8 (57.0 ± 5.8)

20 ± 2 (144 ± 14)

17.2 ± 1.7 (124 ± 12)

37 ± 4 (267 ± 29)

31 ± 3 (224 ± 22)

M20 P=1.5

19 ± 9 (137 ± 14)

15.8 ± 1.6 (114 ± 14)

41 ± 4 (296 ± 29)

34 ± 3 (246 ± 22)

74 ± 7 (535 ± 51)

62 ± 6 (448 ± 43)

M24 P=2

32 ± 3 (231 ± 22)

27 ± 3 (195 ± 22)

70 ± 7 (506 ± 51)

58 ± 6 (419 ± 43)

126 ± 12 (910 ± 87)

105 ± 10 (758 ± 72)

118 ± 12 (852 ± 87)

255 ± 26 (1840 ± 190) 212 ± 21 (1530 ± 150)

M30 P=2

65 ± 6 (469 ± 43)

54 ± 5 (390 ± 36)

142 ± 14 (1030 ± 100)

M36 P=3

109 ± 11 (787 ± 79)

91 ± 9 (657 ± 65)

238 ± 23 (1720 ± 170) 198 ± 20 (1430 ± 140) 428 ± 43 (3090 ± 310) 357 ± 36 (2580 ± 260) F18239gb

169

SECTION VI - SPECIFICATIONS B. NUTS AND SLEEVES

B

NUT

SLEEVE

O.D. (Ø)

O.D. (Ø)

F16261

WORKING PRESSURE kgf/cm2 (psi)

350 (4,980) Travel line only

350 (4,980) Travel line only

F16259

TUBE SIZE O.D. X THICKNESS mm (in) 10 X 1.5 (0.394 X 0.059) 15 X 2.0 (0.591 X 0.079) 18 X 2.5 (0.709 X 0.098) 22 X 3.0 (0.866 X 0.118) 28 X 4.0 (1.10 X 0.157)

OPPOSING FLATS mm Dimension B 19 27 32 36 41

35 X 5.0 (1.38 X 0.20)

55

TORQUE VALUE kgf·m (lbf·ft) 4.5 ± 0.5 (33 ± 4) 15 ± 2 (108 ± 14) 18 ± 2 (130 ± 14) 22 ± 2 (159 ± 14) 28 ± 3 (203 ± 22) 35 ± 4.5 (253 ± 33) F18502gb

C. FLARE TYPE FITTING JOINTS Overtightening of flare type (union nut type) metal joints may cause damage to nuts, seat surfaces and prevent optimum sealing resulting in oil leaks.

1. Pipe threads Unit : kgf·m (lbf·ft) NOMINAL SIZE

TORQUE VALUE

1 / 4˝

2.5 ± 0.3 (18.1 ± 1.8)

3 / 8˝

5 ± 0.5 (36.2 ± 3.6)

1 / 2˝

6 ± 0.6 (43.4 ± 4.3)

3 / 4˝

12 ± 1.2 (86.8 ± 8.7)

1˝

14 ± 1.4 (101 ± 10)

1-1 / 4˝

17 ± 1.7 (123 ± 12)

1-1 / 2˝

21 ± 2.1 (152 ± 15)

2˝

42 ± 4.2 (304 ± 30)

D. N2 (NYLON) TUBE FITTING JOINTS 1. Clean tube and make certain tube end is trimmed smooth.

2. Insert tube into fitting until tube end is securely seated in fitting body.

3. Tighten the nut by hand.

4. Use a spanner wrench, securely tighten nut by turning 1-1/4 turns.

PLASTIC SLEEVE

BODY

NYLON TUBE

NUT F16260

F18503gb

E. ORS JOINT (O-RING SEALING TYPE) NOMINAL SIZE

OPPOSING FLATS mm

TORQUE VALUE kgf·m (lbf·ft)

Hose mouth ring and coupling CONNECTOR

1-14 UNS

30 • 32

14 ± 1.4 (101 ± 10)

1-3/16 12 UN

36 • 41

18 ± 1.8 (130 ± 13)

1-7/16 12 UN

41 • 46

21 ± 2.1 (152 ± 15)

O-RING

NIPPLE

F16262

NUT

170

WORKING PRESSURE kgf/cm2 (psi) 350 (4,980) F18501gb

SECTION VI - SPECIFICATIONS F. TORQUE VALUES FOR MOST COMMON BOLTS Follow the table below and tighten or retighten every capscrew and nut. Check for any loose or missing capscrews or nuts before daily operation and during periodical inspections. Retighten or supply new parts for missing ones as required.

Size

Q'ty

M5

5

• Sending unit mounting (fuel tank)

• 0.2 ± 0.02 (1.4 ± 0.1)

M6

6

• A/C Condenser mounting

• 0.45 ± 0.1 (3.2 ± 0.7)

M8

4 4 4 2 4

• Air cleaner mounting • Muffler mounting (Nut-Upper) • Muffler mounting (Nut-Lower) • Exhaust tube mounting • A/C compressor mounting

• 2.0 ± 0.02 (1.4 ± 0.1) • 1.1 ± 0.1 (8.0 ± 0.7) • 0.9 ± 0.09 (6.5 ± 0.6) • 2.0 ± 0.2 (14 ± 1.4) • 1.1 ± 0.1 (8.0 ± 0.7)

