New Holland E80BMSR Hydraulic Excavator Operator's Manual S2LF00013ZE01 - PDF DOWNLOAD

OPERATOR’S MANUAL E80BMSR

Hydraulic Excavator from PIN LF06 - 04501 and higher

Part number S2LF00013ZE01 1st edition English October 2010

E80BMSR HYDRAULIC EXCAVATOR

OPERATOR’S MANUAL

Part Number: S2LF00013ZE01

Applicable PIN Number LF06 -04501 and higher

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

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

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

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

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

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

DANGER: Indicates an immediate hazardous situation that, if not avoided, will result in death or serious injury. The color associated with Danger is RED.

●

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

●

CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices. The color associated with Caution is YELLOW.

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

The first panel indicates the nature of the hazard.

●

The second panel indicates the appropriate avoidance of the hazard.

●

Background color is YELLOW

●

Prohibition symbols such as

and

STOP

if used, are RED.

IMPROPER OPERATION OF THIS MACHINE CAN CAUSE DEATH OR SERIOUS INJURY. BEFORE USING THIS MACHINE, MAKE CERTAIN THAT EVERY OPERATOR: ●

Is instructed in safe and proper use of the machine.

●

Reads and understands the Manual(s) pertaining to the machine.

●

Reads and understands ALL Safety Decals on the machine.

●

Clears the area of other persons.

●

Learns and practices safe use of machine controls in a safe, clear area before operating this machine on a job site.

It is your responsibility to observe pertinent laws and regulations and follow CNH America LLC instructions on machine operation and maintenance.

WARNING_01_NA

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

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

Wash hands after handling.

Copyright © 2010 CNH America LLC All Rights Reserved New Holland is a registered trademark of CNH America LLC

TABLE OF CONTENTS GENERAL INFORMATION To the Owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Right, Left, Front, and Rear of the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Machine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Identification Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 2 SAFETY, DECALS, AND HAND SIGNALS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Location of Warning Labels and Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hand Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1 1-2 1-3 1-4

. . . . . 2-1 . . . . . 2-3 . . . . . 2-3 . . . . . 2-5 . . . . 2-10 . . . . 2-11 . . . . 2-22

CHAPTER 3 INSTRUMENTS AND CONTROLS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Operator Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator Cab Controls and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1 3-3 3-7 3-9

CHAPTER 4 OPERATING INSTRUCTIONS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Before Operating the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Operating the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Starting and Stopping Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Machine Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Operating and Travel Controls Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Machine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Machine Attachment and Swing Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 Practices to Improve Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28 Prohibited Work In Use Of Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32 Prohibited Work In Use Of Nibbler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37 Precaution for Breakers from Different Manufacturers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40 Use of an Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41 Proportional Hand Control (Extra, Nibbler, and Breaker) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43 Proportional Hand Control (Nibbler and Breaker) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45 Proportional Hand Control (Extra) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46 Handling Suspended Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47 CHAPTER 5 TRANSPORTATION . . . . . . . . . . . . . . . .

Table of Contents . . . . . . . . . . . . . . . . . . .

Transporting the Machine . . . . . . . . . . . .

Securing the Machine . . . . . . . . . . . . . . .

Lifting the Machine . . . . . . . . . . . . . . . . . .

Installation and Removal of Mirrors . . . . .

Machine Storage . . . . . . . . . . . . . . . . . . .

...... ...... ...... ...... ...... ...... ......

....................................... ....................................... ....................................... ....................................... ....................................... ....................................... .......................................

. . . . . 5-1 . . . . . 5-1 . . . . . 5-3 . . . . . 5-6 . . . . . 5-8 . . . . 5-10 . . . . 5-13

I

CHAPTER 6 MAINTENANCE AND ADJUSTMENTS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Lubricant, Fuel and Coolant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Maintenance Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 Inspection and Maintenance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 When Required Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 Daily (8 Hour) Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25 50 Hour (Weekly) Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35 100 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39 120 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40 250 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42 500 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52 1000 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62 2000 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-67 5000 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-76 Special Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-79 CHAPTER 7 ELECTRICAL Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuses and Relay Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fusible Link (for Starter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechatro-Controller (CPU) and Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

...... ...... ...... ...... ...... ...... ......

..... ..... ..... ..... ..... ..... .....

7-1 7-3 7-5 7-5 7-6 7-6 7-6

CHAPTER 8 SPECIFICATIONS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Shoe Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Working Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Bucket and Arm Combinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 Lifting Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 CHAPTER 9 INDEX

II

CHAPTER 1 - GENERAL INFORMATION

GENERAL INFORMATION TO THE OWNER E80BMSR HYDRAULIC EXCAVATOR

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

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

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

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

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

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

Always keep this manual in the operator's compartment (in the seat back, behind the operator's seat). Make sure it is complete and in good condition. If you wish to obtain extra copies, or copies in languages other than that of the country of use, consult your authorized New Holland Construction, LLC Dealer. Your New Holland Construction Dealer is available for any further information. They will also provide any after sales service you may need, and genuine New Holland spare parts, your guarantee of quality and match. Contact your dealer for operator manuals translated into Spanish or French Canadian.

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

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

1-1

CHAPTER 1 - GENERAL INFORMATION

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

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

1

6

6

4

3

5

5

2 DC03H142

1. FRONT 2. REAR

1-2

3. RIGHT HAND SIDE 4. LEFT HAND SIDE

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

CHAPTER 1 - GENERAL INFORMATION

MACHINE COMPONENTS 12

11

13

15 14

7 30 29 10

6

5 4

9 3

16 17

34

19 20

21 18

2 22

32 1

23 24

25 26

8

28

27 31 ULFX1301004B01

MACHINE COMPONENTS

1.

2.

3.

4.

5.

6.

7.

ISUZU ENGINE HYDRAULIC PUMP ENGINE MUFFLER MAIN CONTROL VALVE HYDRAULIC OIL TANK FUEL TANK SWING MOTOR

10.

11.

12.

13.

14.

15.

16.

BOOM ARM CYLINDER ARM BUCKET CYLINDER IDLER LINK BUCKET LINK BUCKET

19.

20.

21.

22.

23.

24.

25.

DOZER BLADE 28.

TRACK SHOE ASSEMBLY29.

TRACK IDLER 30.

TRACK SPRING 31.

LOWER ROLLER 32.

UPPER ROLLER 33.

TRACK GUIDE 34.

8. SWIVEL JOINT

17. OPERATOR CAB

26. SLEWING RING

9. BOOM CYLINDER

18. DOZER CYLINDER

27. BATTERY

TRAVEL MOTOR ENGINE RADIATOR OIL COOLER COUNTERWEIGHT ENGINE AIR CLEANER ENGINE HOOD SWING FLASHER

1-3

CHAPTER 1 - GENERAL INFORMATION

IDENTIFICATION NUMBERS MODEL, SERIAL NUMBER, AND YEAR OF MANUFACTURE

ENGINE

When orde rin g p ar ts, o btaining in for mation or a ss ist a n ce, a lway s su p p ly yo u r N ew H o lla n d Construction Dealer with the type and serial number of your machine or accessories.

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

UYTX2700001E01ENGINE

ENGINE ➤ Make and Model ➤ Serial Number . MACHINE SERIAL No.

COMPONENT SERIAL NUMBERS COMPONENT SERIAL NUMBERS ULFX1300005E901SERIAL

PRODUCT IDENTIFICATION PLATE

➤ Hydraulic Pump

➤ Model

➤ Swing Reduction Gear

➤ Serial Number

➤ Travel Reduction Gears

➤ Manufacturing Year

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

1-4

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

CHAPTER 2

SAFETY, DECALS, AND HAND SIGNALS TABLE OF CONTENTS SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 PERSONAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Safety Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Utility Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 OPERATOR PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting and Dismounting Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting and Stopping Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Handling Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Burn Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hazardous Chemical Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transporting Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Roll-Over Protective Structure (If equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seat Belt Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Emergency Exit Hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fire Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specific Precautions to this Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-5 2-5 2-5 2-5 2-5 2-6 2-7 2-8 2-8 2-8 2-8 2-8 2-9 2-9 2-9 2-9 2-9

DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 LOCATION OF WARNING LABELS AND DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 1. Do Not Use Counterweight Lifting Eyes Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 2. Working Above Ground Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 3. Pressurized Hot Oil Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 4. Swing Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 5. Booster Cable Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 6. Battery Cable Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 7. Hot Coolant Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 8. Engine Stop Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 9. Rotating and Hot Parts Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 10. Hot Parts Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 11. Adjusting Track Tension Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 12. Hot Parts Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 13. Handling Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 14. Prevent Battery Explosions Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 15. Handling Battery Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 16. California Proposition 65 Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 17. Handling Batttery Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 18. Handling Grease Gun Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 19. Travel Speed, Adjusting Track Tension, Leaving Machine, Read Operator’s Manual, Power Boost Switch, Engine Stop, Bucket to Cab Contact, Electrical Power Lines Leaving Machine Decal . . . . . . . . . . . . . . . . . 2-18 20. Do Not Insert Hand in the Moving Part Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 21. Lock Front Window at the Housed Position Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 22. Swing Brake Release Switch Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 23. Operation by Foot Pedal Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 24. Handling Change Lever and Selector Valve Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

2-1

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS 25. Procedure to Change Selector Valve Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20 26. Rotary Multi Control Valve Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20 27. Rotary Multi Control Valve Operation Procedure Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20 28. Keep Clear Working Area Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-21 29. Use Specified Diesel Oil for Fuel According to EPA Regulation Decal . . . . . . . . . . . . . . . . . . . . . . . . . . .2-21 29. Boom to Cab Contact Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-21 HAND SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 Raise Load Vertically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22 Lower Load Vertically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22 Move Load In Horizontally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22 Move Load Out Horizontally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22 Raise Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22 Lower Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23 Swing Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23 Swing Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23 Arm In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23 Arm Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23 Counter Rotate Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23 Counter Rotate Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-24 Travel Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-24 Travel Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-24 Close Bucket (Bucket In Or Dig) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-24 Open Bucket (Bucket Out Or Dump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-24 Turn Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-24 Turn Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25 Move This Much . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25 Move Slowly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25 Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25 Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25 Stop Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25

2-2

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

SAFETY RULES WARNING

PERSONAL SAFETY

This safety alert symbol indicates important safety message s in th is ma nual. W hen you see this symbol, carefully read the message that follows and be alert to the possibility of death or serious injury.

M171C

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

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

• The first panel indicates the nature of the hazard.

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

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

and

STOP

if

SAFETY AREA

1

1

2 BC02N198 ULFX1200002B01

1. OPERATOR’S MANUAL STORAGE SPACE

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

1. WORKING AREA 2. SAFETY AREA

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

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

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

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

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

2-3

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

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

• • • •

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

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

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

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

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

RH99G001

CALL ALL LOCAL UTILITY COMPANIES BEFORE YOU PERFORM ANY MACHINE OPERATION

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

2-4

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

OPERATOR PRECAUTIONS PERSONNEL

MOUNTING AND DISMOUNTING PRECAUTIONS

• Be prepared for emergencies. Always have a first

• Use the hand holds and steps with at least three

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

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

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

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

• Do not jump off the machine.

• Do not dismount while the machine is in motion.

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

STARTING AND STOPPING PRECAUTIONS

• Certain protective equipment should be replaced

• Walk around the machine and warn all personnel

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

See the manufacturer’s recommendation.

• Walk around the machine’s tool, attachment, or

• Do not rush. Walk, do not run.

• Know and use the hand signals required for

furthermost contact point to view operation danger area from the work site personnel view and angle.

particular jobs and know responsibility for signaling.

who

has

the

GENERAL

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

Sound the horn, if equipped, before starting.

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

• It is the responsibility of the operator to read and

• Adjust, secure and latch the seat and fasten the

understand the Operator’s Manual and other information provided and use the correct operating procedure. Machines should be operated only by qualified operators.

• Start and operate the machine only from the

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

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

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

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

• DO NOT use the bucket or attachment to lift persons or carry riders on the machine.

• Make sure that all protective guards, canopies, doors, etc. are in place and secure.

• Remove all loose objects stored in the machine.

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

seat belt before starting the machine. operator’s seat.

• Do not bypass the machine’s neutral-start system.

The neutral-start system must be repaired if it malfunctions.

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

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

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

• Park the machine on level ground whenever possible and apply the parking brake. On grades, park the machine with the wheels or track securely blocked.

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

• Remove the starter key or disconnect switch when leaving the machine parked or unattended.

2-5

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS OPERATING PRECAUTIONS

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

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

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

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

• Operate and drive the machine with care and at speed compatible with conditions. Use extra caution when operating over rough ground, on slopes, and when turning.

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

• Carry loads in recommended positions for maximum stability.

• Never lift loads in excess of capacity.

• Use the recommended machine ballast and counterweighting.

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

• Know and understand that job site conditions may

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

• Use the recommended transport devices when roading the machine.

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

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

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

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

• Check all controls in a clear area and make sure the machine is operating correctly.

• Dust, fog, smoke, etc., can decrease your vision and cause an accident. Stop the machine or decrease the speed until you can see.

• Contact

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

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

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

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

• If a part of the machine touches high voltage

• Watch for bystanders and never allow anyone to

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

be under or to reach through the machine and its equipment while operating.

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

• When roading a machine, know and use the signaling devices required on the machine.

Provide an escort for roading where required.

2-6

power: 1. Warn other workers NOT TO TOUCH THE MACHINE and to stay away from the machine.

• If you have extreme conditions, such as a fire, etc., and you are forced to leave the machine, do not step off the machine. Jump as far from the machine as possible with your feet together and do not touch the ground with your hands.

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

• DO NOT OPERATE the machine if you do not feel

• Avoid lubrication or mechanical adjustments with

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

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

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

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

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

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

MAINTENANCE PRECAUTIONS

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

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

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

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

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

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

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

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

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

DC04E084

• Before beginning any inspection or maintenance

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

• Wear protective glasses and other required safety equipment when machine.

servicing

or

repairing

the

• Wear gloves to protect hands when handling cable.

• Disconnect the battery before working on the

• Observe proper maintenance procedures.

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

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

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

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

2-7

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

• When the battery electrolyte is frozen, the battery

FUEL HANDLING PRECAUTIONS

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

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

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

• Do not fill the fuel tank completely to the top. Allow room for expansion.

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

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

• Never use fuel for cleaning purposes.

• Use the correct fuel grade for the operating season.

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

HAZARDOUS CHEMICAL PRECAUTIONS

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

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

• Before you service your machine, check the

BURN PREVENTION

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

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

Antidote: EXTERNAL - Flush with water.

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

DO NOT induce vomiting. Seek medical attention immediately.

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

M144B

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

Ventilate when charging or using in enclosed area.

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

M422A

2-8

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

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

• Check with your local environmental or recycling center or your information.

dealer for correct disposal

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

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

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

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

SEAT BELT PRECAUTIONS

1

2 DC04D529

DC04D572

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

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

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

FIRE EXTINGUISHER

1. RIGHT HAND BELT STRAP 2. LATCH MECHANISM

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

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

M422A

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

FIRE PREVENTION Remove all trash or debris from the machine each day. Check the engine area and exhaust system SPECIFIC PRECAUTIONS TO THIS MACHINE

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

• Never smoke while refueling.

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

• Do not use swinging force of the machine for operations.

• Do not perform “hammering” operation with the bucket.

• Do not use this machine for anything other than its intended purpose.

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

• Do not over exert the machine’s capacities.

• Never pull standing objects toward the machine.

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

2-9

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

DECALS Decals are affixed to the machine to remind operators of specific safety precautions in certain areas of the machine.

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

CE-NA000

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

CE-NA000

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

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

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

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

The color associated with Danger is RED.

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

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

• • • •

The first panel indicates the nature of the hazard.

The second panel indicates the appropriate avoidance of the hazard.

Background color is YELLOW Prohibition symbols such as

2-10

and

STOP

if used are RED.

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

LOCATION OF WARNING LABELS AND DECALS 19

26

21

23

21

30 24 20 VIEW II

II

28

VIEW I 29

7

3

2

25 10

III 22 I

12 9

11 8

16

1

13

4 5 14

6 15

17 18

27 VIEW ULFX1301003E01

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

DO NOT USE COUNTERWEIGHT LIFTING EYES DECAL 16.

WORKING ABOVE GROUND DECAL 17.

PRESSURIZED HOT OIL DECAL 18.

SWING DECAL (2 REQUIRED) 19.

BOOSTER CABLE DECAL 20.

BATTERY CABLE DECAL 21.

HOT COOLANT DECAL 22.

ENGINE STOP DECAL 23.

ROTATING & HOT PARTS DECAL 24.

HOT PARTS DECAL (FOR HYDRAULIC PUMP COVER) 25.

ADJUSTING TRACK TENSION DECAL 26.

HOT PARTS DECAL (FOR ENGINE OIL FILLER BRACKET)27.

HANDLING BATTERY DECAL 28.

PREVENT BATTERY EXPLOSIONS DECAL 29.

HANDLING BATTERY DECAL 30.

CALIFORNIA PROPOSITION 65 DECAL HANDLING BATTERY DECAL HANDLING GREASE GUN MULTIPLE DECALS DO NOT INSERT HAND IN THE MOVING PART DECAL LOCK FRONT WINDOW AT THE HOUSED POSITION DECAL SWING BRAKE RELEASE SWITCH DECAL OPERATION BY FOOT PEDAL HANDLING CHANGE LEVER AND SELECTOR VALVE DECAL PROCEDURE TO CHANGE SELECTOR VALVE ROTARY MULTI-CONTROL VALVE (FOR CAB REAR SIDE COVER) ROTARY MULTI-CONTROL VALVE (FOR FUEL TANK) KEEP CLEAR WORKING AREA USE SPECIFIED DIESEL OIL FOR FUEL DECAL BOOM TO CAB CONTACT DECAL

2-11

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS 1. Do Not Use Counterweight Lifting Eyes Decal Located on each side of counterweight.

DANGER

Part Number - YN20T01221P1 (2 required, one for each side of counterweight) Do not use counterweight lifting eyes to lift whole machine. Lifting eyes can fall under this load, resulting in personal injur y. Refer to Operator’s Manual for proper way to lift machine.

ULC00010026E01

2. Working Above Ground Decal Located on fuel tank Part Number - YN20T01049P1 When servicing or repairing machine, keep surfaces free of oil, water, grease, tools, etc. to avoid possible slipping and/or falling from machine, which can cause personal injury.