M10

5 5 4 3 2 12 8 4 4 12

• Swivel joint dust cover mounting • Cab mounting • Muffler bracket mounting • Stepping motor mounting • Exhaust tube clamp mounting • Take-up bracket mounting • Floor plate rubber mounting • Step mounting • Travelling lever mounting • Hydraulic oil tank cover mounting

• 1.5 ± 0.2 (10.8 ± 1.4) • 4.7 ± 0.5 (34 ± 3.6) • 6.6 ± 0.6 (48 ± 43) Apply Loctite #262 • 2.0 ± 0.2 (14 ± 1.4) • 2.0 ± 0.2 (14 ± 1.4) • 6.6 ± 0.6 (48 ± 4.3) Apply Loctite #262 • 4.7 ± 0.5 (34 ± 3.6) • 2.2 ± 0.2 (16 ± 1.4) • 4.3 ± 0.4 (31 ± 2.9) • 4.7 ± 0.5 (34 ± 3.6)

• Idler and idler adjuster connection • Travel motor cover mounting • Swivel joint mounting • Radiator stay mounting

• 11.7 ± 1.2 (85 ± 8.7) • 8.5 ± 0.8 (61 ± 6.0) • 11.0 ± 1.0 (79 ± 7.0) • 10.3 ± 1.0 (74 ± 7.0)

Apply Loctite #262

M12

4 10 3 2

• Slewing bearing outer race mounting • Slewing bearing inner race mounting • Hyd. pump mounting • Idler and idler adjuster connection • Radiator mounting • Fuel tank mounting • Sprocket mounting • Sprocket mounting • Hyd. tank mounting • Travel motor mounting • Travel motor mounting • Lower roller mounting • Lower roller mounting • Shoe bolt mounting • Track guide mounting

• 28.5 ± 3.0 (206 ± 22) • 28.5 ± 3.0 (206 ± 22) • 19.5 ± 2.0 (141 ± 14) • 28.5 ± 1.0 (206 ± 7.0) • 16.4 ± 1.6 (118 ± 12) • 22.0 ± 2.0 (159 ± 14) • 28.5 ± 3.0 (206 ± 22) • 28.5 ± 3.0 (206 ± 22) • 22.0 ± 2.0 (159 ± 14) • 28.5 ± 3.0 (206 ± 22) • 28.5 ± 3.0 (206 ± 22) • 28.5 ± 3.0 (206 ± 22) • 28.5 ± 3.0 (206 ± 22) • 41.0 ± 4.0 (296 ± 29) • 28.5 ± 3.0 (206 ± 22)

Apply Loctite #262 Apply Loctite #262

M16

28 36 4 4-L 3 4 30 42-L 4 40 60-L 48 56-L 164 12

M18

4

• Engine mounting

• 23.0 ± 2.0 (166 ± 14) Apply Loctite #271

M20

10 8 2 4-L 168-L

• Swing motor mounting • Side cutter mounting • Upper roller mounting • Upper roller mounting • Shoe bolt mounting

• 55.0 ± 5.5 (397 ± 40) Apply Loctite #262 • 55.0 ± 5.5 (397 ± 40) • 55.0 ± 5.5 (397 ± 40) Apply Loctite #262 • 55.0 ± 5.5 (397 ± 40) Apply Loctite #262 • 87 ± 5.0 (629 ± 36)

M24

4

• Counterweight mounting

+0 • 105+0 -5 (760-36 )

5/8-18 UNF

2

• Idler adjuster grease fitting mounting

• 6.0 ± 1.0 (43 ± 7)

Location

Tightening torque kgf·m (lbf·ft)

Apply Loctite #262

Apply Loctite #262 Apply Loctite #262 Apply Loctite #262 Apply Loctite #262 Apply Loctite #262 Apply Loctite #262 Apply Loctite #262 Apply Loctite #262 Apply Loctite #262 Apply Loctite #262 Apply SAE30 CD

Apply Loctite #262

171

SECTION VI - SPECIFICATIONS

6.7 MISCELLANEOUS INFORMATION

D. CAPS AND PLUGS FOR TUBES AND HOSE FITTINGS

A. TEMPERATURE TABLE °C -10 -5 0 5 10 15 20 25 30 35 40 45 50

°F

°C

14 23 32 41 50 59 68 77 86 95 104 113 122

55 60 65 70 75 80 85 90 95 100 105 110 115

°F 131 140 149 158 167 176 185 194 203 212 221 230 239

°C 120 125 130 135 140 145 150 155 160 165 170 175 180

°F 248 257 266 275 284 293 302 311 320 329 338 347 356

°C 185 190 195 200 205 210 215 220 225 230 235 240 245

°F 365 374 383 392 401 410 419 428 437 446 455 464 473

°C 250 255 260 265 270 275 280 285 290 295 300 305 310

°F 482 491 500 509 518 527 536 245 554 563 572 581 590

°C 315 320 325 330 335 340 345 350 355 360 365 370 375

°F 599 608 617 626 635 644 653 662 671 680 689 698 707

Tube & hose plugs

Ø Diameter 10 mm 15 mm 18 mm 22 mm 28 mm

F18505gb Example of how to convert 45°C to °F: °F = 1.8 X °C + 32 °F = 1.8 X 45 + 32 = 81 + 32 = 113˚F ° Example of how to convert 122˚F to C ° ° ° ° C = 0.56 ( F - 32) C = 0.56 (122 - 32) = 0.56 X 90 = 50 C

35 mm

B. SPECIAL PIPE WRENCHES A

B

"D" "C"

C

F

D

E A

B

C

"B"

F16263

"A" Dia. (Ø)

G

TUBE DIA.