UYF00010011E01

3. Pressurized Hot Oil Decal Located on top of hydraulic tank

WARNING

Part Number - PW20T01007P1 Pressurized hot oil can cause burns.

Dep ress cap slowly with eng ine oil to relieve hydraulic tank pressure.

PW20T01007P1

UYH00010002e01

4. Swing Decal Located on each side of the rear counterweight Part Number - PE20T01014P1 (2 required) DANGER: Keep clear of swing area

ULC00010030E01

2-12

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS 5. Booster Cable Decal Located on battery relay cover

WARNING

Part Number - YN20T01015P2 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 upper frame of troubled machine.

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

ULC000010031E01

6. Battery Cable Decal Located on battery cover Part Number - YN20T01338P1

WARNING

Electronic hazard may cause injur y when mishandling the cable. Read operator manual for safe and proper handling.

ULC00010032E01

7. Hot Coolant Decal Located on top of engine fan shroud

WARNING

Part Number - YN20T01010P1 Steam of hot coolant can cause injury or blindness.

Never loosen or open readiator cap when coolant is hot and under pressure.

Before opening radiator cap: - Cool down engine completely.

- Cover radiator with cloth rag.

- Loosen cap slowly to relieve pressure.

ULC00010033E01

2-13

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS 8. Engine Stop Decal Located on top of engine fan shroud

WARNING

Part Number - YN20T01009P1 Rotating parts can cause personal injury.

Ke ep away fr om fan an d b elt wh en en gine is running.

Stop engine before servicing.

ULC00010034E01

9. Rotating and Hot Parts Decal Located on engine hood.

Part Number - YN20T01012P1

CAUTION

Rotating engine fan, hot engine parts and drive belt can cause severe injury. Do not open engine cover or service engine with engine running.

ULC00010035E01

10. Hot Parts Decal Located on hydraulic pump cover.

CAUTION

Part Number - YT20T01352P1 Engine may be hot which could cause burns.

Do not touch engine until it cools down.

YT20T01352P1

UYTX2701002E01

2-14

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS 11. Adjusting Track Tension Decal Located on both sides of crawler frame Part Number - YN20T01813P1 (2 required) This work must be done carefully by two people.

Th e o p e ra t o r m u s t o p e r a te t h e m a c h in e a s instructed by the signals of the partner. The crawler belt is changed by lifting one side of the machine at a time. Unexpected lowering or movement of the machine can result in serious injury or death.

Do not operate the boom, arm or bucket/attachment while removing or installing a crawler belt.

Follow the instructions provided.

• Grease in track tensioning mechanism is under extreme pressure and can penetrate skin causing severy injury. Keep face and body away from grease fitting area. Do not loosen grease fitting more than one turn. If grease does not release after one turn of the fitting, call your dealer/distributor for assistance.

• Before removing the rubber crawler belt, confirm that the pressure inside the track tensioning cylinder has been compeltely released. Then, turn the sprocket.

YN20T01813P1

• If the procedure on releaseing the pressure in the track tensioning cylinderis not followed, grease can penetrate skin causing severe injury. If the tension of rubber crawler belt does not release, call your dealer/distributor for repair service.

ULC00010011E01

1

3

12. Hot Parts Decal Located on engine oil filter bracket

CAUTION

Part Number - YT20T01353P1 Engine oil filter may be hot which could cause burns.

Do not touch engine oil filter until it cools down.

Engine oil filter may be hot which could cause burns.

Do not touch engine oil filter until it cools down.

YT20T01353P1 UYTX2701003E01

2-15

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS 13. Handling Battery Located on battery cover Part Number - YN20T01017P1

• Electrolyte is an acid and can cause injury or blindness if it contacts skin or eyes.

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

• If electrolyte contacts skin or eyes, flush affected areas immediately with clean water and seek medical attention.

UYF0001001E01

14. Prevent Battery Explosions Decal Located on battery cover.

WARNING

Part Number - ULC0010039E01 PREVENT BATTERY EXPLOSION

• Batteries gives off hydrogen gases 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 ULC00010039E01

when charging.

1

3

15. Handling Battery Decal Located on battery cover Part Number - PY20T01069P1 DANGER EXPLOSIVE GASES Cigarettes, flames or sparks could cause battery to explode. Always shield eyes and fact from battery.

Do not charge or use booster cables or adjust post connections without proper instruction and training.

KEEP VENT CAPS TIGHT AND LEVEL POISON CAUSES SEVERE BURNS Contains sulfuric acid. Avoid contact with skin, eyes or clothes. In event of accident flush with water and call a physician immediately.

2-16

ULC00010040E01

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS 16. California Proposition 65 Decal Located on battery cover Part Number - UYF0001001301

WARNING

CALIFORNIA Proposition 65

UYF0001001301

17. Handling Batttery Decal Located on side of radiator duct Part Number - YN20T01854P1

WARNING

ULC00010012E01

18. Handling Grease Gun Decal Located on engine dust cover

CAUTION

Part Number - YT20T01287P1 Be sure to store a grease gun in this grease gun holder.

ULC00010015E02

2-17

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS 19. Travel Speed, Adjusting Track Tension, Leaving Machine, Read Operator’s Manual, Power Boost Switch, Engine Stop, Bucket to Cab Contact, Electrical Power Lines Leaving Machine Decal Located inside cab on the right-hand side Part Number - YN20T01863P1 WARNING DO NOT INSTAL ANY OBJECT ON THE HANDRAIL

NOTICE

WARNING

WARNING

CAUTION

CAUTION

WARNING

WARNING

WARNING

DANGER WARNING

WARNING

UYF00010012E01

2-18

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS 20. Do Not Insert Hand in the Moving Part Decal Located on seat stand Part Number - YN20T01339P1 Be careful not to pinch your hand(s) when operating the lever.

CAUTION

ULC00010043E01

21. Lock Front Window at the Housed Position Decal Located inside cab on the right-hand side Part Number - ZL11M06008 Lock front window at the housed position.

There is always possibility of slipping down of the housed front window resulting in injury.

ZL11M06008

ULC00010018E01

22. Swing Brake Release Switch Decal Located on rear cover

CAUTION

Part Number - YN20T01639P1 While operating swing action, when the parking brake cannot be released, set the toggle switch to “RELEASE” po sition and the parking brake is released. Usually, this toggle switch should be set to “NORMAL” position and contact our service shop immediately.

ULC00010045E01

23. Operation by Foot Pedal Decal Located inside cab, right-hand side.

Part Number - PY20T01062P1 (Optional)

CAUTION

ULC00010047E01

2-19

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS 24. Handling Change Lever and Selector Valve Decal

CAUTION

(Nibbler and breaker) Located on inside cab, right-hand side.

Part Number - YT20T01284P1 (Optional)

UYT00010017E02

25. Procedure to Change Selector Valve Decal

1

3

CAUTION

(Nibbler and breaker) Located on right side door.

Part Number - YT20T01285P2 (Optional)

YT20T01285P2 UYT00010016E06

26. Rotary Multi Control Valve Decal

1

3

WARNING

Located on inside cab, right-hand.

Part Number - YN20T01039P1 (Optional)

UYF00010023E01

27. Rotary Multi Control Valve Operation Procedure Decal Located on fuel tank.

Part Number _YY20T01208P1 (Optional)

UYF00010024E02

1

2-20

3

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS 28. Keep Clear Working Area Decal Located on both arms.

Part Number - YN20T01337P1 (2 required) Make sure the a rea is clear of obstacle s a nd persons before beginning the operation of the machine. Always look around before you start the swing operation. Sound horn before beginning swing operation.

ULC0001005E01

29. Use Specified Diesel Oil for Fuel According to EPA Regulation Decal Located on fuel tank.

Part Number - PV20T01068P1 EPA regulations require the use of low sulfur or ultra low sulfur diesel fuel.

PV20T01068P1

ULC00010050E02

29. Boom to Cab Contact Decal Located inside cab, right-hand side.

Part number - LF20T01012P1 (Optional)

CAUTION FOR INTERFERE

CAUTION The accumulator, mounted on boom, can contact and damage opened cab skylight when boom is retracted toward cab or during boom retracted rotation.

Use caution by checking clearance between opened cab skylight and accumulator, mounted on boom, before operating machine.

LF20T01012P1

ULF00010117E01

2-21

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

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

MOVE LOAD IN HORIZONTALLY

The following is a compilation of the Hand Signals to be used when a flagman is required for Excavator O p er at io n . All p e r so n ne l as so c ia t ed with th e operation of the excavator should know these signals and their meaning before attempting to operate this machine.

RAISE LOAD VERTICALLY

DC04E040

Figure 3

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

MOVE LOAD OUT HORIZONTALLY

DC04E038

Figure 1

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

LOWER LOAD VERTICALLY

DC04E041

Figure 4

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

RAISE BOOM

DC04E039

Figure 2

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

DC04E042

Figure 5

Fac e ma ch in e op e ra to r, ext en d r ig ht a r m o ut horizontally from shoulder, make a fist with thumb up.

2-22

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

LOWER BOOM

DC04E043

Figure 6

DC04E046

Figure 9

Fac e ma ch in e op e ra to r, ext en d r ig ht a r m ou t horizontally from shoulder, make a fist with thumb down.

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

SWING LEFT

ARM OUT

DC04E044

Figure 7

DC04E047

Figure 10

Fac e ma ch in e op e ra to r, ext en d r ig ht a r m ou t horizontally from shoulder, make a fist with index finger pointing in swing direction.

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

SWING RIGHT

COUNTER ROTATE LEFT

DC04E045

Figure 8

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

DC04E048

Figure 11

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

2-23

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

COUNTER ROTATE RIGHT

DC04E049

Figure 12

DC04E052

Figure 15

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

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

TRAVEL FORWARD

OPEN BUCKET (BUCKET OUT OR DUMP)

DC04E050

Figure 13

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

DC04E053

Figure 16

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

TRAVEL REVERSE TURN LEFT

DC04E051

Figure 14

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

2-24

DC04E054

Figure 17

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

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS STOP

TURN RIGHT

DE04E055

Figure 18

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

DC04E058

Figure 21

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

EMERGENCY STOP

MOVE THIS MUCH

DC04E059 DC04E056

Figure 19

Figure 22

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

Fa c e m a c h in e o p e ra t o r, r a is e b o t h a r ms o u t horizontally from shoulders with hands open and facing down, move arms in a horizontal motion back and forth.

MOVE SLOWLY

STOP ENGINE

DC04E057

Figure 20

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

DC04E060

Figure 23

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

2-25

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

2-26

CHAPTER 3 - INSTRUMENTS AND CONTROLS

CHAPTER 3

INSTRUMENTS AND CONTROLS TABLE OF CONTENTS OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Document Storage Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Locking/Unlocking Cab Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Releasing Door Lock from inside cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Opening and Closing Front Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and Storing Lower Front Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cab Dome Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Emergency Escape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cup Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Grease Gun Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

..... ..... ..... ..... ..... ..... ..... ..... ..... .....

3-3 3-3 3-3 3-3 3-4 3-5 3-5 3-5 3-6 3-6

OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seat Front and Rear Height Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seat Back Reclining Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Armrest Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Lever Stand Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

..... ..... ..... ..... ..... .....

3-7 3-7 3-7 3-8 3-8 3-8

OPERATOR CAB CONTROLS AND ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Levers and Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Gauge Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 LCD Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Battery Charging System Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 Nibbler and Breaker Mode Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 Switch and Meter Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29 Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 Climate Control System/Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36 Cap for Optional Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41 12 Volt Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41 Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41 Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42 Swing Parking Brake Release Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

3-1

CHAPTER 3 - INSTRUMENTS AND CONTROLS

3-2

CHAPTER 3 - INSTRUMENTS AND CONTROLS

OPERATOR CAB RELEASING DOOR LOCK FROM INSIDE CAB

DOCUMENT STORAGE COMPARTMENT

3

ULFX1200002B01

ULFX1202017B01

3. RELEASE LEVER

DOCUMENT STORAGE COMPARTMENT

The document storage compartment is located on the right rear of the operator’s seat. Keep the manual for this machine in this location at all times for quick, easy reference.

When necessary, the cab door can be opened from the inside of the cab.

Pull lever (3) to open the door.

LOCKING/UNLOCKING CAB DOOR

22 11

UYN00020092J01

1. DOOR LATCH 2. HANDLE

Use the ignition key to lock or unlock cab door. Insert key fully into door lock and turn clockwise to unlock or turn counterclockwise to lock cab door.

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

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

Failure to comply could result in death or serious injury.

R131B

3-3

CHAPTER 3 - INSTRUMENTS AND CONTROLS OPENING AND CLOSING FRONT WINDOW The front window should be opened and closed when the machine is parked on level ground and locked securely. The upper front window can be stored in the ceiling.

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

1. Park the machine on firm, level ground, lower the bucket to the ground, pull up the safety lock lever (A) to the locked position and stop the engine.

A

UYN00020094J01

2. Push lock lever (4) on the upper center part of the window (upper) right and release the lock.

4

ULFX1202018B01

4. LOCK LEVER

3. Hold and push up the handle on the upper and lower parts of the front window. The front upper window locks automatically when it reaches the end of the rear side of the roof. check to make sure it is locked.

4. When closing the front upper window, follow this procedure in reverse.

5. When closing the front window, push the upper sides forward and lock securely.

3-4

WARNING A falling window can cause injury to you or others.

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

M1709

CHAPTER 3 - INSTRUMENTS AND CONTROLS REMOVING AND STORING LOWER FRONT WINDOW

EMERGENCY ESCAPE

19 LOCK

5

UYTX2702002E01HAMMER

19.EMERGENCY HAMMER

ULFX1202019B01

1. LOWER FRONT WINDOW

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

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

Be p roa ctive an d familiar ize yo urse lf w ith th e emergency exits and emergency hammer.

In an emergency if the cab door cannot be opened, escape ca n be made through the front or rear windows or skylight. For how to open the windows, see the instructions in this section.

If it is impossible to open the front window, use the emergency hammer (19) to break it. The hammer is mounted on the rear right side of the cab.

CAB DOME LIGHT

If the front window is unavailable for escape, use the rear window and if it cannot be opened, use the hammer to break it.

If the rear window is unavailable, use the skylight and if the skylight cannot be opened, use the hammer to break it.

OFF ON

.

OFF ON

ULFX1202020B01

1. CAB DOME LIGHT

1. Turn cab dome light ON by pushing the dome light switch upward.

2. The light goes out in the neutral position.

2

3. Turn OFF by pushing the switch downward.

REAR INSIDE OF CAB

3-5

CHAPTER 3 - INSTRUMENTS AND CONTROLS CUP HOLDER

UYN00020102J01

The cup holder is located on the right side console in the cab.

GREASE GUN HOLDER

1

UYV00020012E02

1.GREASE GUN HOLDER

The grease gun holder is on the inside of the cover on the left rear side of the machine. When the grease gun is not in use, put it on the holder.

3-6

CHAPTER 3 - INSTRUMENTS AND CONTROLS

OPERATOR SEAT This excavator has a suspension seat with a dual slide mechanism that can be adjusted seven ways. It allows the operator to adjust the seat in relation to the travel levers, the console-mounted joysticks and controls. The height and angle of the armrest and headresat can also be adjusted.

SEAT FRONT AND REAR HEIGHT ADJUSTMENT

SEAT BACK RECLINING ADJUSTMENT

7

1 2 3

4

ULC000200002J0AWEIGHT

1.

2.

3.

4.

SEAT WEIGHT ADJUSTMENT KNOB SEAT HEIGHT ADJUSTMENT LEVER RECLINING ADJUSTMENT LEVER SEAT FORWARD - BACKWARD BAIL

• Rotate the weight adjustment knob (1) until weight close to operator’s weight is at the top end of the dial.

• Pull height adjustment lever (2) up to raise or lower rear of seat.

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

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

4

5

6 BS08D260

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

• Lower arm rest (5) and turn adjustment wheel (6) until arm rest is in desired position.

• Move head rest (7) forward or backward to desired reclining angle. Raise or lower head rest to desired height.

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

3-7

CHAPTER 3 - INSTRUMENTS AND CONTROLS SEAT BELT

ARMREST ADJUSTMENT

1

2 2

1 DC04D529

1. BUCKLE 2. RED BUTTON ULFX1202015B01

1. CLAMP 2. PROTRUDED PIN

The armrest has four levels of height adjustment.

To adjust, open the clamp (1) in the direction of the arrow.

Push on the protruded pin (2).

Slide the armrest up or down to adjust the height.

CONTROL LEVER STAND ADJUSTMENT

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

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

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

3. When the seat belt is used, draw out a moderate length and insert it in the buckle until it locks in p l a c e. R e l e a s e h a n d s, a n d t h e le n g t h i s automatically adjusted.

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

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

2

WARNING

1 B

Always wear seat belt while sitting in operator seat.

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

A C

M422B BD08B476-01

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

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

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

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

3-8

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

CHAPTER 3 - INSTRUMENTS AND CONTROLS

OPERATOR CAB CONTROLS AND ACCESSORIES 3

4

5

6

7

8

10

26 9 12

2

13 1

14 15

24

16 23

17 19

18 21

FRONT

DETAIL A 20 A 22

ULFX1302009E01

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

LEFT HAND OPERATOR CONTROL LEVER (HORN SWITCH) SAFETY LOCK LEVER (FOR HYDRAULICS) OPERATING PEDAL (BREAKER AND NIBBLER OPTION) LEFT TRAVEL PEDAL LEFT TRAVEL LEVER RIGHT TRAVEL LEVER RIGHT TRAVEL PEDAL OPERATING PEDAL (BOOM SWING) HOUR METER GAUGE CLUSTER DOZER OPERATING LEVER CUP HOLDER

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

RIGHT HAND OPERATOR CONTROL LEVER STARTER KEY SWITCH THROTTLE POTENTIOMETER WORKING LIGHT SWITCH (BOOM, DECK) TUNER AIR CONDITIONER CONTROL PANEL CAP (FOR OPTIONAL SWITCH) EMERGENCY HAMMER OPERATOR SEAT 12-VOLT POWER SUPPLY SWING PARKING BRAKE RELEASE SWITCH FUSE AND RELAY BOX

3-9

CHAPTER 3 - INSTRUMENTS AND CONTROLS

CONTROLS AND ACCESSORIES The following section identifies locations of operator controls and accessories for your hydraulic excavator. Study these areas and locate the components on the machine.

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

M1087

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

LEVERS AND PEDALS

3

4

5

1 2 2

6

ULFX120211B01

1.

2.

3.

4.

5.

6.

3-10

SAFETY LOCK LEVER CONTROL LEVER (ISO CONTROL PATTERN) OPERATING PEDAL (BREAKER AND NIBBLER) OPTION TRAVEL LEVER BOOM SWING OPERATING PEDAL DOZER BLADE OPERATING LEVER

CHAPTER 3 - INSTRUMENTS AND CONTROLS OPERATING PEDAL (BREAKER AND NIBBLER OPTIONS)

SAFETY LOCK LEVER

WARNING Always place the hydraulic safety lock lever in the locked (up) position before leaving the cab. Never leave the machine unattended with engine running.

Failure to comply could result in death or serious injury.

See Chapter 4 Operating Instructions for operation of optional hydraulic breaker and nibbler.

M1710

BS06H080

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

The safety lock lever is provided to prevent any u n ex p e c t e d o p e ra t io n d u e t o t h e a c c id e n t a l movement of the control lever.

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

3-11

CHAPTER 3 - INSTRUMENTS AND CONTROLS CONTROL LEVERS (ISO CONTROL PATTERN) FOR RIGHT AND LEFT HAND

WARNING Check and make sure that operations pattern control matches the decal provided inside the right side window.

Failure to comply could result in death or serious injury.

M1713

(3) (2)

(5) (1)

(7)

(4)

(8) (6)

(6) (3)

(1) (2)

(4) (5) (8)

(7)

ULFX1202012B01

LEFT CONTROL LEVER 1. SWING RIGHT 2. SWING LEFT 3. ARM OUT 4. ARM IN N. NEUTRAL

RIGHT CONTROL LEVER 5. BOOM DOWN 6. BOOM UP 7. BUCKET DIGGING 8. BUCKET DUMPING N. NEUTRAL

Two ISO operating pattern control levers activate the operations shown.

Release the hand and the lever returns to the neutral position and the attachment stops moving.

The left control lever controls the upper structure and arm. The right control lever controls the boom and bucket.

I t is p o s s i bl e t o p e r fo r m va r io u s o p e r a t i o n s simultaneously.

3-12

CHAPTER 3 - INSTRUMENTS AND CONTROLS TRAVEL LEVERS AND PEDALS

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

M1727

(a)

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

(N)

• FORWARD - Variable speed forward track

(a)

movement (b)

• BACKWARD - Variable speed reverse track

(N)

movement

• CENTER - Neutral position

(b)

Use the operating levers to move the track either backward or forward. The pedals can also be used to move either the left or right track.

(a)

(a) (b) (b)

(a)

(b)

UXTX2802020B01

a. FORWARD - VARIABLE SPEED FORWARD TRACK MOVEMENT b. BACKWARD - VARIABLE SPEED REVERSE TRACK MOVEMENT N. NEUTRAL

- CENTER NEUTRAL POSITION

3-13

CHAPTER 3 - INSTRUMENTS AND CONTROLS BOOM SWING OPERATION PEDAL

WARNING Make sure to set the pedal lock to LOCKED position while the boom swing is not used. Unexpected contact with UNLOCKED position of pedal may cause severe injury or death. Do not put foot on the pedal except at the time of operation using pedal.

B

A

ULFX1202003E01PEDALS

A. RIGHT PUSHING DOWN - RIGHT SWING MAX. 82” B. LEFT PUSHING DOWN - LEFT SWING MAX. 50”

This control pedal (1) is used to operate the boom right and left swing.

Pedal operation Unlocking and locking of pedal

B

A

To unlock this pedal, pull the pin (2) rightward as shown. To lock this pedal, push the pin (2) leftward and engage the pin into the pedal notch as shown in the figure.

1

Locked position

Unlocked position

2 ULFX1202003E01

1. LOCKED POSITION 2. UNLOCKED POSITION

3-14

CHAPTER 3 - INSTRUMENTS AND CONTROLS DOZER BLADE OPERATING LEVER

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

B 1

CE-NA000

A

The dozer blade is attached on the lower frame with pins and is used for backfilling and leveling after digging operations. Move the blade up and down with the dozer lever.

The dozer blade lever (1) is located on the right hand operator console.

1. Start machine and place the safety lock lever in the unlocked (down) position.

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

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

4. Pull (A) the dozer blade operating lever to lift up the blade.

5. Push (B) the dozer blade operating lever to lift up the blade.

A

B ULFX1202014B01

1. DOZER BLADE OPERATING LEVER A. PULL TO LIFT UP THE BLADE B. PUSH TO LOWER THE BLADE

3-15

CHAPTER 3 - INSTRUMENTS AND CONTROLS GAUGE CLUSTER

11

1

2 3

10 6 4

9

8

5

7 BS06H115

1.

2.

3.

4.

5.

6.

ENGINE COOLANT TEMPERATURE GAUGE FUEL LEVEL GAUGE SCREEN CHANGE SWITCH BUZZER STOP SWITCH WORK MODE SELECT SWITCH WASHER SWITCH

7.

8.

9.

10.

11.

WIPER SWITCH TRAVEL SPEED SELECT SWITCH AUTO ACCEL SWITCH SELECT SWITCH L.C.D. DISPLAY

NOTICE: When CAUTION is displayed on the LCD multi-display, stop the work immediately and check and service the machine.

NOTICE: The messages on the LCD multi-display do not entirely assure the condition of the machine. A visual check should also be done during inspection and maintenance.

Engine Coolant Temperature Gauge This gauge indicates the temperature of the engine coolant water and operates when the starter key switch is turned to the ON position. The temperature is normal in the white range. If the indicator enters the red range, let the engine idle until the water cools down and the indicator returns to the white range.

This gauge indicates the amount of fuel.

1 2

3 UYN00020012J01

1. RED - MAY BE OVERHEATED 2. WHITE - OPERATING CONDITION 3. BLUE - COLD, WARM UP ENGINE AND HYDRAULIC OIL

3-16

CHAPTER 3 - INSTRUMENTS AND CONTROLS FueL Level Gauge This gauge indicates the remaining volume of fuel in the fue l tan k. R efill with diesel fuel whe n the in dica tor app roa ches the “E” po in t. See Specifications section for recommended fuel.

1

F = Full tank 120 L (31.7 gal)

2

E = Empty tank

UYN00020013J01

1. WHITE - OPERATING CONDITION 2. RED - REFILL

Screen Change Switch

A

1

2 B

4

3

BS06H070 / BS06H071

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

1. Remaining time until oil change.

2. Remaining time until fuel filter change.

3. Remaining time until hydraulic filter change.

4. Remaining time until hydraulic oil change.

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

3-17

CHAPTER 3 - INSTRUMENTS AND CONTROLS Work Mode Select Switch

Buzzer Stop Switch

BS06H065

BS06H065

To st o p t h e bu z ze r s o u n d w h e n a w a r n in g is displayed on the monitor, press the buzzer stop switch and the buzzer will stop. If the engine coolant temperature is too high, o r vario us sensors of mechatro controller (self-diagnosis) fail, the alarm sounds intermittently and cannot be stopped.

When the engine starts, it is set to the last engaged mode. To select the proper work mode select one of the ma ch ine ’s fo ur mod e s. Mod e s ca n b e s et according to the work conditions. The work modes are H and S. After initial start-up, the mode last used will be retained. Always check the mode selected conforms to intended work.

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

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

After star ting the engine, select the work mode desired. The mode in use at work operation is retained when the machine is restarted.

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

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

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

3-18

CHAPTER 3 - INSTRUMENTS AND CONTROLS Travel Speed Select Switch

Windshield Wiper and Washer Switches

BS06H066

Wiper Switch

• Pressed once - Wiper moves intermittently.

• Pressed again - Wiper moves continuously.

• Pressed once more - Wiper stops moving.

BS06H067

The travel speed select switch is located on the gauge cluster switch panel.

When the engine starts, travel speed is automatically set to LOW and t he tur tle ic on appears on the display.

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

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

• Remove floor mat to access floor plate and reservoir.

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

To change to HIGH speed, press the travel speed switch on the gauge cluster (rabbit symbol). The speed is changed to HIGH, the rabbit icon appears on the display, and the light indicator above the switch is turned ON. Set to LOW when moving the machine on a rough or soft road, slope, or in narrow place, or when powerful tractive force is required.

Set to HIGH when moving the machine on flat, hard ground. Do not use high speed when performing delicate operations such as pipe laying, fine grading or loading machine onto a trailer.

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

M1697

3-19

CHAPTER 3 - INSTRUMENTS AND CONTROLS Select Switch

Auto Accel Switch

BS06H068

BS06H068

This switch is used to activate and cancel th e automatic acceleration function.

The select switch is located on the gauge cluster switch panel and is used during swing flasher, clock setting, LCD display contrast adjustment and other funct ions. Its operation is des cribed in the instructions for those functions.

When the key switch is turned on, the automatic acceleration system activates. This system lowers the engine speed to the idle level, conserving fuel and reducing noise under the following conditions.

1. The auto accel dial position is set over the idle level.

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

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

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

M1697

NOTICE: The excavator will default to the auto accel function when the key switch is turned to the OFF position.

3-20

CHAPTER 3 - INSTRUMENTS AND CONTROLS LCD DISPLAY The LCD Display has the following functions: 1. System operation status

LOW ENG OIL PRESS.

2. Switch operation status H

3. Warning displays 4. Nibbler and breaker mode operation display 5. Maintenance displays The display uses a wide variety of icons to convey information to the operator. The icons are illustrated in the following pages. Study these icons and their definitions so that possible problems will be quickly recognized and repairs made in a timely fashion.

To adjust the contrast of the display, see below:

UYN00020053E06

LCD Display Contrast Adjustment

A

B

C

D

E

A

F BS06H077

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

2. Press UP ARROW (washer switch) and DOWN ARROW (wiper switch). Move cursor to SWITCH STATUS CLOCK CONTRAST screen (C) then press select switch. ADJUST CLOCK ADJUST CONTRAST (D) displays.

3. Press UP ARROW (washer switch) and DOWN ARROW (wiper switch). Move cursor to ADJUST CLOCK ADJUST CONTRAST then press select switch. “ADJUST CLOCK ADJUST CONTRAST” screen (E) displays.

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

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

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

3-21

CHAPTER 3 - INSTRUMENTS AND CONTROLS SYSTEM OPERATION STATUS 4. Select any of “Y (Year) M (Month) D (Day) H (Hour) M (Minutes) in operation of FEED (4) and FEED (5) and vary the values in operations of FEED (4) and FEED (5).

Clock Display Five seconds after the system status is shown on the LCD, the time will be displayed.

5. After adjustment, press select switch (8) and the adjusted values are stored as memory and time setting is completed, then the screen returns to the main screen.

Clock Adjustment Switches The clock adjustment switches are used to set and adjust the time on the clock.

1. Turn the starter key switch on and display the main screen (a) for the operator, then press the select s w i t c h ( 8 ) a n d d i s p l a y “ S W I T C H S TAT U S / CLOCK/CONTRAST” screen (b).

2. In operations of FEED (4) and FEED (5) move the cursor to the “CLOCK/CONTRAST” screen (c) then press select switch (8) and the “ADJUST CLOCK ADJUST CONTRAST” screen (d) is displayed.

3. In operations of FEED (4) and FEED (5), move the cursor to “ADJUST CLOCK” then press select switch (8) and the “ADJUST CLOCK” screen (e) is displayed.

8 UYN00020042J01CLOCKADJUST

8. SELECT SWITCH

(a)

Main screen

10:25

SWITCH STATUS CLOCK/CONTRAST

13:15

H (a)

H (b)

(c) SWITCH STATUS CLOCK/CONTRAST

(d)

(e)

ADJUST CLOCK ADJ CONTRAST

Y M D H M 06 04 01 13 15

Select Year/Month/Day/Hour/Minute

Enter

Increase/Decrese UYN000200047E01

3-22

CHAPTER 3 - INSTRUMENTS AND CONTROLS SWITCH OPERATION STATUS

22:00

22:00 H

H 1 1 2 3 4 5

3

1

2

2

3

4

Work Mode Displays (H, S) Travel Speed Displays ( , Auto Accel Display Wiper Displays (Intermittent/Continuation) Failure Displays

5

)

4 UYN00020055E02

UYN00020055E02

There are four switch buttons that, when selected, will display icons on the lower portion of the display.

There is also a failure icon (5) that will appear on the display in the event of a serious machine system failure.

Work mode, travel speed, auto accel and wiper displays were described in previous sections of this chapter. The Failure Display icon (5) will appear on the screen when serious trouble occurs - should this icon appear, contact your dealer or distributor.

3-23

CHAPTER 3 - INSTRUMENTS AND CONTROLS WARNING DISPLAYS Audible Buzzer Warning Condition Priority of Group

A

B

Warning Level

Screen

Condition

Buzzer Sounds

Key On Only

Engine Running

Type

Auto Stop

Manual Stop

1

DATA COMMUNICATION ERROR

Data from the mechatro controller is not received.

O

O

3

X

O

1

SWING BRAKE DISENGAGED

The swing parking brake switch is turned ON.

O

O

2

O

O

1

CPU HYDRAULIC SYSTEM BACK UP MODE

KPSS release switch is switch to Release side

O

1

O

X

1

SELECTOR VALVE FAILURE

Selector valve malfunctions

X

O

2

-

O

2

WARM - FINISH WARM UP

After warm up is complete

X

O

2

O

-

3

HIGH ENGINE WATER TEMPERATURE

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

O

O

3

X

O

3

LOW ENGINE WATER LEVEL

Coolant level is low

O

O

3

X

O

3

CLOGGED AIR FILTER

The Air Filter is clogged

O

O

3

X

O

3

DRAIN WATER SEPARATOR

Water level is high in fuel/water separator

O

O

3

X

O

3

(SELF DIAGNOSIS SCREENS)

According to the self diagnosis control

O

O

3

X

O

4

CHARGE ERROR

Battery error - High voltage/low voltage/poor charge

O

O

4

X

X

4

LOW FUEL LEVEL

Displayed when fuel level is low

O

O

4

X

5

CHANGE ENGINE OIL

Remaining time to specified engine oil gauge is zero

O

O

5

X

X

5

TRAVEL INDEPENDENT MODE

Displayed when the travel independent select switch is on

O

O

5

X

X

Warning Level 1. These may affect safety and the machine performance - contact your authorized dealer 2. These warn that the machine control mode is switched.

3. Equipment/System failure.

4. Normal priority warning.

5. Low priority message Buzzer Sounds 1. Constant 2. Beep ON 0.2 sec. OFF 0.3 sec.

3. Beep ON 0.5 sec. OFF 0.5 sec.

NOTICE: When warnings are displayed, there is a possibility of serious malfunctions. Stop the machine immediately and investigate and correct the problem. Contact your authorized dealer if problem persists or warning so indicates. Failure to comply could result in machine damage.

3-24

CHAPTER 3 - INSTRUMENTS AND CONTROLS LCD Screen Warnings Controller CPU Display This icon will display when a problem exists in the Data Communication System.

Turn key switch “OFF”, wait 4 s e co n d s u n t il th e s y s te m shuts down completely, then turn the switch back to “ON” to reset the CPU program.

Should this icon remain on display, stop operation, shut down the engine, remove rear panel cover and flip the Swing Parking Brake switch to the “RELEASE” position. Contact your autho rized de aler for repair.

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

Wh ile th is war n ing is displayed, the swing parking brake does not actuate. This switch should be used only in t h e ev e n t o f e m e r g e n c y.

Contact your author ized dealer for repair.

Engine Air Cleaner Display This icon will display should the Engine Air Cleaner Element(s) ( F I LT E R S ) be co me to o dir ty to allow proper air flow to the engine.

Should this icon display, stop engine immediately and clean or replace engine air cleaner element(s) as required.This ic o n wil l di s play on ly if alternator is charging.

Engine Stop Display When the Engine Stop Display is s h o w n , th e bu z z e r w il l sound for 5 seconds and the engine is stopped. The oil pressure is low and this is a high priority warning.

Check the oil level. If the level is correct and the filter does not require replacing, contact your authorized dealer. Do no t a ttemp t to r un th e machine.

Engine Oil Pressure Display This icon will display and the alarm will sound should the En g in e O il Pre ss u re d ro p be low a safe op eratin g pressure.

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 wi ll a ut om a t i c a lly g o to “LO” Idle, and immediately shut down.

This icon will Display only if alternator is charging.

Engine Coolant Temperature Display This icon will display and the alarm will sound should the Engine Coolant Temperature r is e a bove sa fe o p era tin g temperature.

Reduce engine RPM to idle and stop operation until engine coolant temperature r e a ch e s a sa fe o p e ra ti n g temperature range.

3-25

CHAPTER 3 - INSTRUMENTS AND CONTROLS Battery Charging System Display This icon will display when the electrical charging system is not functioning properly.

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

Ic on dis plays only when engine is running with normal oil pressure and a problem occurs in the charging system.

Fuel Level Display This icon will display when the Fuel Level is low.

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

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

The recommended oil change interval is every 500 hours of operation. Proceed with oil change and make sure to recalibrate the engine oil change interval.

Nibbler and Breaker Mode Display See Chapter 4 Operating Instructions for details on use of the gauge cluster and LCD multi-display during nibbler and breaker operation.

3-26

CHAPTER 3 - INSTRUMENTS AND CONTROLS

Maintenance DIsplay The gauge cluster displays remaining time for the next replacement/change time of engine oil, fuel filter, hydraulic oil filter, and hydraulic oil.

When the remaining time elapses, replace or change components, then reset the maintenance interval to restart maintenance count down. See steps below fo reset.

Recommended replacement intervals Engine Oil . . . . . . . . . . . . . . . . . . . . . . 500 hours Fuel Filter . . . . . . . . . . . . . . . . . . . . . . 500 hours Hydraulic Filter . . . . . . . . . . . . . . . . . 1000 hours Hydraulic Oil . . . . . . . . . . . . . . . . . . . 5000 hours NOTICE: The display automatically changes to the main screen if the switch is not operated for 30 seconds.

492Hr

This display shows the remaining time to the next engine oil change.