Male PF Plugs

Unit : mm (in) D

E

F

"A" Dia. (ø)

G

15 (0.591)

16 40 8 12.7 22 27 70 (1.06) (2.76) (0.87) (0.50) (0.32) (1.57) (0.63)

18 (0.709)

19 42 11 12.7 22 70 32 (1.26) (2.76) (0.87) (0.50) (0.43) (1.65) (0.75)

22 (0.866)

23 48 12.7 11.5 22 70 36 (1.42) (2.76) (0.87) (0.50) (0.44) (1.89) (0.91)

28 (1.10)

29 60 12.7 14.5 22 109 41 (1.614) (4.29) (0.87) (0.50) (0.57) (2.36) (1.14)

35 (1.38)

41 81 20.5 20 45 90 55 (2.17) (3.54) (1.77) (0.79) (0.81) (3.19) (1.61)

60˚

Unit : mm (in)

F18507gb

C. WEIGHT OF MATERIALS TABLE lb/yd3 700 750 950 1170 1600 1780 2100 2100 2250 2400 2500 2550 2600 2700 2800 2800 2850 2900 3100 3400

kg/m3 420 440 560 690 950 1050 1250 1250 1330 1420 1480 1510 1540 1600 1660 1660 1690 1720 1840 2020

Material (loose weight) Wood chips Peat, dry Cinders Peat, wet Topsoil Coal Caliches Earth, loam Shale Sand, dry Clay, dry Earth, dry Limestone, broken or crushed Earth, wet Clay, wet Rock, granite, blasted & broken Sand, moist Sand and gravel, dry Sand, wet Sand and gravel, wet

PLUG SIZE

"A" O.D. (Ø)

"B" LENGTH

"C" LENGTH

"D" FLATS

PF 1/4

13.5

16.5

24.5

14

PF 3/8

16.6

17.5

25.5

17

PF 1/2

20.6

20.0

31.0

22

PF 3/4

26.2

21.5

34.0

27

PF 1

33.3

23.5

36.0

36 F18509gb

Female PF caps SIZE PF 1/4 PF 3/8 PF 1/2 THREAD SCREW

PF 3/4 F16264

PF 1 PF 11/4

F18508gb

172

F16265

Section VII TROUBLESHOOTING

SECTION VII - TROUBLESHOOTING

7.1 GENERAL TROUBLESHOOTING This troubleshooting information covers the components and systems as described in this MANUAL. Should in depth troubleshooting, repair or replacement of components or adjustment of valves be required, contact your Dealer for assistance.

OPERATING Problem

Probable cause

Possible remedy

All operating speeds are slow or power is lost.

Low hydraulic oil level.

Fill oil to specified level.

Air leaking into the suction pipe.

Tighten suction pipe hose clamp or replace hose.

Hydraulic pump is damaged.

Repair or replace.

Pilot gear pump is damaged.

Repair or replace.

Main relief valve is not adjusted correctly.

Adjust or replace.

Pilot relief valve is not adjusted correctly.

Adjust or replace.

Cylinder seal is damaged.

Repair or replace.

Control valve or overload valve functions incorrectly or there are signs of air in the cylinder.

Repair or replace/Bleed air from cylinder.

Pilot valve is damaged.

Repair or replace.

Pilot valve piping is loose.

Retighten.

Cylinder seal is scored.

Repair or replace.

Control valve or overload valve is damaged.

Repair or replace.

Overload valve is not operating.

Repair or replace.

Pilot valve is damaged.

Repair or replace.

Brake valve is not working.

Repair or replace.

Hydraulic motor (swing) is not working or slewing gear is damaged.

Repair or replace.

Swing bearing is damaged.

Repair or replace.

Pilot valve is not working.

Repair or replace.

Swing reduction unit is damaged.

Repair or replace.

A specific cylinder functions improperly or loses power.

The cylinder position will not hold with operating lever in neutral.

Machine does not swing.

174

SECTION VII - TROUBLESHOOTING OPERATING Problem

Probable cause

Possible remedy

Swing speed is slow.

Brake valve is not working.

Repair or replace.

Control valve is not working.

Repair or replace.

Hydraulic motor (swing) is not working.

Repair or replace.

Repair or replace.

Hydraulic pump is not working.

Abnormal sound occurs when swing.

With swing stopped, the machine drifts and is hard to control.

Insufficient lubrication of slewing gear and bearings.

Grease.

Low oil level in the swing reduction unit.

Refill with proper oil.

Brake valve malfunctions.

Repair or replace.

Set pressure of brake valve is incorrect.

Adjust or replace.

Brake lining is worn.

Repair or replace.

175

SECTION VII - TROUBLESHOOTING TRAVEL Problem

Probable cause

Possible remedy

Machine does not travel smoothly.

Too much track tension.

Adjuster track tension.

Dirty track links and shoes.

Clean tracks.

Brake valve is not working.

Repair or replace.

Travel reduction unit is damaged.

Repair or replace.

Hydraulic pump is damaged.

Repair or replace.

Poor engine performance.

Repair or replace.

Main relief valve pressure is set incorrectly.

Adjust or replace.

Low hydraulic oil level.

Fill to proper level.

Hydraulic motor (travel) is not working.

Repair or replace.