ENG OIL

H

492Hr

Th is d is p lay s hows t he rem ain in g time to t he n ext engine fuel filter replacement.

FUEL FILTER

H

992Hr

Th is d is p lay s hows t he rem ain in g time to t he n ext hydraulic oil filter replacement.

4993Hr

Th is di s pl ay s hows th e rem ain in g time to t he n ext hydraulic oil change.

H

H

3-27

CHAPTER 3 - INSTRUMENTS AND CONTROLS RESTARTING THE MAINTENANCE COUNTDOWN STEP

PROCEDURE

DISPLAY

Turn starter key on

After several seconds, display is changed to clock autmatically.

1

10:25 H

2

3

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

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

10:25

Press screen change switch once more.

H

250 Hr ENGINE OIL

H

250 Hr ENGINE OIL

Press select switch once more.

250 Hr ENGINE OIL

H

4

5

3-28

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

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

250 Hr ENGINE OIL

500 Hr ENGINE OIL

Replacing interval is changed with each pressing of switch.

To set the desired interval, press the select switch

500 Hr ENGINE OIL

500 Hr ENGINE OIL

H

CHAPTER 3 - INSTRUMENTS AND CONTROLS SWITCH AND METER LOCATIONS

26 10

9

1 2 3 11

4 5 7 6

A 8 FRONT

DETAIL A ULFX130201E01

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

STARTER KEY SWITCH THROTTLE POTENTIOMETER WORK LIGHT SWITCH (BOOM, DECK) OVERLOAD ALARM SELECT SWITCH TUNER AIR CONDITIONER CONTROL PANEL CAP (FOR OPTIONAL SWITCH) 12-VOLT POWER SUPPLY HORN SWITCH HOUR METER SWING PARKING BRAKE RELEASE SWITCH

3-29

CHAPTER 3 - INSTRUMENTS AND CONTROLS THROTTLE POTENTIOMETER

STARTER KEY SWITCH

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 (Low idling) Engine speed will reduce to a minimum when the throttle potentiometer is turned completely to the left.

HI (High idling) BS06H116

1. STARTER KEY SWITCH 2. THROTTLE POTENTIOMETER

The starter key switch is located on the right hand operator console and has four operating functions.

Engine spe ed rise s to th e maximum w hen the potentiometer switch is turned completely to the right.

WORK LIGHT SWITCH

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

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

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

START - When key is turned to this position, ele ctr ic al p owe r is s up p lie d to th e sta r te r solenoid causing the starter to start the engine.

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

3-30

BS08B185

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

CHAPTER 3 - INSTRUMENTS AND CONTROLS RADIO The radio is located on the right side control panel.

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

The following describes the different available radio functions.

Power control key 5

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

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

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

ULFX130201E01RADIO

4.RADIO

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

2

6

5

3

8

4

POWER CONTROL KEY AM / FM SELECTOR KEY VOLUME CONTROL KEY UP / DOWN KEY

5.

6.

7.

8.

7

1 UYN00020201J01

1.

2.

3.

4.

PRESET KEY DISPLAY CHANGE KEY SOUND CONTROL KEY TIME/FREQUENCY KEY

3-31

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

1 step: AM 9kHz 1 step: PM 0.1MHz 2. Auto selection When pressing UP or DOWN keys for more than o n e s e c o n d , th e f r e q u e n c y i n c r e a s e s o r decreases. When radio waves are received during auto tuning, or while pressing the UP or DOWN key, the auto tuning is interrupted but the frequency stays the same.

UYN00020202J01

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

Aut o P r e s e t : Th e r a d i o d e t e c t s a n d c a n memorize the strongest frequencies.

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

5

7 UYN00020204J01

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

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

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

Frequency display

Repe at this p rocedure to pre set the six strongest radio frequencies, using the six PRESET keys (5).

(After a certain time)

Auto presetting display (After a certain time)

(After a certain time)

Auto presetting display

(Auto preset end)

Auto presetting display

Frequency display UYN00020205E01

3-32

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

5

7 UYN00020204J01

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

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

Frequency display

(After 3 flickerings of preset No.)

Preset No. display

Frequency display UYN00020207E01

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

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

Frequency display

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

Frequency display UYN00020208E01

3-33

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

4

7 UYN00020204J01

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

(Example of FM1 is selected)

BAL (balance control) TRE (treble control)

Frequency display "SOUND" key

BAS (bass control)

Sound control display (Balance) "SOUND" key

Sound control display (Treble) "SOUND" key

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

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

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

"DOWN" key

Sound control display (Balance) "DOWN" key

Sound control display (Balance)

Sound control display (Balance)

"UP" key

Sound control display (Balance) "UP" key

Sound control display (Balance) UYN00020212E01

3-34

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

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

"UP" key

Sound control display (Treble)

Sound control display (Treble)

"DOWN" key

Sound control display (Treble)

"UP" key

"DOWN" key

Sound control display (Treble)

Sound control display (Treble) UYN00020217E01

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

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

"UP" key

Sound control display (Bass)

"DOWN" key

Sound control display (Bass)

Sound control display (Bass)

"UP" key

"DOWN" key

Sound control display (Bass)

Sound control display (Bass) UYN00020207E01

CLOCK Setting the time

6

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

The HOUR display will flicker.

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

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

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

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

4 UYN00020216J01

5. Press DISP key again to complete time setting.

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

UYN00020084J01

3-35

CHAPTER 3 - INSTRUMENTS AND CONTROLS CLIMATE CONTROL SYSTEM/AIR CONDITIONER The climate control system and air conditioner is located under the operator seat. It provides heating or cooling, removes moisture from humid air and reduces window glass fogging.

(A) (A)

Four air outlets are located inside the cab (A), (B), (C), an d (D). The dir ectio n of air flow ca n be adjusted by hand.

(E)

The solar radiation sensor (E) is located to the right of the operator’s seat.

(C)

NOTICE: When the climate control system is running-in, start the engine at slow speed. Do not start the air conditioner at high speed. This might cause failure of the air conditioner.

(B) (D)

NOTICE: Do not splash water on the control panel an d so lar ra dia tio n se n so r. Wa te r c an c au se unexpected failure.

4

NOTICE: Keep fire away from the climate control system.

UYNX641005J03

A. B. C. AND D. AIR OUTLETS E. SOLAR RADIATION SENSOR

NOTICE: Keep the solar radiator sensor clean and clear of objects that may interrupt its function.

Control Panel NOTICE: The LCD display indicates temperature, air outlet mode, compressor ON - OFF - AUTO, recirculate, fresh air, and fan speed. The background of the control panel is illuminated whenever the A/C system is activated.

2

3

4

5

1

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

1. Press the AUTO control switch (5) to control air capacity and blower outlet automatically and set the temperature range from 18.5°C (65.3°F) to 31.5°C (88.7°F). The outlet temperature, outlet o p e n i n g a n d fa n s p e e d a r e a d j u s t e d automatically.

2. If desired, select the mode manually using the Fresh and Recirculate Air Selector Switch (2) and A/C (Compressor) Switch (4).

3. The fan speed is adjusted automatically but it can also be set manually using the Fan Speed Selector Switch (7). The AUTO indicator in the LCD display will then go out. To re tu r n to automatic fan speed selection, press the AUTO switch (5).

3-36

9

8

7

6 DC04D550

1.

2.

3.

4.

5.

6.

7.

8.

AIR OUTLET MODE SELECTOR SWITCH FRESH AND RECIRCULATE AIR SELECTOR SWITCH LCD DISPLAY A/C (COMPRESSOR) SWITCH AUTO CONTROL SWITCH MAIN POWER SWITCH FAN SPEED SELECTOR SWITCH TEMPERATURE SETTING SWITCH & °C / °F SELECTOR SWITCH 9. DEFROSTER SWITCH

CHAPTER 3 - INSTRUMENTS AND CONTROLS Control Panel Functions Main Power Switch and Display

3

The LCD display (3) is illuminated when the climate control AC is operating.

When the climate control system system stops operating, the LCD will turn off.

Press the main power switch (6) and all functions switch ON or OFF. When switched ON, the system starts operating in the mode set before switching off, i.e. when it is set to AUTO mode, it starts operating in AUTO mode.

6

NOTICE: The key switch will turn the air conditioner OFF but the operating mode may not be restored when the key switch is turned back ON.

DC04D550

3. LCD DISPLAY 6. MAIN POWER SWITCH

Auto Control Switch and Display

3

1. Press the main power switch (6) to activate the Climate Control System/Air Conditioner and the LCD display (3) will illuminate.

5

2. Press the auto control switch (5) and fan speed and air outlet are automatically controlled, and the “AUTO” indicator lamp on LCD display is illuminated.

3. When the main power switch (6) is turned OFF, the system will retain the previous setting in memory. When the main power switch is turned on ag a in , the Climate Co ntro l Syste m/Air Conditioner will come on in the auto control mode.

6 DC03D550

3. LCD DISPLAY 5. AUTO CONTROL SWITCH 6. MAIN POWER SWITCH

Temperature Setting Switch and Display 1. The set temperature is indicated in digits onthe LCD display. Temperature set range is 18.5°C (65.3°F) to 31.5°C (88.7°F).

2

2. Press the two temperature set switches simultaneously for 5 seconds to change the display from °C to °F. 3. Press the temperature set switch DOWN or UP to change the set temperature. The temperature goes up or down by 0.5°C (0.9°F). The set temp era ture may b e ra is ed or lowe red by continued pressing of the switch.

4. The set temperature 18°C (64.4°F) is the lowest cooling temperature, and 32°C (89.6°F) is the highest heating temperature. Control beyond either of these limits is not possible.

8 DC03D550

2. FRESH AND RECIRCULATE AIR SELECTOR SWITCH 8. TEMPERATURE SETTING SWITCH & °C / °F SELECTOR SWITCH

3-37

CHAPTER 3 - INSTRUMENTS AND CONTROLS Air Outlet Mode Selector Switch and Display 1. Air outlet position is indicated by the icon (3) on the LCD display.

1

3

2. Press air outlet mode switch (1) so the auto display light is on, and the display mode is fixed, AUTO indicator lamp on LCD display goes out, and AUTO control of the air outlet opening is re le as e d. Pr es s it a ga in , a n d th e leve l is changed to: VENT

BI-LEVEL

FOOT

FACE

DC03D550

1. AIR OUTLET MODE SELECTOR SWITCH 2. LCD DISPLAY

DC04D551

Defroster Switch and Display 1. Press defroster switch (9) and the defroster icon will display on the LCD screen (3).

1

3

2. Press the air outlet mode selector switch (1) and it returns to the air outlet mode just before pressing the defroster switch.

3. Press the defroster switch so the AUTO display is indicated, AUTO indicator lamp on LCD display goes out and the auto control of the air outlet opening is released.

9 DC03D550

1. AIR OUTLET MODE SELECTOR SWITCH 3. LCD DISPLAY 9. DEFROSTER SWITCH

3-38

CHAPTER 3 - INSTRUMENTS AND CONTROLS Recirculation and Fresh Air (R/F) Switch and Display

2

3

6

1. Press the Recirculation and Fresh Air (R/F) Switch (2) to change the air intake mode from recirculation to fresh air.

2. An icon appears on the LCD display (5) showing which air intake mode the machine is using.

A = Air recirculation B = Fresh air intake 3. The speed of the fan can be adjusted by pushing the UP/DOWN switches (7). Press the UP switch for faster fan speed. Press the DOWN switch for slower fan speed.

4. The fan speed (6) shows in an icon on the LCD display.

7 A

B UYNX002005E01

2.

3.

6.

7.

RECIRCULATION/FRESH AIR (R/F) SELECTOR SWITCH LCD DISPLAY FAN SPEED DISPLAY FAN SPEED SELECTOR SWITCH

Compressor Switch and Display 1. Press the Compressor Switch (4), and the snow flake icon will be indicated on LCD display (3).

3

2. Press it again, the compressor turns off, and its indicator icon on the LCD display goes out.

DC04D550

3. LCD DISPLAY 4. A/C (COMPRESSOR) SWITCH

Fan Speed Selector Switch and Display

6

Fan speed is adjusted automatically when in the AUTO mode.

To adjust fan speed manually, press the FAN UP or DOWN switches (7) to increase or decrease fan speed. The AUTO indicator light (5) on the LCD display will go out.

When in MANUAL mode, the fan speed icon (6) displays on the LCD screen.

7 DC04D550

5. AUTO INDICATOR LIGHT 6. FAN SPEED DISPLAY 7. FAN SPEED SELECTOR SWITCH

Air capacity is depicted as a series of bars on the icon.

DC04D552

3-39

CHAPTER 3 - INSTRUMENTS AND CONTROLS Setting Temperature Display The temperature can be displayed in Fahrenheit or Celsius, but the letter (F or C) is not displayed with the number.

2

If the number displayed ranges from 18.0 to 32.0, th e t e mp e ra tu r e is in C e lsiu s. If th e nu m b e r displayed ranges from 63 to 91, it is in Fahrenheit.

To change from Fahrenheit to Celsius (or from Celsius to Fahrenheit): 1. Turn the fan on.

2. Press the TEMP DOWN and UP switches (8) simultaneously for five or more seconds. The display will switch from Fahrenheit to Celsius.

Numeric display of temperature on LCD screen

LC (Liquid crystal) display 18.0~32.0 63~91 UYN00020089E01

Seasonal Use of Climate Control System Con tact you r de ale r/distr ibu to r be for e the h ot weather season begins to check and service the climate control system/air conditioner.

In the off season, operate the air conditioner for several minutes once a week to keep the oil flowing well in each part of the compressor and keep the system in good operating condition.

3-40

8 DC04D550

5. AUTO INDICATOR LIGHT 6. FAN SPEED DISPLAY 7. FAN SPEED SELECTOR SWITCH

CHAPTER 3 - INSTRUMENTS AND CONTROLS CAP FOR OPTIONAL SWITCH There is room for optional switches to be installed on this machine. When not installed, they are capped.

18

ULFX130201E01CAP

18.CAP FOR OPTIONAL SWITCH

12 VOLT POWER SUPPLY The 12-volt power supply (1) is located next to the reqr side cover and is for commonly used auto accessories requiring 12-volt power.

Remove the cover and insert the 12-volt male socket into the power supply. Replace cover after use.

1

Maximum continuous output = 180 watts

ULFX1202001E01

1. 12-VOLT POWER SUPPLY

HORN SWITCH The horn switch is a momentary push button on the left hand control lever. Always sound the horn before starting the engine to alert personnel the machine is going to be operated.

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

Failure to comply could result in death or serious injury.

UYTX2802015E01

M1121

1. HORN SWITCH

3-41

CHAPTER 3 - INSTRUMENTS AND CONTROLS HOUR METER The hour meter indicates total time the engine has run. It continues counting as long as the engine is running.

It is located under the gauge cluster in the front of the cab.

ULV00020050J01

1. HOUR METER

SWING PARKING BRAKE RELEASE SWITCH The swing parking brake is usually locked, and released only for swing and arm-in operation.

When it cannot be unlocked, turn the toggle switch to RELEASE LOCK (unlock) and the parking brake is released.

Then, move the machine to a safe area and contact your dealer. Return toggle switch to NORMAL in normal operating conditions.

FRONT ULFX1202002E01

1. SWING PARKING BRAKE

3-42

CHAPTER 4 - OPERATING INSTRUCTIONS

CHAPTER 4

OPERATING INSTRUCTIONS TABLE OF CONTENTS BEFORE OPERATING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 OPERATING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 STARTING AND STOPPING ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting the Engine with Booster Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Releasing Hydraulic Tank Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection After Starting Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5 4-5 4-5 4-7 4-7 4-7

MACHINE WARM UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 OPERATING AND TRAVEL CONTROLS DECAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Operating Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Operating Pattern Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 MACHINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Caution in Machine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Machine Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Forward/Reverse Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pivot Turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Counter Rotating Machine (Spin Turn) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing Travel Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Travel Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parking the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Machine Operation in Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Getting Out of Soft Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-13 4-13 4-14 4-14 4-14 4-15 4-15 4-16 4-16 4-18 4-18

MACHINE ATTACHMENT AND SWING CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 PRACTICES TO IMPROVE EFFICIENCY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 Precautions after Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26 Machine Operation in Adverse Weather Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27 OPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28 PROHIBITED WORK IN USE OF BREAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32 Periodic Inspection and Maintenance Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36 Reinforcing Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36 PROHIBITED WORK IN USE OF NIBBLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37 PRECAUTION FOR BREAKERS FROM DIFFERENT MANUFACTURERS . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40 USE OF AN ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41 PROPORTIONAL HAND CONTROL (EXTRA, NIBBLER, AND BREAKER) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43 PROPORTIONAL HAND CONTROL (NIBBLER AND BREAKER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45 PROPORTIONAL HAND CONTROL (EXTRA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46 HANDLING SUSPENDED LOADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating Procedure for Suspended Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

How to Read the Table of Suspended Load Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-47 4-47 4-48 4-50

4-1

CHAPTER 4 - OPERATING INSTRUCTIONS

4-2

CHAPTER 4 - OPERATING INSTRUCTIONS

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

Before operating this machine, be sure to do the following: 1. Check the level of all fluids (engine oil, hydraulic fluid, and coolant) and make sure that the fluids a n d lu b r ic a n ts a r e s u i ta bl e fo r p r eva ili n g conditions. See Chapter 6 - Maintenance and Adjustments.

2. Carry out the daily maintenance operations.

3. Inspect the machine, look for any signs of possible leakage and check the hoses. Tighten or re p la ce a s n ec es sa r y. Se e C h ap te r 6 Maintenance and Adjustments.

15. Work out a convenient means of escape from the m a c h in e ( b e p r o a ct ive a n d d e te r m in e a n emergency exit) in the event of the cab door being jammed or the machine turning over. Cab m o d e ls a r e e q u i p p e d w it h a n e m e r g e n c y hammer.

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

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

5. Check the track assemblies.

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

7. Clean or replace any decals which are illegible.

See Decals in Chapter 2 - Safety and Decals.

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

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

10. Remove any obstructions which hinder visibility.

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

11. Check that no tools or other items have been left on t he ma ch in e (th e un d er ca rr ia g e o r th e upp erstr ucture ) or in the o pe ra to r's compartment.

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

The operator must be alone on the machine.

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

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

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CHAPTER 4 - OPERATING INSTRUCTIONS

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

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

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

3. If you use your machine in particularly harsh conditions (dusty or corrosive atmosphere), the ser v icin g i nter val s sho uld be re duce d accordingly.

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

5. Do not work near overhead high-voltage electric line s withou t che cking be fo reh and tha t all necessary measures have been taken to respect the safest distances: See the decal on this machine for safe working distances.

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

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

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

9. Do not allow anyone within the machine's op era tin g ra dius. Sto p a ll o pe ration s un til everyone has cleared the area.

10. Operate all controls gradually to ensure smooth machine operation.

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

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

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

4-4

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

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

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

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

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

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

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

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

22. When travelling with the hydraulic breaker (optional), make sure it is not too close to the gr ou n d o r t he c ab an d n o t p o in tin g in th e direction of the cab.

CHAPTER 4 - OPERATING INSTRUCTIONS

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

Fasten the seat belt.

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

A

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

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

STARTING THE ENGINE WITH BOOSTER CABLES

1

B UYN00020077J01

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

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

4. Set throttle potentiometer (2) to “LO” idling position.

1

2

BS07M79

Obser ve the following precautions when using booster cables to start a disabled machine,

WARNING Explosion hazard!

If battery electrolyte is frozen, attempting to charge the battery or jump-start the engine can cause the battery to explode. Always keep batteries at full charge to prevent frozen battery electrolyte. Never charge a frozen battery.

Failure to comply could result in death or serious injury.

W0203A

UYN00030041J02

1. STARTER KEY SWITCH 2. THROTTLE POTENTIOMETER

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

5. Insert key into starter key switch (1) and turn to th e “ O N ” p o s it io n . C o n f ir m t h e o p e r a ti n g condition of the gauge cluster (multi-display).

NOTICE: When starting the engine, if a warning displays on the gauge cluster, stop the engine immediately, identify the cause, then repair if necessary.

WARNING Explosive gas!

Batteries emit explosive hydrogen gas and other fumes while charging. Ventilate the charging area.

Keep the battery away from sparks, open flames and other ignition sources. Never charge a frozen battery. Failure to comply could result in death or serious injury.

W0005A

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CHAPTER 4 - OPERATING INSTRUCTIONS

WARNING

3

W0111A

1

2

Battery acid causes burns. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing.

Antidote (external): Flush with water. Antidote (eyes): Flush with water for 15 minutes and seek medical attention immediately. Antidote (internal): Drink large quantities of water or milk. Do not induce vomiting. Seek medical attention immediately.

Failure to comply could result in death or serious injury.

4 1

2

3

4 DC04D588

Two persons are required for this procedure. One person should sit in the machine operator’s seat and the other should make the connection. Make sure the person making the connection is wearing hand and face protection.

The starting system of this machine is 24 volt so make sure the booster battery is also 24 volt.

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

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

1. Move vehicle or machine to be used for boosting as close to the ba tter y box o f the disabled machine as possible.

2. Set the starter key switch to OFF for both boost vehicle and disabled vehicle. Check that the safety lock lever is in the LOCKED position and the control lever is in the NEUTRAL position on both boost vehicle and disabled vehicle.

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

3. Connect the booster cable (red) clip to the po sitive (+) te r mina l on th e ba tter y o f th e disabled machine.

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

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

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

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

8. Start the engine of the disabled machine.

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

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

10. Check and repair the cause of the problem on the disabled vehicle.

4-6

CHAPTER 4 - OPERATING INSTRUCTIONS STOPPING THE ENGINE

INSPECTION AFTER STARTING ENGINE

NOTICE: Run the engine for at least five minutes at low speed before stopping. Stopping the engine while running at high speed can damage seals and oil due to increased engine temperature.

Check the following after starting the engine.

2

1

NOTICE: Careless movement of any control levers may cause unexpected movement of the machine.

Set the safety lock lever to the LOCKED (up) position before leaving the cab.

NOTICE: Make sure the swing area of the machine is clear of people and obstacles before operating, Know the position of the travel motors before starting to travel and sound the horn before starting operation.

Safety Lock Lever Locked

UYN00020077J01

Unlocked

1. STARTER KEY SWITCH 2. THROTTLE POTENTIOMETER

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

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

ULFX1203007E01

3. Turn the throttle potentiometer (2) all the way to the LO speed position for five minutes. This lowers the coolant temperature.

4. Turn the starter key switch (1) to OFF to stop the engine.

5. Remove the starter key switch (2).

RELEASING HYDRAULIC TANK PRESSURE After the engine stops, the air pressure remaining in the hydraulic tank can be released by pushing the valve on the air breather rubber cap five to seven times. The air breather is mounted on the upper part of the hydraulic tank.

1. With the engine running, set the safety control lever to the LOCKED (up) position.

2. Move all control levers.

3. Make sure all functions do not operate when the safety control lever is in the LOC KED (up) position.

4. Move the travel control levers to make sure the machine does not move.

NOTICE: If any improper operation is found, stop the machine immediately. Contact the dealer/distributor and have the machine repaired.

Push Valve

UYN00020077J01

4-7

CHAPTER 4 - OPERATING INSTRUCTIONS Checking Function of Engine and Gauge Cluster (Multi-Display) NOTICE: If a warning is displayed on the gauge cluster (multi-display), stop the engine immediately and investigate the cause.

CHARGE ERROR

H

1

2

UYN00030074E05

1. ENGINE COOLANT TEMPERATURE METER 2. FUEL LEVEL METER

1. Check for oil and water leaks around the engine.

2. Check that there are no warnings displayed on battery charge and engine hydraulic pressure and that the readings of the engine coolant temperature meter (1) and fuel level meter (2) are correct.

3. Check that exhaust sound, color and vibration are normal, especially after warmup and without load.

Exhaust gas color Colorless or light blue

Symptom Normal

Black

Abnormal; incomplete combustion

White*

Abnormal; Oil combustion due to oil loss through piston ring or valve guides

* NOTE: In cold weather, exhaust gas may appear white. Be careful not to mis-diagnose.

4-8

CHAPTER 4 - OPERATING INSTRUCTIONS

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

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

4. When the engine coolant temperature gauge points within the white range, engine warm-up is complete.

10:25 H

2

M1715

The optimum operating temperature for this machine is a bo u t 5 0 de gr ee s C. Pe r fo r m th e fo llowin g procedure to warm up the machine.

1

2

ENGINE WARM-UP NOTICE: Do not rev the engine while idling. It may cause engine and machine failure.

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

UYN00030075E05

2 UYN00020077J01

2. During warm up, visually and audibly inspect engine for abnormal conditions such as unusual ex h a u s t c o l o r, e x c e s s i ve v i b r a t i o n s a n d excessive or unusual noises.

3. Should problems occur, adjustments or repairs.

make

necessary

4-9

CHAPTER 4 - OPERATING INSTRUCTIONS 4. Extend and retract each hydraulic cylinder several times to circulate and warm the hydraulic oil.

HYDRAULIC OIL WARM-UP

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

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

M1715

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

A ULC00030007E01BOOM

5. Operate the swing and travel functions slowly to circulate and warm the hydraulic oil.

1 B UYN00020077J01

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

2. Move throttle control to HI idle position.

3. Operate the bucket slowly for about 2 minutes, alternately dumping and holding for 10 to 15 seconds each time.

ULC00030007E01BUCKET

4-10

CHAPTER 4 - OPERATING INSTRUCTIONS WORK MODE SELECT KEY The work mode select (MODE) key is used to select the most effective work mode for the job.

There are two settings:

10:25 10:25

S (s t and ard) - s ui ta bl e for standard digging and loading, sa ve s fu e l c o n s u m p ti o n a n d provides balanced power distribution.

H (he avy d uty) - su itable fo r heavy duty digging, gives priority to the workload at high speed.

The S mode is the default factory setting, but the machine will remember the last setting used and start operating in that mode when the engine starts.

NOTICE: Operation of the machine with the improper work mode may cause damage to the machine. When the wrong work mode has been selected, the work mode lamp will flicker.

To change the work mode, press the MODE button. If “S” appears in the LCD screen, the machine will operate in standard mode. If “H” appears, it will operate with the heavy duty mode.

10:25 H

UYN00030075E05

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CHAPTER 4 - OPERATING INSTRUCTIONS

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

OPERATING PATTERN DECAL Th e i llu s t ra t io n s a r e a r e p r e s e n ta t io n o f th e CONTROLS decal located inside the right side window of the operator cab. Study this decal and understand the directions each control can be operated and the functions associated with each movement of particular control. Detailed instructions for each control and its functions are explained on the following pages of this chapter. Should this decal become damaged or missing, install a new one.

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

WARNING If your machine is set to the operational BHL pattern control, change, make sure to remove the ISO/SAE operation pattern control decal inside the right side window and use the decal supplied for the optional BHL pattern control. This decal should be placed inside the door below the handle. See Pattern Control Change (BHL pattern) for detailed information on how to operate the pattern control changer. Failure to comply could result in death or serious injury. M1716

HYDRAULIC CONTROL LEVERS

LEFT CONTROL LEVER OPERATING PEDAL (BREAKER AND NIBBLER)

LEFT TRAVEL LEVER AND PEDAL

RIGHT TRAVEL LEVER AND PEDAL

RIGHT CONTROL LEVER

DOZER CONTROL LEVER

OPERATING PEDAL (BOOM SWING)

ULFX1203008E01

HYDRAULIC CONTROL LEVERS

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CHAPTER 4 - OPERATING INSTRUCTIONS

MACHINE OPERATION The following instructions describe the basic function of each hydraulic control. Read these instructions and practice with a machine in a safe, clear area in order to operate safely and efficiently.

CAUTION IN MACHINE OPERATION

Front

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

Always have the travel motor positioned correctly.

Failure to comply could result in machine damage, injury or death.

Right

M1726

Track Idler Rear Left ULFX1203009E01

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

M1727

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

4-13

CHAPTER 4 - OPERATING INSTRUCTIONS MACHINE TRAVEL This machine incorporates several travel controls for the convenience of the operator. Each track can be op erated in dep end en tly to tur n the ma chine, simultaneously counter rotate the machine or travel straight.

F

N R

The travel motor is normally on the rear side of the machine and the track idler is on the front side.

Before operating the machine, identify the position of the travel moto r. Wh en th e trave l mo tor is positioned on the front side, the travelling operation reverses.

Before operating the machine, sound the horn to warn workers on the site.

WARNING

ULFX1203010B01

F. FORWARD N. NEUTRAL (STOP) R. REVERSE

Do not move the travel speed switch during travelling. Change the travel speed in low (1st) speed when the machine is running downhill or loading/unloading from trailer. Sudden change of machine stability may cause an accident resulting in injury or death.

FORWARD/REVERSE TRAVEL 1. Make sure the safety lock lever is in the UNLO CKED (down) position. O perate the boom, arm, and bucket control levers to raise the attachments from the ground.

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

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

ULFX120311B01

FORWARD/REVERSE

PIVOT TURN 1. Push the left travel lever toward front of machine to turn machine to the RIGHT in forward motion.

2. Push the right travel lever toward front of machine to tur n mach ine LEFT in forwa rd motion.

3. Pull the left travel lever back to turn machine LEFT in reverse motion.

4. Pull the right travel lever back to turn machine RIGHT in reverse motion.

ULFX1203012B01

PIVOT TURN

4-14

CHAPTER 4 - OPERATING INSTRUCTIONS COUNTER ROTATING MACHINE (SPIN TURN) To counter rotate machine to the left, pull the left travel lever back and push the right travel lever forward.

ULFX1203013B01

COUNTER ROTATING MACHINE

CHANGING TRAVEL SPEED The travel speed change switch is located on the switch panel of the gauge cluster.

There are two travel speeds available - LOW (1st) and HIGH (2nd).

Wh en the en gin e sta r ts, travel sp eed i s automatically set to LOW (1st) speed and the turtle icon appears on the display.

To change to HIGH (2nd) speed, press the travel speed key on the gauge cluster (symbolized by the rabbit symbol).

The speed is changed to HIGH, the rabbit icon replaces the turtle icon on the display, and the light indicator above the key is turned ON.

BS06H067

Se t to L OW ( 1s t sp e ed turtle icon) when moving the machine on a rough or soft road, slope, or narrow place, or when powerful tractive force is required.

Set to HIG H (2 nd spee d rabbit icon) when moving the machine on flat, hard ground.

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

4-15

CHAPTER 4 - OPERATING INSTRUCTIONS TRAVEL STOP NOTICE: Do not stop the machine suddenly -- slow down to low speed before coming to a complete stop. Sudden change of machine stability may cause an accident resulting in serious injury or death.

N N

To stop the machine, return the right and left travel levers (1) to neutral (N) position.

1

UYN0030050J01

1

PARKING THE MACHINE

3

WARNING A machine that is not parked correctly can go out of control and cause an accident. If you must temporarily park on the side of a hill, put the front of the machine toward the bottom of the hill. Make sure the machine is behind an object that will not move.

Put blocks in front of each track on the downhill side.

Failure to follow these instructions can cause injury or death.

1 UYF00030017E02

SA152

Always park the machine on a hard, level surface.

1. When parking on a slope is unavoidable, position the machine as shown. Block (1) the crawler track, dig the bucket teeth into the ground, lower the dozer blade (if equipped) to the ground. This will help prevent machine movement.

2. Set the safety lock lever to the LOCKED (up) position to avoid any unexpecte d machine movement.

3. Stop the engine before leaving the cab.

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

4-16

1. BLOCK

CHAPTER 4 - OPERATING INSTRUCTIONS 5. Place both travel levers (1) in the NEUTRAL position.

11

UYFX1203015B01

1. BLOCK

6. Turn throttle dial (2) to low idling position and cool the engine down for about five minutes.

7. Put the bucket on the ground, holding the bucket bottom level.

8. Set the starter key switch (3) to OFF and stop the engine, then pull out the starter key.

3

2 UYN00030063J01

2. THROTTLE DIAL 3. STARTER KEY SWITCH

9. Pull up the safety lock lever (4) to LOCKED (up) position.

10. When necessary to leave the machine, close the windows and doors and lock it.

4

UYN00030064J02

4. SAFETY LOCK LEVER - LOCKED

4-17

CHAPTER 4 - OPERATING INSTRUCTIONS MACHINE OPERATION IN WATER If necessary to travel or operate machine in a river or other water, the bed must be firm and water curren t slow. Wa te r must no t be dee per than indicated in the illustration.

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

Water depth

(A) Bed must be firm & stable

(A) 540 mm (1'-9") ULFX1203001E01

GETTING OUT OF SOFT GROUND

1

3

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

Freeing one crawler belt/track 1. When either side of the crawler belts/tracks gets caught in the mud, place logs or boards on the mud to form a base.

2. Operate the boom to form a 90-to-100 degree angle with the arm.

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

UYN0030053J01

ONE CRAWLER BELT/TRACK CAUGHT IN MUD

Freeing both crawler belt/tracks 1. When both sides of the crawler belt/tracks get caught in the mud, and the machine skids, place logs or boards on the mud to form a base as described above.

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

3. Then move the bucket control to pull the machine toward hard ground.

4. If no hard ground is available, get expert help to free the stuck machine.

UYN0030054J01

BOTH CRAWLER BELTS/TRACKS CAUGHT IN MUD

4-18

CHAPTER 4 - OPERATING INSTRUCTIONS Cleaning the belt/tracks To clear the belt/tracks of mud, sand, gravel, or soft ground, follow this procedure.

1. Lift each crawler belt/track off the ground by placing the bucket on the ground and pushing the boom and arm against the ground.

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

3. With the belt/track raised, rotate it in forward and reverse to allow the clogged material to loosen and fall off.

4. Scrape remaining material off the belt/track.

UYN0030055J01

CLEANING BELTS/TRACKS

4-19

CHAPTER 4 - OPERATING INSTRUCTIONS

MACHINE ATTACHMENT AND SWING CONTROLS The following instructions are to be used with hoe bucket attachment only. If other attachments are used, consult the operator’s manual for those attachment.

WARNING Before operating this machine, review and understand all Safety Precautions in the Safety Section of this manual.

Failure to comply could result in death or serious injury.

M1416

Boom operation Operation of the boom is performed by pushing and pulling the right control lever forward and backward.

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

1. Pulling right control lever BACK raises boom.

2. Pushing right control lever FORWARD lowers boom.

3. Returning right control lever to the neutral (center) position stops operation of the boom.

ULC00030010E01

PULL BACK - BOOM UP

PUSH FORWARD - BOOM DOWN

Arm operation Operation of the arm is performed by pushing or pulling the left control lever forward and backward.

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

1. Pulling left control lever FORWARD moves the arm out.

2. Pushing left control lever BACK moves the arm in.

3. Returning left control lever to the neutral (center) position stops operation of the arm.

ULC00030011E01

PULL BACK - ARM IN

PUSH FORWARD - ARM OUT

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

Operation of the bucket is performed by moving the right control lever to the right or left.

1. Moving right control lever to the LEFT moves the bucket IN (digging).

2. Moving the right control lever to the RIGHT moves the bucket OUT (dumping).

4-20

ULC00030012E01

PULL LEFT - BUCKET IN (DIGGING)

PUSH RIGHT - BUCKET OUT (DUMPING)

CHAPTER 4 - OPERATING INSTRUCTIONS Swing operation Swing operation is performed by moving the left control lever to the right and left. swing speed is determined by the amount the lever is moved.

WARNING Check all controls and safety devices in a safe, open area before starting work. Failure to comply could result in injury or death.

M1088

NOTICE: Use swing flashers during swing operations.

Turning on the swing flashers Main screen

10:25

SWITCH STATUS CLOCK/CONTRAST

H (a)

SWING FLASHER OFF

(b) AUTO WARM-UP

SWING FLASHER ON

FEED

FEED

OFF

(d) FEED

(c)

SWING FLASHER OFF

SWING FLASHER ON

OFF ON

OFF ON

(e) ULY00020003E02

The swing flashers should always be turned ON during swing operations.

1. Press the SELECT key on the gauge cluster.

“SWITCH STATUS” will display on the screen.

SWITCH STATUS CLOCK/CONTRAST

10:25

H S

UYN0020042J01

1

3

8 UYN0020039J01

8. SELECT KEY

4-21

CHAPTER 4 - OPERATING INSTRUCTIONS 2. Press the SELECT key again. “AUTO WARMUP OFF” will display on the screen.