Brake valve is not working.

Repair or replace.

Seal in swivel joint is scored or oil is leaking.

Repair or replace.

Unequal tensions on tracks.

Adjust tension.

Set pressures of main relief valves unbalanced.

Adjust.

Performances of hydraulic travel motor has deteriorated.

Repair or replace.

Traveling power is insufficient.

Machine does not travel in a straight line.

176

SECTION VII - TROUBLESHOOTING HYDRAULIC Problem

Probable cause

Possible remedy

Temperature rise in the hydraulic oil temp.

Oil cooler core clogged.

Clean.

Engine fan belt slipping.

Adjust or replace.

Low hydraulic oil level.

Refill to specified level.

Wrong type hydraulic oil used.

Replace with correct, new oil.

Hydraulic pump is not working.

Repair or replace.

177

SECTION VII - TROUBLESHOOTING GAUGE CLUSTER DISPLAY Problem

Probable cause

Possible remedy

Engine oil pressure is too low.

(Buzzer sounds and icon displays).

Engine oil level low.

Fill to specified level.

Oil leaking.

Repair and fill to proper level.

Wrong oil viscosity.

Replace with proper oil.

Low coolant.

Fill to proper level.

Coolant leaking.

Repair and fill to proper level.

Loose radiator cap.

Tighten.

Radiator core clogged.

Clean cooling system.

V-belt loose or damaged.

Tighten to proper tension.

Rust or scale in coolant.

Flush system/fill to level.

Faulty thermostat.

Replace.

Clogged air cleaner.

Replace elements.

Hoses from air cleaner to turbo clogged.

Clean, repair or replace.

Abnormal rise in the coolant temperature.

(Buzzer sounds and icon displays).

Air cleaner clogged.

178

SECTION VII - TROUBLESHOOTING ENGINE Problem

Probable cause

Possible remedy

Starter does not turn or turns slowly which does not start the engine.

Battery disconnected.

Connect.

Battery discharged.

Charge.

Battery terminals disconnected, loose, or corroded

Clean and connect.

Ground cable disconnected.

Connect.

Engine oil viscosity too thick (Cold Weather)

Change to proper oil.

Insufficient fuel.

Refuel.

Improper starting procedure.

Refer to section “BASIC MACHINE OPERATION”.

Air in fuel line.

Bleed.

Clogged fuel filter.

Replace element.

Clogged air cleaner.

Replace elements.

Air heater circuit malfunctioning.

Check circuit.

Low idling RPM.

Contact authorized workshop/Dealer.

Fuel filter clogged.

Replace element.

Air cleaner clogged.

Replace elements.

Improper valve clearance.

Contact authorized workshop/Dealer.

Fuel filter clogged.

Replace element.

Air cleaner clogged.

Replace element.

Improper valve clearance.

Contact authorized workshop/Dealer.

Loose clamps on the air inlet hose (with turbo charger).

Tighten clamps.

Cracked air inlet hose (with turbo charger).

Replace hose.

Insufficient coolant

Refill coolant.

Clogged radiator.

Clean cooling components.

V-belt to loose or damaged.

Adjust or replace belt.

Faulty thermostat.

Replace.

Air cleaner clogged.

Replace elements.

Improper valve clearance.

Contact authorized workshop/Dealer.

Starter turns but engine does not start.

Engine tends to stop at low speed.

No power.

Engine overheats.

Engine exhaust is black.

179

SECTION VII - TROUBLESHOOTING ENGINE Problem

Probable cause

Possible remedy

Poor fuel consumption.

Fuel leak.

Contact authorized workshop/Dealer.

Air cleaner clogged.

Replace elements.

Loose clamps on suction hose (with turbo charger).

Tighten clamps.

Cracked suction hose (with turbo charger).

Replace w/new hose.

Improper oil.

Replace with correct oil.

Oil leak.

Contact authorized workshop/Dealer.

Improper oil replacement intervals.

Change at correct interval.

Improper warming-up operation.

Refer to the section III “MACHINE WARM UP”.

Low oil volume.

Fill to specified level.

Oil leak.

Contact authorized workshop/Dealer.

Improper oil viscosity.

Replace with proper oil.

Battery teminals disconnected loose, or corroded.

Clean and tighten terminals.

Low battery electrolyte.

Fill cells w/distilled water.

V-belt loose or damaged.

Adjust or replace belt.

Defective battery.

Replace battery.

Excessive oil consumption.

Engine oil pressure does not rise.

Battery dies often.

180

Section VIII OPTIONAL EQUIPMENT

SECTION VIII - OPTIONAL EQUIPMENT

8.1 HYDRAULIC BREAKER A. SELECTION OF THE HYDRAULIC BREAKER When mounting the breaker on the hydraulic excavator, it is necessary to match stability, hydraulic pressure, and the oil level for each breaker. To select hydraulic breakers, contact your Dealer.

B. BEFORE OPERATING THE HYDRAULIC BREAKER Consult your Dealer for the piping needed for the boom and arm when installing a hydraulic breaker.

REPLACE THE HYDRAULIC RETURN FILTER ACCORDING TO THE REPLACEMENT SCHEDULE TABLE IN CHAPTER “MAINTENANCE FOR NIBBLER / BREAKER”. Thoroughly read the hydraulic breaker operation manual and SAFETY PRECAUTIONS from this section, as well as the safety precaution’s section on this manual to avoid damaging the machine or hydraulic breaker during operation. SELECT THE APPROPRIATE HYDRAULIC FLOW FOR THE BREAKER BY FOLLOWING THE INSTRUCTIONS DETAILED IN PARAGRAPH “E. BREAKER AND NIBBLER SELECTOR SWITCH”.