3. In operation of FEED, “SWING FLASHER OFF” is displayed.

4. Press the SELECT key again, the background color behind the word, “OFF” reverses and “SWING FLASHER OFF” displays.

OFF 10:25

AUTO WARM-UP

H S

FEED

5. Switch from OFF to ON in operation of FEED and set by pressing the SELECT key.

6. After adjustment, press the SELECT key again and store “SWING FLASHER ON”.

7. Turn the starter key switch ON to start the engine and the swing flasher flickers to warn workers during swing operation.

8. Swing flashers and the rear work light synchronize; therefore they are turned on and off simultaneously.

8 UYN0020039J01

8. SELECT KEY

WARNING Make certain the area around the machine is clear of people and objects before attempting these procedures. Failure to comply could result in death or serious injury.

M103B

NOTICE: Sound horn before beginning swing operation.

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

ULC00030013C01L

4-22

CHAPTER 4 - OPERATING INSTRUCTIONS 2. Moving the left control lever to the RIGHT swings the machine to the right.

3. Returning control to the neutral (CENTER) position stops swing.

ULC00030013C01LR

1

3

Dozer operation

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

M1416

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

The dozer blade operating lever (1) is located on the right side of the right hand operator console.

B

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

1

2. Move throttle potentiometer to the “HI IDLE” position.

A

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

4. Pull the dozer blade operating lever (A) to lift the blade.

5. Push the blade operating lever (B) forward to lower the blade.

A

B ULFX1203014B01

1. DOZER BLADE OPERATING LEVER

4-23

CHAPTER 4 - OPERATING INSTRUCTIONS

PRACTICES TO IMPROVE EFFICIENCY Use Arm In Action Operate the bucket at shallow depths and use the arm in action to fill it. Setting the bucket too deep will decrease machine efficiency.

ULC00030016E01

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.

ULC00030017E01

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

ULC000300108E01

Maximum digging force position The attachment will provide maximum digging force when the arm and boom are at 90 to 100 degrees of each other.

1

ULC000300109E01

1. 90 - 110 DEGREE ANGLE

4-24

CHAPTER 4 - OPERATING INSTRUCTIONS Cleaning sand and soil from bucket Operate arm to a near level position and bring the bucket to a dumping position. If sand and soil do not fall out, move the bucket lever right and left a few times.

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

ULC00030020E01

Stop swing motion early To stop swing action, release the swing lever before reaching the final point of digging or dumping.

ULC00030021E01

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

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

1. When levelling ground toward the 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.

ULC00030022E01

2. When levelling ground away from the machine, reverse the procedure described in Step 1.

3. The bucket may be used with the boom to back fill and level. By controlling the action of the boom work lever, you can dig a slope.

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

4-25

CHAPTER 4 - OPERATING INSTRUCTIONS Operating the shovel Digging with the shovel differs slightly from digging with the backhoe.The excavating power during shovel operations is less than that during backhoe operations.

1. Using the arm cylinder, scrape the ground.

A

2. Scrape the ground at a 2-3 degree angle to improve drainage in areas not near the groundwater level.

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

4. If the 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.

ULC00030023E01

A. GRADE AT A 2 - 3 DEGREE SLOPE FOR DRAINAGE

PRECAUTIONS AFTER OPERATION 1. Check the gauge cluster for engine coolant level, engine oil pressure and fuel level.

HIGH ENG WATER TEMP.

2. If warnings of engine coolant and engine oil pressure are displayed, move the machine to a s a fe p l a c e a n d s t o p t h e e n g in e . R e p a i r according to applicable proc edures in "INSPECTION & MAINTENANCE CHART".

H

3. Check for any oil or coolant leakage. Check the a t t a c h m e n t , ex t e r i o r, a n d t r a ve l s y s t e m components. If leakage and damage are found, repair immediately according to applicable procedures in "INSPECTION & MAINTENANCE CHART".

4. Refill with fuel. However, do not overfill (to the top of the tank) to avoid overflowing due to fluid expansion under normal temperature.

5. Remove mud, etc., stuck to the traveling components.

4-26

UYN00030082E02

2

CHAPTER 4 - OPERATING INSTRUCTIONS MACHINE OPERATION IN ADVERSE WEATHER CONDITIONS Operation in Extreme Cold 1. Follow procedures at the beginning of this chapter as starting the engine may be difficult in extremely cold temperature.

2. Use an engine oil, hydraulic oil, and diesel fuel d e s i g n e d fo r u s e i n c o l d c l i m a t e s . S e e Ma in te n a n c e S e ct io n fo r r e fe re n c e. Ke e p batteries fully charged.

3. Make certain to perform machine warm-up procedures as described at the beginning of this chapter to prevent premature wear or damage to pumps, motors, and other components.

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

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

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

5. Keep battery terminals free of ice and snow that could cause the terminals to short circuit and d a m a g e t h e m a c h i n e . C h e ck t h e b a t t e r y electrolyte (acid) level frequently and fill as necessary with distilled water. If the machine will be left outside overnight, removing the batteries and storing in a warm area is recommended.

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

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

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

7. Keep a close watch on the gauges for warning icons during operation. Avoid unnecessary low speed running of the engine during operation.

Operation in High Altitudes 1. Due to low atmospheric pressure at high altitudes, a decrease in engine power will be experienced. Be aware of this when handling heavy loads in high altitude climates.

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

Operation in Sandy and Dusty Areas 1. Check the engine air cleaner elements frequently in sandy or dusty conditions.

2. When air cleaner restriction lamp illuminates, change filters immediately regardless of time intervals.

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

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

Operation at Seashore or Salty Climate

Operation in Extreme Heat 1. Use an engine oil, hydraulic oil and fuel designed for use in hot climates. See Maintenance Section for reference. Also keep batteries fully charged.

2. Clean radiator, oil cooler and debris screen often to prevent damage or overheating.

NOTICE: Do not allow dirt and debris to accumulate in the radiator fins, oil cooler fins or debris screen, as this may cause a fire.

3. Keep all belts properly tensioned.

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

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

2. Frequently check all mounting hardware for proper tightness. Torque to proper value to aid in preve nting sa lt from e nter ing th e mach in e systems.

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

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

4-27

CHAPTER 4 - OPERATING INSTRUCTIONS

OPTIONAL EQUIPMENT When installing optional equipment on the machine, it is necessary to match stability, hydraulic system pressure, and required hydraulic oil volume. Consult with your dealer when selecting optional equipment.

HYDRAULIC BREAKER AND NIBBLER When installing a hydraulic breaker or nibbler on the machine, it may be necessary to install additional hydraulic piping and reinforcement for the machine arm. Consult your dealer to make the necessary arrangements.

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

M1087

Before using the breaker or nibbler, read and understand the operator’s manual that comes with the device. Also, read and understand the section on Prohibited Work in Use of Nibbler/Breaker in this manual.

Precautions for Hydraulic Oil When the hydraulic breaker or nibbler is removed after its installation, apply a blinding plug to the stop valves attached on the tip of the arm and openings on the hydraulic piping to prevent invasion of dust, water, etc.

Before operation, check clamps for looseness and check for any leakage on hose and tube connections.

Before Operating the Nibbler or Breaker The nibbler/breaker attachment must have the selector valve set to the correct position for the breaker or nibbler operation.

CAUTION

The procedure for switching is described on a safety decal located near the valve. Read and understand the switching procedure before operating the nibbler or breaker.

UYT00010016F0E

SAFETY DECAL FOR NIBBLER/BREAKER SELECTOR VALVE

4-28

CHAPTER 4 - OPERATING INSTRUCTIONS Setting the selector valve 1. Position the attachment on the ground and stop the engine.

2. Place the safety lock lever in the LOCKED (up) position.

N

B

3. Use a 3 mm Allen wrench to loosen and remove bolt (1) on the selector valve lever.

1

4. Turn the selector valve lever (2) to the desired position.

2

To operate the nibbler, move the selector valve lever toward the N marked on the valve (N).

To operate the breaker, move the selector valve toward the B marked on the valve (B).

UYT0070002E01

1. BOLT N. NIBBLER 2. SELECTOR VALVE LEVER B. BREAKER

5. After positioning the lever, use the Allen wrench to tighten the bolt.

Setting the stop valve The stop valve (1) located on the top end of the excavator arm is used to stop the flow of hydraulic oil.

The diagram at right depicts the flow:

1

Free: Hydraulic oil flows Stop: Hydraulic oil stops flowing Before removing the attachment set the stop valve to the STOP position.

24

Tools used STOP VALVE (1)

LOCATION ARM

mm

TOOLS SPANNER (24 MM)

Free

Stop UYN0070006E01

1. STOP VALVE

Using the foot pedal

1

NOTICE: Always check the foot pedal control pattern before operation.

1. To operate the pedal, release the pedal lock on the right front side of the driver’s seat.

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

M1087

UYT0070014E01

1. PEDAL LOCK

4-29

CHAPTER 4 - OPERATING INSTRUCTIONS

WARNING

B

Make sure to set the pedal lock to UNLOCKED position when the breaker or nibbler is not in use.

Unexpected contact with the UNLOCKED position of the pedal may cause severe injury or death. Do not put your foot on the pedal except when operating the machine.

C

1

2. Raise the selector valve lever (1) upward and shift it to position (A) to lock the lever.

A

3. When the breaker is used, set the lever to position B.

ULF00070001E01

1.

A. B. C.

4. When the nibbler is used, set the lever to position C. Take note of the safety decal that describes the operation of the selector lever and foot pedal.

LEVER LOCKED POSITION BREAKER NIBBLER

CAUTION

UYT00010017E03

Pedal Operation for the Nibbler (Crusher) The re latio nsh ip be twe en p ed al p os itio n an d direction of oil flow is shown at right.

When the toe side (A) of the pedal is depressed, oil flows into the left piping of the attachment.

A

When the heel side (B) of the pedal is depressed, oil flows into the right piping of the attachment.

Foot Pedal Depress toe section (A) Depress heel section (B)

Operation Nibbler closes Nibbler opens

B UYT0007006E02

A. TOE SIDE OF PEDAL B. HEEL SIDE OF PEDAL

4-30

CHAPTER 4 - OPERATING INSTRUCTIONS Pedal Operation for the Breaker W h en th e b re a ke r is us e d , th e pe d a l c a n b e operated only on the toe side (A).

Low pressure side

When the toe side (A) is depressed, oil flows into the left piping of the attachment.

Foot Pedal Depress toe section (A) Pedal in neutral position

Operation Breaker starts operation Breaker stops operating

High pressure side

A

NOTICE: Do not leave machine with engine running.

B

UYT00070007E02

4-31

CHAPTER 4 - OPERATING INSTRUCTIONS

PROHIBITED WORK IN USE OF BREAKER Do Not Use Swing Force Do not use the swing force of the machine for pushing or sliding objects. This will cause premature fa ilur e o f th e at ta ch m e nt a n d o th e r m ac h in e components.

UYN00070014J01

Do Not Pry and Break Forcibly Do not use the breaker to pry and break rock and concrete. This may damage the hydraulic breaker, a n d t h e ex ca va to r b o o m, a r m a n d hy d ra u lic cylinders.

UYN00070028J01

Do Not Put the Arm in Vertical Position The arm should not be operated in the ver tical position to prevent the hydraulic cylinder from vertical shocks. This may damage the rod seal and piston and cause oil to leak from those sections.

UYN00070029J01

Do Not Overstroke the Cylinders Do not operate boom, arm or bucket cylinders at stroke ends when using a breaker attachment. Doing this can cause undue load on the cylinder rods and result in damage.

UYN00070015501

4-32

CHAPTER 4 - OPERATING INSTRUCTIONS Do Not Use for Unintended Purposes Use the attachment only for its intended purpose. If not used in accordance with the manufacturers instructions, the excessive pressure exerted on the boom, arm and frame structure of the machine will cause premature failure of the components.

UYN00070016J01

Do Not Operate Continuously Operate the nibbler/breaker in 1 minute intervals.

Operation for longer than 1 minute at a time can cause high oil temperatures and the accumulators, cylinder seals and possibly pump damage.

Within One Minute

UYN00070018E01

Stop Hose Surge Should the hydraulic hoses begin to surge or vibrate abnormally during operation of a breaker or nibbler, im me d ia t e ly s t o p o p e r a ti o n a n d c o n t a ct o u r dealer/distributor for assistance. This problem often is a result of damaged accumulators and can also result in valve failure.

UYN00070019J01

Do Not Use Dropping Force Do not use the dropping force of the attachment to break or drive objects. This will cause extensive damage to the attachment and machine structure.

UYN00070017J01

4-33

CHAPTER 4 - OPERATING INSTRUCTIONS Do Not Lift Do not use an optional attachment to lift or transport objects or material. Doing so can cause extensive damage to the attachment, the machine structures or cause injury or death due to slipping or dropping of load due to improper attachment.

UYN00070020J01

Do Not Work Underwater Do not use the breaker underwater - it can rust and damage the seals of the hydraulic system. If rust, dust, water or other contaminants enter the hydraulic oil, it could damage the hydraulic equipment.

UYN00070021J01

Do Not Exceed Working Ranges The balance on the machine becomes unstable in the unacceptable working range positions indicated w it h a ( B ) - s h o w n a t r i g h t . Th e r e i s r is k o f overturning the machine in these ranges. Do not carry out breaker work in unacceptable working ranges.

B

A

A

B UYN00070022J01

A. ACCEPTABLE WORK RANGE B. UNACCEPTABLE WORK RANGE

Do Not Hit Chisel Against Boom To avoid interference of chisel with boom, operate control lever of arm and boom carefully.

UYNX0007001E01

4-34

CHAPTER 4 - OPERATING INSTRUCTIONS Do Not Lift the Machine Unless Necessary Unnecessary machine lifting is not allowed because it may damage the attachment.

To properly lift the machine, slowly press the ground with the attachment and lift the machine only slightly - 10-15 cm (3.9 - 5.9 in).

A

UYN00070024E01

A. 10-15 CM (3.9 - 5.9 IN)

4-35

CHAPTER 4 - OPERATING INSTRUCTIONS PERIODIC INSPECTION AND MAINTENANCE INTERVAL Operation of the breaker accelerates the deterioration of hydraulic oil. Early deterioration of hydraulic oil may cause problems with control valves, early wear and possible seizure of the hydraulic pump, leading to breakdown of the machine’s hydraulic system. Replace filters and oil as indicated in the table below. Prepare and update a maintenance record using the example provided.

Component

Location

Hydraulic oil Return filter element kit (P/No. YR52V01004R300

Replacement Interval First Replacement

Second Replacement

Interval

Hydraulic tank

-

-

Every 1000 hours

Hydraulic tank

50 hours

250 hours

250 hours

REINFORCING ATTACHMENT When operating the machine with the standard nibbler/breaker attachment, reinforcement of the arm is not necessary. However, when operated in special applications, it may be necessary to provide reinforcement to the arm. Consult your dealer if operating a nibbler/breaker attachment under special conditions.

4-36

CHAPTER 4 - OPERATING INSTRUCTIONS

PROHIBITED WORK IN USE OF NIBBLER The wrong nibbler operating method may cause damage to the attachment or excavator or cause dangerous work conditions. Learn the correct and safe method of operating the nibbler.

Do Not Strike Objects Do not hit or strike objects with the nibbler. Hitting or striking will put undue force on the nibbler, machine, boom, arm and link and result in equipment damage.

UYN00070035J01

Do Not Pry or Pull While Holding Do not pry or pull with the nibbler while it is holding an object.

UYN00070033J01

Do Not Swing While Holding Do not swing the machine while the nibbler is holding an object.

UYN00070034J01

4-37

CHAPTER 4 - OPERATING INSTRUCTIONS Do Not Hold Objects Obliquely Position the machine and the nibbler so that the nibble jaws do not open at an oblique angle. This puts undue stress on the cylinders.

UYN00070036J01

Do Not Travel While Nibbler is Holding Do not use travelling force to pull a building or structure while the nibbler is holding the top of it.

UYN00070038J01

Watch for Falling Debris Position the machine to protect it from falling debris.

NOTICE: A three-faced guard is provided for machines used for demolition work. When using a standard machine for demolition work, it is advisable to use a three-faced guard. Contact your dealer.

UYN00070039J01

Do Not Overstroke the Cylinders Do not exte nd the hydra ulic cylinders to the ir m a x i m u m s t r o k e w h e n u s i n g t h e n i b b l e r.

Overstroking the cylinders can cause damage to the cylinders, links, and rod pins.

UYN00070037J01

4-38

CHAPTER 4 - OPERATING INSTRUCTIONS Do Not Work Facing Sideways Do not operate the attachment over the sides of the machine. This could cause machine rollover. Do not operate the machine abruptly. Always operate it slowly.

UYN00070040J01

Do Not Move Arm Rapidly Do not lower the arm rapidly or extend the cylinder to stroke end rapidly. The impact could damage the arm cylinder. Operate the attachment slowly.

UYN00070040J02

4-39

CHAPTER 4 - OPERATING INSTRUCTIONS

PRECAUTION FOR BREAKERS FROM DIFFERENT MANUFACTURERS This is a general outline of how breakers should be used and may differ with excavator models. Always contact the breaker manufacturer before field mounting.

NOTICE: There are some differences between manufacturers in the design and handling of breakers. The hydraulic system and piping may differ. For this reason, consult with the manufacturer before mounting a breaker in the field.

4-40

CHAPTER 4 - OPERATING INSTRUCTIONS

USE OF AN ACCUMULATOR NOTICE: Check the hydraulic system pressure while using the breaker/nibbler attachment. If there are pressure “spikes” during operation, an accumulator should be installed. Check with your dealer on the proper installation of high and low pressure accumulators. The following instruction is a general guideline.

Placing High and Low Pressure Accumulators See graphic at right.

N P K T O K U KRUPP OKADA FURUKAWA

They must be placed basically (depending upon models) Check the oscillation of the pulsation of the breaker pressure and if pulsation is large, always install accumulators.