C. HYDRAULIC OIL LEVEL CHECK AND CONTAMINATION PREVENTION When the hydraulic breaker is not installed on the machine, attach the blank plugs to the tube end on the arm-bucket end and the hose end on the hydraulic breaker side to prevent dust and water from entering into the piping.

Before starting operation, check the capscrews on the tube fixing clamps for looseness, and the connections of the tubes and hoses for oil leakage.

D. BASIC OPERATION

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

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

2. Move throttle control to the “HI” idle position.

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

SAFETY LOCK LEVER IN UNLOCKED (DOWN) POSITION F16271

182

SECTION VIII - OPTIONAL EQUIPMENT 4. Release control pedal lock rod.

5. Make certain breaker or nibbler is in desired position and against material to be broken.

6. Place right foot on pedal and depress with toe to activate breaker.

7. Operate breaker for one minute then release pedal.

WARNING Operation of breaker or nibbler longer than one minute intervals could cause premature wear or damage to the attachment and the machine. If material is not breaking, reposition breaker or nibbler and repeat operation in one minute intervals.

PUSH LOCK ROD FORWARD TO RELEASE

PULL LOCK ROD BACKWARD TO LOCK PEDAL

DEPRESS PEDAL WITH TOE TO ACTIVATE

F16272

WARNING Never leave the operator cab with engine running.

E. BREAKER AND NIBBLER SELECTOR SWITCH This machine is provided with breaker single circuit and nibbler and breaker Bi direction flow circuit. To use breaker or nibbler, select circuit appropriate to the specification through switch on the rear side of operator’s seat.

1. Switch position F16273

Specification

Switch Position

Circuit

Breaker

Single flow

Nibbler

Bi direction flow

CAUTION Never turn switch on (Bi direction flow) to operate breaker. It may cause damage of machine.

183

SECTION VIII - OPTIONAL EQUIPMENT F. CONTROL PEDAL 1. Hydraulic breaker single circuit Release pedal lock on the right front side of operator’s seat to operate pedal.

CAUTION Precaution for pedal operation.

The operation varies in the specifications, so before operating, read the operator’s manual carefully.

Foot Pedal Depressing Section

Operating Condition

Depress toe section

Breaker starts operation

Pedal in neutral section

Breaker stops operation

PUSH LOCK ROD FORWARD TO RELEASE TOE

2. Nibbler and breaker combined circuit (conflux) Release pedal lock on the right front side of operator’s seat to operate pedal.

PULL LOCK ROD BACKWARD TO LOCK PEDAL F16274

DEPRESS PEDAL WITH TOE TO ACTIVATE

Hydraulic breaker

HEEL

Foot Pedal Depressing Section

Operating Condition

Pedal in neutral section

Breaker stops operation

Depress heel section

Breaker starts operation

WARNING Never leave the operator cab with engine running.

Nibbler Foot Pedal Depressing Section

Operating Condition

Depress toe section

Nibbler close

Depress heel section

Nibbler open

184

SECTION VIII - OPTIONAL EQUIPMENT G. SETTING SELECTOR VALVE For machines provided in nibbler and breaker specification, the selector valve installed on the main control valve is required to be switched to the position corresponding to the specification.

(A)

NOTE: • Inappropriate switching of selector valve may cause decrease of work efficiency and operating speed due to inferior operation, and also cause damage of machine. Securely switch selector valve.

• Be sure to switch selector valve 1 or 2 times a month periodically.

TO HYD. TANK

1. Tools used Selector Valve (A)

Circuit

TO HYD. TANK

SOCKET BOLT

SOCKET BOLT

Tools

TO C/V (A02)

TO C/V

TO ATT (A02)

TO ATT

Main (circuit) Spanner (24 mm) Allen Wrench (5 mm)

F16457

USE BREAKER

USE NIBBLER

2. Setting procedure a. Use an allen wrench to loosen and remove the socket bolt. b. Use a spanner to turn the selector valve to the proper position. c. After the valve is in the proper position, tighten the socket bolt. d. Markings of the selector valve are shown below.

B: Breaker N: Bi direction flow of nibbler H. SETTING STOP VALVE Stop valve on arm top end is used to stop hydraulic oil flowing.

Free: Hydraulic oil flows.

Stop: Hydraulic oil stops flowing.

Before removing attachment, set stop valve to “STOP” position.

(B)

1. Tools used Stop valve (B)

Circuit

Tools

Main (Arm)

Spanner (24 mm) mm 24

F16276

FREE

STOP

185

SECTION VIII - OPTIONAL EQUIPMENT

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

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

F16277

A. USE FOR INTENDED PURPOSE Use the attachment only for its intended purpose. If not used in accordance with the manufactures instructions, the excessive pressure exerted on the boom, arm and frame structure of the machine will cause premature failure of the components.

B. PASSENGERS Never allow passengers on the attachment or machine.

C. PROTECTIVE EQUIPMENT When operating attachments that produce flying debris, it is highly recommended to procure and install protective guards on the machine and close the all window to protect the operator from flying debris. Also the operator and all personnel in the vicinity of the machine should wear protective gear such as safety shoes, hard hat, gloves and face shield or goggles.

INSTALL GUARD AND CLOSE WINDOWS F16278

D. CYLINDERS Do not operate boom, arm or bucket cylinders at stroke ends when using a breaker attachment. Doing this can cause undue stress on the cylinder rods and result in damage.

F16279

E. AVOID CONTINUOUS OPERATION Operate the nibbler/breaker in 60 sec. intervals.

Operation for longer than 60 sec. at a time can cause high oil temperatures and damage the accumulators, cylinder seals and possibly pump damage.

Within One Minute

FREE

F16280

186

SECTION VIII - OPTIONAL EQUIPMENT F. HOSE SURGE Should the hydraulic hoses begin to surge or vibrate abnormally during operation of a Breaker or Nibbler, immediately stop operation and contact your Dealer for assistance. This problem often is a result of damaged accumulators and can also result in valve failure.

F16281

G. DO NOT USE DROPPING FORCE Never use the dropping force of the attachment to break or drive objects. This will cause extensive damage to the attachment and machine structure.

F16282

H. DO NOT USE SLEW FORCE Never use the slew force of the machine for pushing or sliding objects. This will cause premature failure of the attachment and other machine components.

F16283

I. DO NOT LIFT Never use an optional attachment to lift or transport objects or material. Doing so can cause extensive damage to the attachment, the machine structures or cause injury or death due to slipping or dropping of load due to improper attachment.

F16284

J. WORKING RANGES Never operate an optional attachment over the sides of the machine. Only operate over the front or rear of the machine.

UNACCEPTABLE WORK RANGE

ACCEPTABLE WORK RANGE

ACCEPTABLE WORK RANGE

UNACCEPTABLE WORK RANGE F16285

187

SECTION VIII - OPTIONAL EQUIPMENT

8.3 MAINTENANCE FOR NIBBLER / BREAKER DEPRESS RUBBER CAP TO RELEASE PRESSURE

It is necessary to perform the following maintenance schedule in regard to hydraulic oil and filters along with normal inspection and maintenance as described in “MAINTENANCE” section of this manual for the nibbler / breaker optional attachment.

HYDRAULIC TANK F16354

Replacement Schedule Component

Location

1st Maintenance

2nd Maintenance

Regular Maintenance

Change Hydraulic oil

Hydraulic tank

-

-

Every 500 hours

Return filter element kit

Hydraulic tank

50 hours

250 hours

Every 250 hours

8.4 REINFORCEMENT OF ATTACHMENT The use of machine with breaker and nibbler may cause damage of attachment. So contact your Dealer to reinforce arm.

188

SECTION VIII - OPTIONAL EQUIPMENT

8.5 EXTRA (GRAPPLE, CLAMSHELL, ETC) & BREAKER A. BASIC OPERATION

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

SAFETY LOCK LEVER IN UNLOCKED (DOWN) POSITION F16271

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

2. Move throttle control to the “HI” idle position.

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

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

5. Place left foot on pedal and depress with toe to close attachment and depress back of pedal with heel to open attachment.

6. After operation is complete or operator is required to leave the machine, place pedal lock rod in the locked position, position attachment in hydraulic oil check position, move throttle control to “LO” idle position.

PUSH LOCK ROD FORWARD TO RELEASE

DEPRESS PEDAL WITH TOE TO ACTIVATE

PULL LOCK ROD BACKWARD TO LOCK PEDAL EXTRA SPEC.

SUPPLEMENTARY EXPLANATION For machine provided in extra & breaker specification, before starting operating, unlock left control pedal.

THROTTLE CONTROL

WARNING Never leave the operator cab with engine running.

PUSH LOCK ROD FORWARD TO RELEASE

DEPRESS PEDAL WITH TOE TO ACTIVATE

PULL LOCK ROD BACKWARD TO LOCK PEDAL BRAKER SPEC. F16287

189

SECTION VIII - OPTIONAL EQUIPMENT B. SETTING THE STOP VALVE (ENGINE OFF)

(A)

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

1. Arm Stop Valves 1. Locate the two stop valves on the arm.

2. Remove the socket bolt with an allen wrench.

3. Using a spanner wrench, turn the stop valve free position.

4. Reinstall the socket bolt and tighten securely.

(A)

REMOVE SOCKET BOLT

TURN STOP VALVE TO “STOP” SETTING

mm 24

NOTE: When the extra and breaker are used, the stop valve on the arm top should be set to the free position.

F16458

FREE

2. Tools Used STOP VALVE

POSITION

(A)

ARM

TOOLS SPANNER (24 mm) ALLEN WRENCH (5 mm) F19038gb

190

STOP

SECTION VIII - OPTIONAL EQUIPMENT

8.6 DOZER BLADE SPECIFICATIONS The specifications found in this section are given on the standard E115SR No modifications or options are taken into consideration in regard to these specifications.