UYN00070045E01

Installing Accumulators 1. High pressure side: Measure the pulse oscillation by pressure on the high pressure side of the breaker at the inspection por t for the pump’s d eliver y p re ssure by actuating the breaker at the full revolution of the engine in m o d e H a n d s e t t h e m a x u mu m p r e ss u r e difference to within 20% of the excavator’s recommended hydraulic system pressure of 29.4 MPa {300 kgf/cm2} (4.270 psi).

max

min

Max. - Min. < system press

20% SYT000630052E02

If it exce ed s 20 %, ins tall a h ig h p re ssu re accumulator.

NOTICE: The recommended hydraulic system pressure is 29.4 MPa {300 kgf/cm2} x 20% = 5.88 Mpa {60 kgf/cm2} (850 psi). If it is more than this, install an accumulator.

2. Install accumulator depending on the result of verification test.

3. Low pressure side: Measure the inlet pressure of th e re tur n filte r o n the br ea ke r sid e by actuating the breaker at full engine revolution in the H mode. If the maximum pressure exceeds 0.48 Mpa (4.9 kgf/cm 2 ) (70 psi), install a low pressure accumulator.

Max. < 0.48 MPa {4.9 kgf/cm2} (70 psi).

Contact the breaker manufacturer regarding the capacity and charge pressure of accumulators.

4-41

CHAPTER 4 - OPERATING INSTRUCTIONS Installing a Relief Valve

N&B High Pressure side

Depending on the type of accumulator installed, it may also be necessar y to install a relief valve.

Contact the breaker manufacturer for relief valve specification and proper pressure-setting method.

N&B Low Pressure side (Return)

Plug

Boom UYV00070002E03

4-42

CHAPTER 4 - OPERATING INSTRUCTIONS

PROPORTIONAL HAND CONTROL (EXTRA, NIBBLER, AND BREAKER) 1

3

4

2

5

ULFX1307001E01

LEFT HAND CONTROL LEVER SWITCH 1. EXTRA CONTROL SWITCH 2. HORN SWITCH

RIGHT HAND CONTROL LEVER SWITCH 3. NIBBLER (CRUSHER) CONTROL SWITCH 4. BREAKER CONTROL SWITCH 5. RESERVE SWITCH

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

M1087

Extra hand control .

To actuate the “extra operation” control, slide the switch (1) located on the left control lever. The hydraulic flow rate increases according to the slide distance of the option switch.

Extra Hand Control Switch Operation Procedure

1

Oil Flow

Slide to the left

Extra (LH)

Slide to the right

Extra (RH)

UFX1707002E01

1. EXTRA HAND CONTROL SWITCH

4-43

CHAPTER 4 - OPERATING INSTRUCTIONS Horn switch To sound the horn, push the grey button located on the operator’s left control lever. The hor n is a momentary push button.

2

UFX1707003E01

2. HORN BUTTON

Nibbler (Crusher) control switch .

NOTICE: Before operating the nibbler or breaker, make sure the selector valve is switched to the correct option. See section on switching the selector valve in this manual.

To actuate the nibbler (crusher), operate the switch (3) located on the right control lever. The hydraulic flow rate increases according to the slide distance of the option switch.

NOTICE: Do not touch the breaker switch button (4) when you operate the nibbler.

Nibbler Switch Operation Procedure

3

4 UFX1707004E01

3. NIBBLER (CRUSHER) SWITCH 4. BREAKER BUTTON

Operation

Slide to the left

Nibbler close.

Slide to the right

Nibbler open.

NOTICE: Avoid injury or death. Do not leave the machine with the engine running.

Breaker control NOTICE: Before operating the nibbler or breaker, make sure the selector valve is switched to the correct option. See section on switching the selector valve in this manual.

3 4

5

To actuate the breaker, push the button (4). Release the button to stop operation. Operate the breaker for 30 seconds, then release the button.

Breaker Button Operation Procedure

Operation

Depress the button.

Breaker starts operating.

Release the button.

Breaker stops operating.

NOTICE: The breaker can also be operated by sliding the switch (3) to the left. However, it is preferable to use the breaker button.

NOTICE: Avoid injury or death. Do not leave the machine with the engine running.

Reserve switch When the machine has an additional option, the reserve switch (5) is configured to control that option.

4-44

UFX1707005E01

3. BREAKER SWITCH 4. BREAKER BUTTON 5. RESERVE BUTTON

CHAPTER 4 - OPERATING INSTRUCTIONS

PROPORTIONAL HAND CONTROL (NIBBLER AND BREAKER) 2

3

1

4

ULFX1307002E01

LEFT HAND CONTROL LEVER SWITCH RIGHT HAND CONTROL LEVER SWITCH 1. HORN SWITCH 2. NIBBLER CONTROL SWITCH 3. BREAKER CONTROL SWITCH 4. RESERVE SWITCH

To actuate the nibbler, operate the switch (3) located on the right control lever.

To actuate the breaker, operate the switch (4) located on the right control lever.

4-45

CHAPTER 4 - OPERATING INSTRUCTIONS

PROPORTIONAL HAND CONTROL (EXTRA) 1

3

2

ULFX1307003E01

LEFT HAND CONTROL LEVER SWITCH RIGHT HAND CONTROL LEVER SWITCH 1. EXTRA CONTROL SWITCH 3. RESERVE SWITCH 2. HORN SWITCH

To actuate the extra, operate the switch (1) located on the left control lever.

Extra hand control .

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

1

Slide the switch (1) located on the left control lever to actuate the extra operation. As the switch slides, the hydraulic flow rate increases.

Switch operation Operatio procedure of option switch (1)

Oil flow

Slide to the left

Extra (L.H.)

Slide to the right

Extra (R.H.)

4-46

UYFX1707002E01

3. BREAKER SWITCH 4. BREAKER BUTTON 5. RESERVE BUTTON

CHAPTER 4 - OPERATING INSTRUCTIONS

HANDLING SUSPENDED LOADS SAFETY PRECAUTIONS The excavator is a machine designed specifically to perform digging/loading works, thus it must not be used to handle suspended loads. In the event, under exceptional conditions, it becomes necessary to handle materials, the following must be strictly implemented: The machine must be equipped with the appropriate options for load handing. Total compliance with the safety precautions for the operation of the excavator as a lifting device is also necessary.

Secure the loads to be raised using cables or chains fastened with appropriate hooking mechanisms.

Do not hook cables or chains to the bucket teeth.

No one should be allowed to remain under the raised load or within the excavator operating range for any reason whatever.

UYV00010127J01

Do not exceed specified lifting capacity. Incorrect fastening of slings or chains may cause boom/arm failure or failure of the lifting means with consequent bodily injuries and even death.

Always ensure that slings and chains used for lifting are adequate for the load and in good condition.

All lifting capacities are for the machine on a level surface. When working on a slope, lifting capacity is reduced.

In any case, comply with the current national or local regulations on this matter.

4-47

CHAPTER 4 - OPERATING INSTRUCTIONS OPERATING PROCEDURE FOR SUSPENDED LOADS The machine has been specifically designed to perfor m d igging and loading. The h andling of suspended loads completing the digging cycle is allowed, provided that the machine is equipped with the appropriate load-handling options.

WARNING: The machine should never be used for towing operations, uprooting or tearing apart.

The anti-drop valves located on the cylinders, the warning buzzer device, the table of loads posted in the cab and the hook on the link of the bucket linkage are safety devices that are par t of the load-handling option for the machine.

Handle suspended loads following current national and local regulations as well as the rules described in the previous section of this chapter.

To handle suspended loads, do the following: 1. Prior to starting work, check that the valves do not show evidence of damage or abnor mal noise. In the event abnormal conditions are found, contact your dealer and do not use the machine to handle suspended loads.

WARNING: To prevent injury, do not exceed the nominal load capacity of the machine. If the machine is not on a flat surface, the load capacity is reduced.

Always proceed with extreme care.

2. Set an engine speed appropriate for the hydraulic load required.

3. Evaluate (if known) the mass of the object to be handled and compare it with the data in the Rated Object Handling Capacities Table located in the cab.

Do not lift loads exceeding the maximum values prescribed by the table.

4. Prior to performing lifting operations, press switch (1 ) to activate the loa d-mome ntum sensor. This sensor, once the safety limit is reached, activates the sound warning device.

5. Check that the lifting devices (hooks, chains, etc.) are safe and free from signs of excessive wear. Ensure that lifting devices not provided with the machine comply with national and local regulations.

4-48

ULFX1207001E01

1. SWITCH

CHAPTER 4 - OPERATING INSTRUCTIONS 6. Secure the load with the appropriate hook (2) located on the bucket linkage rod, using slinging devices and chains adequate for the load to be lifted.

WARNING: Suspended loads can swing and rotate in all directions, thus there is the danger that they can hit bystanders or the cab of the machine. In order to limit this danger, it is required that all bystanders are moved away from the field of action of the machine and that the load is handled slowly. In the event the load rotates or swings during handling, slow down to a stop and lower it slowly to the ground, then correct the way it is slung.

7. To limit swinging of the load, avoid using cables or chains that are too long.

8. Check the surrounding working area and make sure that the path to be travelled with the load is free of obstacles.

WARNING: In the event the sound alarm is activated during the handling of the load, place the load onto the ground and check the load conditions, referring to the appropriate table in the cab.

9. Lift the load slowly, avoiding sharp movements which could cause swinging. Keep the load near the machine to improve stability. Operate along the longitudinal rather than the horizontal axis.

Lift the load from the ground to the minimum height required.

2 UYV00030019E01

2. HOOK

10. Position and place the load where desired, making sure that it is resting on a solid base appropriate for its mass.

11. Remove the chains.

4-49

CHAPTER 4 - OPERATING INSTRUCTIONS HOW TO READ THE TABLE OF SUSPENDED LOAD CAPACITIES A table titled, Rated Object Handling Capacities Table, is posted inside the cab.

Refer to the capacities listed on this table when handling suspended loads.

(2) (1) (7)

(8)

(1) (2)

(3)

(5) (4)

(6)

UYV0030017E01

1.

2.

3.

4.

5.

6.

7.

8.

4-50

BOOM LENGTH LD = LENGTH OF SECOND ARM DISTANCE OF THE LOAD FROM THE SWING CENTER LINE MAXIMUM LIFTABLE LOAD IN TONS, AT THE TILTING LIMIT, ACCORDING TO ISO STANDARD 10567 (75% STABILITY, 87% HYDRAULIC SYSTEM) MAXIMUM LIFTABLE LOADS IN TONS, AT THE MAXIMUM DISTANCE FROM THE SWING CENTER LINE MAXIMUM WORKING DISTANCE FROM THE SWING CENTER LINE COUNTERWEIGHT SET PRESSURE OF MAIN PRESSURE RELIEF VALVE/SAFETY VALVES OF THE HYDRAULIC SYSTEM

CHAPTER 5 - TRANSPORTATION

CHAPTER 5

TRANSPORTATION TABLE OF CONTENTS TRANSPORTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Machine Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Loading and Unloading the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 SECURING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 LIFTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 INSTALLATION AND REMOVAL OF MIRRORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 MACHINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 Care During Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 Removing Machine from Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

5-1

CHAPTER 5 - TRANSPORTATION

NOTES

5-2

CHAPTER 5 - TRANSPORTATION

TRANSPORTING THE MACHINE MACHINE PREPARATION 1. Know the total weight, length, width and height of the machine being transported.

2. Know route to be traveled. Investigate bridges, overpasses, height of road signs on route.

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

4. Use only a trailer with a rated capacity sufficient to transport the machine.

5. Make certain trailer has ramps or a ramp is available for loading and unloading the machine.

Machine Model E80BM SR

Weight 450 mm (17.7") Shoe 8,620 kg (19,000 lb)

7,060 mm (23'-2")

600 mm (23.6") Shoe 8,850 kg (19,510 lb) 2,230 mm (7'-4")

2,240 mm (7'-4") 2,860 mm (9'-5")

360 mm (14.2")

*730 mm (2'-5") 2,780 mm (9'-1")

2,920 mm (9'-7")

1,790 mm (5'-10")

450 mm (17.7") 2,150 mm (7'-1")

3,880 mm (12'-9") 6,640 mm (21'-59) ULFX1205001E01

NOTE: Marked * dimensions do not include height of shoe lug. Dimensions and weights are 2.13 m (7’) Arm, 0.22 m3 (0.29 cu. yd.) Bucket and 3.67 m (12’ 0”) Boom. When transporting the long armed machine, remove the bucket as shown below to limit the overall height of the machine to 3.8 m (12’6").

7,380 mm (24'-3")

3,780 mm (12'-5")

2,780 mm (9'-1") 1,000 mm (3'-3")

3,720 mm (12'-2") 2,720 mm (8'-11")

480 mm (18.9")

ULFX12050004E01

5-3

CHAPTER 5 - TRANSPORTATION LOADING AND UNLOADING THE MACHINE

WARNING Operating the machine too fast and not centering it on the transport device and ramps could cause an accident. When moving the machine on or off of the transport device, trailer or ramps, operate slowly and keep the machine centered. Failure to follow these instructions could cause death or serious injury.

CM113A

NOTICE: Do not use the attachment for loading and unloading the machine.

UYN0005009J01

DO NOT USE ATTACHMENT FOR LOADING/UNLOADING

Using a ramp to load the machine 1. Load the machine on firm and level ground.

NOTICE: Use ramps with sufficient width, length, thickness and strength.

2. The ramp must be high enough to match the trailer and wide enough to match the width of the machine and trailer. Put blocks (1) on the trailer tires to prevent movement before attempting to load or unload machine.

1

3. Make sure the machine position is aligned to the ramps before travelling up the ramp.

UYN00050010J01

SECURE RAMP TO TRAILER BEFORE LOADING/UNLOADING 1. PUT BLOCKS ON TRAILER TIRES

4. Lower the ramp of the trailer. The ramp slope should be 15 degrees or less. Be sure to secure the ramp before beginning to load/unload.

NOTICE: To prevent the arm and bucket cylinder(s) from damage, do not extend them to a “RAMP OVER CENTER” position. 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).

5. Start the machine. Position the arm and boom at the angle shown in the the figure (right). If equipped with a dozer, position it in the raised position, lowered only enough to not touch the trailer bed.

6. Retract the radio antenna. The radio antenna should be retracted during transport.

NOTICE: Use only the travelling controls when the machine is on the ramp.

7. Set travel speed to LOW - 1st speed. Move throttle control to low idle position.

5-4

A UYN00050011J01

A. RAMP SLOPE SHOULD BE 15 DEGREES OR LESS

CHAPTER 5 - TRANSPORTATION 8. Travel slowly up the trailer ramps and onto trailer until in proper transpor t position. Since the machine tends to be unstable when going over the rear wheel, be sure to travel slowly and carefully. Make sure the attachment does not touch the trailer bed.

UYN00050012J01

9. When in the correct position on the trailer, slowly turn the upper structure 180° until attachment is toward rear of trailer.

NOTICE: Do not have bucket and arm cylinders at full stroke during transport as this may cause damage to cylinders.

10. Slowly lower boom until attachment rests on trailer bed.

UYN00050014J01

Using a platform or earth banking 1. Raise the ground to make the earth banking high enough for the base of the truck/trailer and wide enough for the machine.

2. Make the earth banking strong enough to support the weight of the machine. If necessary, use supporting posts to reinforce both sides of the banking.

3. The ramp slope (A) should be 15 degrees or less.

4. When loading a machine with an attachment, climb up to it from the front end. When loading a machine without an attachment, climb up to it from the rear end.

A

UPW0050002J01

A. SLOPE SHOULD BE 15 DEGREES OR LESS

Loading machine without front attachment 1. When loading a machine without the front attachment, position the counterweight upward on the slope.

UYN0050015J01

5-5

CHAPTER 5 - TRANSPORTATION

SECURING THE MACHINE After the machine is loaded and positioned, secure it using the following procedure: 1. Remove mirror when required. See Installation and Removal of Mirror section in this manual for procedure. Secure the removed parts.

2. Move the safety lock lever to the LOCKED position.

3. Retract the radio antenna. It should be retracted during transport.

4. Turn off all switches and remove the engine starter key. Lock all covers and the cab door.

Blocks

5. Position blocks at the front and rear of the crawler belts and secure them to prevent the machine from moving during transport.

UYN00050016E01

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

7. Remove mirror when required. Secure the removed parts.

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

Unloading the machine

WARNING Operating the machine too fast and not centering it on the transport device and ramps could cause an accident. When moving the machine on or off of the transport device, trailer or ramps, operate slowly and keep the machine centered. Failure to follow these instructions could cause death or serious injury.

CM113A

1. Load and unload the machine on firm and level ground.

2. Position blocks at the front and rear of the trailer tires to prevent movement.

3. Make sure the ramp has a slope (A) of 15 degrees or less.

4. Remove the chain or wire rope used to secure the machine.

5. Start the engine.

6. Move the safety lock lever to UNLOCKED position.

5-6

A

UYN00050018J01

A. RAMP SHOULD HAVE SLOPE OF 15 DEGREES OR LESS

CHAPTER 5 - TRANSPORTATION 7. Press the travel speed change key (rabbit symbol) on the keypad of the gauge cluster and change the speed to low speed. Check the display for the turtle symbol to make sure travel speed is set to low.

BS06H067

8. Raise the attachment and travel slowly, placing attachments as shown in the figure (right).

9. Park the machine horizontally on the rear end of the trailer and then stop it.

NOTICE: To prevent the arm and bucket cylinder(s) from damage, do not extend them to a “RAMP OVER CENTER” position. 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).

UYN0050019J01

10. Set arm and boom at a 90 to 100 degree angle and travel down slowly from the trailer to the ramp. This time, the bucket position should be close to the ground.

11. Travel down on ramps slowly while operating boom and arm softly until the machine passes through the ramp completely.

UYN0050020J01

5-7

CHAPTER 5 - TRANSPORTATION

LIFTING THE MACHINE

Center of Gravity

o

(8 )

(45 o )

o

(45

)

Expander 3600 mm (11'-10'')

3,500 mm (11'-6'')

(4 o)

1,800 mm (5'-11'')

NOTICE: The following procedures are for lifting the machine with standard specifications, as built by the manufacturer, without modification. These procedures do not apply to machines with modifications that affect machine weight or center of gravity. Contact your dealer/distributor for lifting machines with optional attachments.