A. DOZER BLADE WORKING RANGES These dimensions consider the following: a. Standard boom ................. 4.26 m (15´-0˝) b. Standard arm ....................... 2.2 m (7´-3˝) c. Bucket 0.45m3 ........................ (0.59 cu yd) d. Shoe ............... 600 mm (23.6˝) triple grouser

2740 mm

2810 mm

7520 mm

2590 mm F16459

B. MACHINE DIMENSIONS

(19’-2”) (21’-1”)

540 mm 490 mm

DOZER BLADE WORKING RANGES

F16460

2310 mm (7’-7”)

191

SECTION VIII - OPTIONAL EQUIPMENT

(8´-6˝)

(1´-10˝)

2590 mm

570 mm

C. STRAIGHT & ANGLE DOZER SPECIFICATIONS

˝)

0 603m 613 R , 1

m-4 m (5´

R

F16461

FEATURES Length (From the center of the arm fixing pin to the tip of the blade)

E115SR R1630 mm (5´-4˝)

Width [600mm (23.6˝) shoe only]

2590 mm (8´-6˝)

Height

570 mm (1´-10˝)

Weight

455 kg (1,000 lb)

Set Pressure of Main Relief Valve

20.6 MPa (210 kgf/cm2)

Set Pressure of Overload Relief Valve

27.5 MPa (280 kgf/cm2) F19039gb

192

Section IX SPECIAL PROCEDURES

SECTION IX - SPECIAL PROCEDURES

9.1 GENERAL The machine incorporates automatically applied spring brake systems in the travel motors and swing motors. These systems will automatically engage the brakes when the engine is stopped, making it possible to move the machine. This section contains the required procedures for releasing the travel motor brakes, the swing motor brake and lowering the attachments to the ground should sudden engine failure be experienced.

ATTACHMENTS ON GROUND

CHOCK BLOCKS AT FRONT AND REAR OF EACH TRACK

F16462

WARNING Read, understand and follow all safety precautions and procedures found in this manual before attempting any operation, inspection, maintenance or repairs of this machine, attachment or any or its systems.

WARNING Make certain chock blocks are secure at front and rear of each track before attempting to release brakes.

Never stand in the path of the tracks when releasing brakes.

WARNING The procedures found in this section should be performed by a well trained experienced service technician.

KEY SWITCH IN “OFF” POSITION HE

AT

OF

F

ACC

ON T AR ST

A. TOOLS AND EQUIPMENT REQUIRED 1. Four chock blocks.

2. One allen wrench for drain plug.

3. Hammer and punch one each.

4. Drilling device for 2 mm diameter.

5. Two 5.0 Liter (1.3 Gal) capacity drain pans.

6. Rubber or soft faced mallet.

HI

LO

9.2 RELEASING TRAVEL MOTOR BRAKES

F16141

B. PROCEDURES NOTE: Make sure to align the plugs on the travel motor covers perpendicular to the ground, before shutting off the engine.

FILL PLUG

1. Place chock blocks at front and rear of each track to prevent machine from moving when brakes are released.

CHECK PLUG

F16463

194

DRAIN PLUG

SECTION IX - SPECIAL PROCEDURES 2. Lower attachment to ground. See “HOW TO LOWER ATTACHMENT” in this section for proper procedures.

3. Turn key switch “OFF” and remove key.

4. Remove check / fill plug from each travel motor using the 10 mm allen wrench.

5. Place a clean 5 liter (1.3 Gallon) capacity drain pan under each travel motor drain plug and remove drain plug using the 8 mm allen wrench.

6. After all of the gear oil has drained, cover the drain pans to prevent contamination and move them to an area away from the machine.

7. Remove the plate mounting bolts from the travel motor reduction unit cover plates.

2,5 LITER (0.7 GAL) CAPACITY DRAIN PAN

F16464

REMOVE MOUNTING BOLTS WITH 10 mm SOCKET WRENCH

8. Remove the covers from both travel reduction units to expose the planetary gears.

CAUTION Be careful not to damage lip of cover plate. Any damage to the lip could result in a gear oil leak.

CAUTION When removing the following components it will be necessary to have a clean area free of dirt and grit to lay these components.

195

SECTION IX - SPECIAL PROCEDURES 9. Remove the ball and sun gear.

BALL

F16467

10. Carefully remove “Sun gear” from the planetary gear assembly by hand and lay it aside.

11. Install cover plates onto housings and tighten all bolts securely.

12. Install fill and drain plugs into cover plates and replace gear oil into travel reduction units through fill / check port to proper level.

13. After steps 4 through 12 have been performed on both travel reduction units, the machine may be towed to an area where repairs can be made.

14. After repairs are made reinstall the “Drive Gear” in reverse order. Use the following torque specifications for bolts and plugs.

TORQUE SPECIFICATIONS COVER BOLTS: 10.4 kgf·m (75 lbf·ft) PLUGS: 5 ~ 6.5 kgf·m (36 ~ 47 lbf·ft) (Use thread Sealant on Plugs)

NOTE: Refer to section “MAINTENANCE” for proper oils specification and capacity.

NOTE: Install new o-ring seals on cover plates after all repairs are completed.

196

INSTALL NEW O-RINGS

SECTION IX - SPECIAL PROCEDURES

9.3 LOWERING ATTACHMENT WHEN SUDDEN ENGINE FAILURE OCCURS A. HOW TO LOWER ATTACHMENT The port relief valve is used to return the oil remaining in the cylinder to the hydraulic tank to protect the piping when the pressure inside of piping rises higher than the set pressure owing to the external load exerted on the cylinder, and also may be used as a measure to lower attachment when the engine stops owing to trouble, etc.

After loosening lock nut of port relief valve as adjuster screw is loosened the set pressure gradually falls.

POPPET

PISTON

When the set pressure decreases lower than the hold pressure of cylinder currently holding attachment, the above hold pressure opens the poppet, the plunger moves rightward and the continuity from P to R is made. And the oil remaining in the cylinder returns to the tank.

With this, attachment can be brought down to the ground while engine stops.

NOTE: Before loosening adjuster screw, mark those positions, and after bringing down attachment to the ground, tighten adjuster screw to the marked positions.

LOCK NUT

P

P R

PLUNGER

R SEAT

SPRING

ADJUSTER SCREW

TO TANK

BUCKET SLEWING TRAVEL LEFT

BOOM SPOOL

TRAVEL RIGHT TRAVEL STRAIGHT PBb

PAb Drc

BOOM BOOM ARM ARM ARM RECIRCULATION

(CRb) R

R

H

H

Ab Bb (LCb)

BOOM CYLINDER F16470

197

SECTION IX - SPECIAL PROCEDURES B. HOW TO LOWER ATTACHMENT When engine stops because of troubles, the relief valve incorporated in the holding valve mounted on the boom cylinder head side is available to lower attachment.

As shown in the figure, after loosening lock nut of stop valve as setscrew is loosened, the poppet is opened and then the oil remaining in the boom cylinder head side returns to the tank through T port enabling attachment to be lowered.

HOLDING VALVE

RELIEF VALVE

NOTE: After lowering attachment, tighten the above setscrew to the specified torque without fail.

CAUTION Be careful when lowering attachment. Do not stand under boom.

LOCK NUT

F16301

9.4 HYDRAULIC TANK PRESSURE How to release air pressure remaining in the hydraulic tank.

After engine stops, the air pressure remaining in the hydraulic tank can be released by pushing valve on the air breather rubber cap several times (5 ~ 7 times). Air breather is mounted on the upper part of hydraulic tank.

DEPRESS RUBBER CAP TO RELEASE PRESSURE

F16302

198

SECTION IX - SPECIAL PROCEDURES

9.5 RELEASING SWING BRAKE

WARNING Make certain that the attachment is on the ground to help prevent sudden rotation of the upper structure before attempting to release the swing brake. Refer to section X “LOWERING ATTACHMENT WHEN SUDDEN ENGINE FAILURE OCCURS”.

A. TOOLS & EQUIPMENT REQUIRED 1. Handtools required for removal of hydraulic tubes, hoses and fittings 2. Plugs and caps for tubes, hoses and fittings 3. 14 mm allen wrench 4. 6 mm allen wrench 5. Overhead lifting device capable of lifting and holding 45 kg (100 lb) 6. Plenty of clean, dry shop rags 7. Torque wrenches B. PROCEDURES 1. Lower attachment to ground. Refer to

INSTALL PROPER CAPS AND PLUGS ON HOSES, TUBES AND FITTINGS TO HELP PREVENT CONTAMINATION ENTERING THE SYSTEM F16305

previous page for proper procedures in lowering the attachment.

2. Remove all hoses and tubes from the swing motor top plate and swing valve to gain access to the top plate mounting bolts.

3. Install the proper plugs and caps onto hoses, tubes and fittings to avoid the possibility of contamination entering the hydraulic system.

M12-1.75X20mm LIFTING EYE

CAUTION Use only plugs and caps designed to properly seal the specific hose, tube or fitting they are to be installed on.

4. Thoroughly clean the top of the slewing motor and slewing valve removing all dirt and debris.

NOTE: Place a large quantity of clean, dry shop rags around the swing motor to help catch any overflow of hydraulic oil from the removal of the top plate.

LOOSEN FOUR TOP PLATE ATTACHING BOLTS

5. Loosen the four top plate attaching bolts with the 14 mm allen wrench.

199

SECTION IX - SPECIAL PROCEDURES 6. Remove two top plate mounting bolts from corners opposite of each other.

7. Attach overhead lifting device to the lifting eyes and remove most of the slack from the cable or chain.

8. Carefully remove the remaining two bolts from the top mounting plate.

REMOVE TWO BOLTS, OPPOSITE CORNERS OF EACH OTHER

NOTE: The top plate will raise from spring pressure as the last two bolts are removed. Some movement of the upper frame may be experienced as the spring tension is released.

9. Using the overhead lifting device, carefully lift the swing motor top cover with swing shockless valve assembly and away from the swing motor.

REMOVE ALL SPRINGS

CAUTION Do not allow any dirt or debris to enter the swing motor or settle on the top plate.

10. Carefully remove all brake springs and place in a container filled with fresh, clean hydraulic oil. Then, seal the container to prevent contamination.

11. Align the holes of the distributor plate in the swing motor until they are located toward the front and back of the swing motor housing.

12. Carefully place the top plate over the swing motor and align the dowel pins of the top plate with the holes in the distributor plate.

13. Carefully and slowly lower the top plate into position on the swing motor and install, by hand, the four top plate mounting bolts.

14. Carefully and slowly lower the top plate into position on the slewing motor and install, by hand, the four top plate attaching bolts.

ALIGN DISTRIBUTOR PLATE HOLES TOWARDS FRONT AND REAR OF HOUSING

DOWEL PINS

CAUTION Make certain the top plate dowel pins and the distributor plate holes mesh together.

200

COPYRIGHT BY NEW HOLLAND KOBELCO CONSTRUCTION MACHINERY S.p.A. Strada di Settimo, 323 - 10099 S. MAURO T.SE ( TO ) ITALY

Reproduction of text or illustrations, in whole or in part, is strictly prohibited

Print No. 604.21.538.00 - 02 - 2005