598mm (1'-12'')

688mm (2'-3'')

247mm (9.7'')

(10 o )

o

(3 )

(45 o )

o

(45

)

Expander 3600 mm (11'-10'')

3,500 mm (11'-6'')

Center of Gravity

1,800 mm (5'-11'')

Place Block between Each Cable and Frame

688mm (2'-3'')

598mm (1'-12'') 234mm (9.2'')

Place Block between Each Cable and Frame ULFX1205002E01

5-8

CHAPTER 5 - TRANSPORTATION

WARNING This machine/component is heavy.

Use a suitable lifting and/or supporting device when lifting, moving or supporting the machine/component. Do not lift the machine/component higher than necessary. Make sure all persons and pets are a safe distance from the machine/component when it is being lifted or moved. Failure to comply could result in death or serious injury.

M1319

1. Carry out the lifting work on firm, level ground.

2. Position the boom to the front of the machine.

3. Stop the engine and move the safety lock lever to the LOCKED position. Get off the machine. Check the operator’s seat and area for any loose items, tools, etc., that could fall or cause a problem or injury during the procedure and remove or secure them.

4. Stop the engine, remove the starter key and get off the machine.

5. Use wire rope and expander of sufficient length to prevent interference with the machine body when lifting up the machine. Cover the wire rope with cloth to protect the machine from damage.

6. Pass wire rope between first and second lower rollers on both front and rear sides of machine, as shown in figure.

7. Slowly fift machine up with two wire ropes adjusted within the range of 12 to 30 degrees.

8. After working, stop machine once and lift machine again slightly after machine has stabilized.

5-9

CHAPTER 5 - TRANSPORTATION

INSTALLATION AND REMOVAL OF MIRRORS

4'-11" 1500 mm

Mirror locations are shown in figures.

2180 mm 7'-2" B

Mirror A Mirror B

A

C

4'-11"

1500 mm

2700 mm 8'-10"

D

3'-3" 1000 mm

1000 mm 3'-3"

Mirror D

*The figures of range show reference values only.

Mirror B,C

6'-11" 2110 mm ULFX1405001E01

NOTICE: Be sure to clean mirrors before operation to ensure good visibility around the machine.

If visibility around machine is not sufficient, it may cause collisions and accidents resulting in injury or death. To avoid damage, do not install mirrors or other devices on the handrail of the cab entrance. This could weaken the handrail.

NOTICE: Do not attach mirrors other than A, B, C, and D. NOTICE: When the machine is shipped both side mirrors on the right frame and cab were removed. Re-install them according to the following procedure.

5-10

CHAPTER 5 - TRANSPORTATION MIRROR A 1. Adjust Mirror A so that the operator can identify the person who stands on the left rear end of the machine (or p ost 1 .5 m high and 30 cm in diameter).

1 2

2. Install the mirror on the small diameter part (E) of the stay shown in the figure.

E

3. Install the mirror so the Mirror A does not come in contacts with the stay (1) of the mirror.

4. During adjustment, if the movement of the mirror (A) is not smooth, loosen nut (2) and adjust it.

ULFX1201004B01

E. SMALL DIAMETER PART OF STAY 1. STAY OF MIRROR 2. NUT OF MIRROR

5. Adjust mirror so that the machine side shown in the right figure is reflected in the mirror.

6. For visible range, refer to the figure on the first page of this section.

ULFX1201005801

MIRROR B 1. Adjust Mirror B so that the operator can identify the person who stands on the left rear end of the machine (or p ost 1 .5 m high and 30 cm in diameter).

B 4

2. Install the mirror on position shown in the figure.

3. Install the mirror so the Mirror B does not come in contacts with the stay (3) of the mirror.

3

4. During adjustment, if the movement of the mirror (A) is not smooth, loosen nut (4) and adjust it.

Tightening torque of nut (4) M8 : 8.6 to 12.7 Nm (6.3 to 9.4 lb. ft.).

UYTX2801006B01

B. MIRROR 3. STAY OF MIRROR 4. NUT OF MIRROR

5-11

CHAPTER 5 - TRANSPORTATION 5. Adjust mirror so that the machine right side is reflected in the mirror as shown in the figure.

6. For visible area, refer to figure on the first page of this section.

UYTX2801007B01

MIRROR C 1. Adjust Mirror C so that the operator can identify the person who stands on the fight front of the machine (or p ost 1 .5 m high and 30 cm in diameter).

6

5

2. Install the mirror on position shown in the figure.

3. Install the mirror so the Mirror C does not come in contacts with the stay (5) of the mirror.

C

4. During adjustment, if the movement of the mirror (C) is not smooth, loosen nut (6) and adjust it.

Tightening torque of nut (6) M8 : 8.6 to 12.7 Nm (6.3 to 9.4 lb. ft.).

5. For visible area, refer to figure on the first page of this section.

UYTX28001008B01

C. SMALL DIAMETER PART OF STAY 5. STAY OF MIRROR 6. NUT OF MIRROR

MIRROR D 1. Adjust Mirror D so that the operator can identify the person who stands on the fight front of the machine (or p ost 1 .5 m high and 30 cm in diameter).

7

2. Install the mirror on position shown in the figure.

3. Install the mirror so the Mirror D does not come in contacts with the stay (7) of the mirror.

4. During adjustment, if the movement of the mirror (D) is not smooth, loosen the adjusting screw adn adjust it. Tightening torque of adjusting screw M10 : 18.6 to 25.5 Nm (13.7 to 18.8 lb. ft.).

5. For visible area, refer to figure on the first page of this section.

5-12

D ULFX1201006B01

D. SMALL DIAMETER PART OF STAY 7. STAY OF MIRROR

CHAPTER 5 - TRANSPORTATION

MACHINE STORAGE

1 UYB00000010E03

1. HEAVILY GREASE ALL CYLINDER RODS TO PREVENT CORROSION DURING STORAGE.

The following procedure applies when the machine is to be stored for a month or more.

1. Perform all inspection and maintenance p r o ce d u re s a s d e s c r i b e d i n M a in t e n a n c e Section.

2. Thoroughly clean the machine, inspect for damaged or worn par ts and components and replace or repair all damaged or worn parts.

NOTICE: Protect CPU and all electrical components from water and steam when cleaning the machine.

3. Completely fill fuel tank with fresh, clean fuel to aid in preventing condensation of moisture inside the fuel tank.

4. Move machine to an indoor location for storage.

5. Operate bucket and arm completely IN, extending cylinders. Then, lower the boom until the attachment is resting on the floor.

6. Coat cylinder rods with heavy coat of grease to prevent corrosion during storage.

7. Remove batteries and store in a well ventilated, warm area.

CARE DURING STORAGE 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.

NOTICE: Run and operate machine for approximately one hour to allow all fluids to circulate well and reach normal operating temperatures.

REMOVING MACHINE FROM STORAGE 1. Perform all inspection and maintenance procedures as described in the Maintenance Section before bringing machine out of storage for normal operation.

2. Remove drain plugs from the travel motors and swing ge ar reduction units to drain off a ny moisture which may have accumulated during storage.

3. Carefully inspect all hydraulic hoses after long periods of storage for signs of deterioration.

Replace all hoses showing signs of deterioration.

4. Refill fluids to proper levels and lubricate as required.

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

M1087

5-13

CHAPTER 5 - TRANSPORTATION

5-14

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

CHAPTER 6

MAINTENANCE AND ADJUSTMENTS TABLE OF CONTENTS GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 GENERAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Keep Machine Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Read the Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stop the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tag Out Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Observe Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hot Surfaces and Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warm Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressurized System Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Prevent Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspect Waste Oils and Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Caution for Oil Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disposal of Hazardous Waste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seals and O-Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Use Support Equipment During Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Use Caution While Changing Bucket/Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation in Dusty Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Tank Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Welding Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Precaution Against Machine Washing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-4 6-4 6-4 6-4 6-5 6-5 6-5 6-5 6-5 6-6 6-6 6-6 6-6 6-7 6-7 6-7 6-7 6-8 6-8 6-9 6-9

LUBRICANT, FUEL AND COOLANT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Biodiesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Use of Bio-Degradable Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 MAINTENANCE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 INSPECTION AND MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 WHEN REQUIRED MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check, Clean or Replace the Radiator Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check and Replace Wiper Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check and Refill Windshield Washer Fluid Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check and Replace Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check and Replace Teeth Points and Side Cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Tooth Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Side Cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reversing the Backhoe Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjusting the Bucket Mount Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-18 6-18 6-18 6-19 6-19 6-20 6-21 6-22 6-23 6-24

DAILY (8 HOUR) INSPECTION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check Fuel Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . drain the Fuel Pre-Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check Radiator, Oil Cooler and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check Hydraulic Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjust Operator Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjust Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check Function of Gauge Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check Work Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubricate the Dozer Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-25 6-26 6-27 6-28 6-29 6-29 6-30 6-31 6-32 6-32 6-32 6-33 6-33 6-1

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 50 HOUR (WEEKLY) MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drain the Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check the Track Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . 6-35 . . . . .6-35 . . . . .6-37 . . . . .6-38

100 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39 Lubricate the Bucket Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-39 120 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40 Check Swing Motor Reduction Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-40 Check Travel Reduction Unit Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-41 250 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42 Check Fan, Alternator, A/C Belts Wear and Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-42 Adjust Alternator and Fan Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-43 Adjust Air Conditioning Compressor Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-43 CHECK THE RADIATOR HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-44 Replace the Radiator Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-44 Check the Air Cleaner Rubber Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-45 Check the Air Cooler Rubber Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-45 Service the Air Conditioner Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-46 Air Cleaning Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-47 Lubricate Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-50 500 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52 Replace Engine Oil and Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-52 Replacing the fuel pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-54 Replacing the Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-55 Bleeding Air from the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-55 Filter Replacement of Electromagnetic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-56 Check Slewing Ring Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-57 Lubricate Push Rod of Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-58 Check the Air Conditioning Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-59 Clean the Fuel Tank Cap and Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-61 1000 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62 Replace the Return Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-62 Replace the Air Breather Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-63 Check the Engine Mounting Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-64 Lubricate the Swing Reduction Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-65 Check the Battery Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-66 2000 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Change the Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Change the Oil in the Swing Reduction Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Change the Oil in the Travel Reduction Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clean the Suction Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check the Swing Bearing Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clean the Pilot Line Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . 6-67 . . . . .6-67 . . . . .6-70 . . . . .6-71 . . . . .6-72 . . . . .6-74 . . . . .6-75

5000 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-76 Change Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-76 SPECIAL MAINTENANCE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-79 Automatic Spring Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-79 Releasing Travel Motor Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-79 Releasing the Swing Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-81 Lowering Attachment When Sudden Engine Failure Occurs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-84 Emergency Manual Valve for Lowering Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-85

6-2

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

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

M1087

WARNING Wear goggles, safety shoes, hard hat, work clothes and work gloves to perform inspection and maintenance on this machine. Failure to comply could result in death or serious injury.

M1070

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

1. It is recommended that an inspection and mainte na nce sch ed ule b e d eve lo pe d a nd maintained on a regular basis for this machine.

Developing and maintaining such a schedule helps to keep the machine in optimum operating condition.

2. The information contained in this section gives the proper procedures for performing inspection and maintenance functions for this machine.

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

DC04B668

NOTICE: The inspection and maintenance charts provided in this section give only general time intervals. It may be necessary to developed a custom schedule to perform machine maintenance at more frequent intervals based on the work conditions.

3. Lubrication and maintenance intervals are determined by the hour meter. If performing lubr ication and main tena nce a ccord ing to calendar time, the hour meter reading must corresond to the lubrication and maintenance period (8 Hours, 50 Hours, 120 Hours, 250 Hours, 500 Hours, 1000 Hours, 2000 Hours, 5000 Hours etc.) in calendar time. Items for which service time cannot be specified are explained in the section “When Required.”

4. Use only oils, fluids, lubricants, filters and replacement parts supplied by your authorized dealer to keep machine in optimum operating condition.

6-3

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

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

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

WARNING Wear goggles, safety shoes, hard hat, work clothes and work gloves to perform inspection and maintenance on this machine. Failure to comply could result in death or serious injury.

M1070

KEEP MACHINE CLEAN Tho roughly clean machine b efore p erfor ming inspection and maintenace procedures. It is easier and safer to locate problems, perform maintenance and al s o r e duc e r is k o f hy drau lic s y s t em contamination when machine is clean.

DC04B669

READ THE HOUR METER Rea d the hou r m eter d ai ly an d ch eck the maintenance schedule in this manual to ensure all maintenance is completed on schedule.

ULFC1204011B01

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

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

If it is un avoida ble to op era te the en gin e fo r inspection or maintenance, carry out the work with two people. The person seated in the operator’s seat should be ready to stop the engine at any time while watching for a signal from the other person.

6-4

UPW00400002J01

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 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.

ULC00010051E01

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

PV20T01005P1

ULC00040002E01

HOT SURFACES AND FLUIDS Wear the proper safety equipment when working around hot areas. Never change oils, engine coolant or filters immediately after a machine has been stop pe d. A llow ma chin e to coo l down be fore performing maintenance procedure.

WARM ENGINE OIL Engine should have a temperature between 20°C 40°C (68°F - 104°F) before the oil is changed. If necessary, run engine until the oil is warm within the recommended oil change temperature.

UPW00400006J01

PRESSURIZED SYSTEM HAZARDS Release the internal perssure before removing the hydraulic system or fuel system, piping, or coupling of the cooing system or other related parts to which inte r na l p re ss ur e is a p plie d. Se e se ctio n on Hydraulic Tank Pressure for procedure to release internal pressure.

ULC000400013E01

6-5

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS PREVENT CONTAMINATION A lway s c a p o r pl ug lin es w hen hy drau li c components are removed to help prevent hydraulic system contamination caused by dir t, dust and debris entering a port.

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

DC04B673

INSPECT WASTE OILS AND FILTERS Before disposal, inspect all waste oils, fluids and f i l t e r s f o r d e b r i s a n d f o r e i g n m a t e r. I t i s recommended to cut open the oil filters to determine any abnormal wear.

UPW00400008J01

CAUTION FOR OIL FILLING When a strainer is provided on the filling port, do not remove it while refilling fuel, oil or fluid.

UPW00400009J01

DISPOSAL OF HAZARDOUS WASTE Dispose of waste oils, fluids, lubricants, filters and other hazardous waste properly.

NOTICE: Dispose of all hazardous waste in accordance with government environmental laws and regulations.

UPW00400010J01

6-6

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS SEALS AND O-RINGS Always replace seals and O-rings with new parts.

Never reuse a seal or O-ring during reassembly of components. Make sure to lubricate all new seals with the appropriate oil before installation.

UPW004000011J01

USE SUPPORT EQUIPMENT DURING SERVICE When machine inspection or maintenance is done und er th e boo m, ar m or u nde r the bucket/attachment, use proper equipment or blocks to secure the attachment.

UPW00400012J01

USE CAUTION WHILE CHANGING BUCKET/ATTACHMENT WARNING: Do not insert your finger, hand or arm into the pin bore. The alignment must be carried out visually or by using a tool.

XPX00400003E01

OPERATION IN DUSTY CONDITIONS When the machine is operated in dusty conditions, do the following: 1. Frequently check for air cleaner clogging.

2. Clean the air cleaner element ahead of the specified period.

3. Clean the radiator core ahead of the specified period.

4. Clean and replace the fuel filter element ahead of the specified period.

5. Clean the electric equipment, especially the starter and generator, to prevent dust deposits.

UYN00040078J01

6-7

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CLEANING PARTS Use only approved cleaning solvents and proper equipment to clean parts.

WARNING Never use gasoline, diesel fuel or other flammable solvents to clean parts. Always clean parts in a well ventilated area. Failure to comply could result in death or serious injury.

M138A

HYDRAULIC TANK PRESSURE

A

WARNING Make sure that there is no pressure in the hydraulic lines before checking or repairing.

Do not use defective hoses or fittings. Always replace worn or defective hoses or fittings. Failure to comply could result in death or serious injury.

B

M1502

Always release the internal pressure of the hydraulic tank before performing inspection or maintenance procedures.

A. CAP B VALVE

1. Remove cap (A).

2. Push DOWN valve (B) to release air pressure in the reservoir.

WARNING Touching hot surfaces could cause burns. The engine and components will be hot after the machine has been running. Allow the engine and components to cool before servicing the machine.

Failure to comply could result in death or serious injury.

M1333

6-8

UYN0040057B02

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS WELDING SAFETY 1. Turn the starter key switch to OFF position and wait four seconds for the electrical power to disconnect.

ULC00040016E01

2. Remove negative terminal.

(-)

cable

from

battery

3. Attach the welder ground cable within 1 m (39 in.) from component being welded.

4. Do not clamp the welder ground cable close to or in location where ground could be separated by bearings or seals.

PRECAUTION AGAINST MACHINE WASHING Wh en wa shing th e ma chine, do n ot u se high pressure water to wash the inside of the body (swivel joint area).

ULC00040017E01

6-9

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

LUBRICANT, FUEL AND COOLANT SPECIFICATIONS The following chart provides information on the specifications of oil, grease, fuel, and coolant to be used in various climates and working conditions.

Components

Hydraulic oil tank

Engine oil pan

Swing motor reduction unit Travel motor reduction unit

Type of Capacities Lubricant (When changed)

Hydraulic oil

[Total volume] 11 Liters (2.9 Gal) Engine oil [H level] 10.3 Liters JASO (2.7 Gal) DH-1 [L level] 7.3 Liters (1.9 Gal)

Gear oil

Swing motor reduction unit (Housing) Attachment pins Slewing ring gear Track tension Adjustment

48 Liters (13 Gal) 90 Liters (24 Gal) Hydraulic system

EP grease

Operating lever (Pilot valve) Swing gear

1.5 Liter (0.4 Gal) 1.35 Liter X 2 (0.4 Gal X 2)

-22 -30

-4 -20

14 -10

Climete Zone 32 0

50 10

68 20

86 30

ISO VG46

104 F Specified Lubricant 40 C (KOBELCO BRAND) Long life hydraulic oil KW5046 (20 L) P/No. KAP2421R157D9

ISO VG32

(KOBELCO BRAND) Long life hydraulic oil KW5032S (20 L) P/No. KAP2421R157D7

SAE 10W-30

(KOBELCO BRAND) JASODH-1 P/No. KAPYN01T01053D1 (20 L)

SAE 15W-40

EXTREME GEAR OIL SAE #90

150 g (0.3 lbs)

EP GREASE

17 places

EP GREASE

1 place

EP GREASE

2 places

EP GREASE

As required

EP GREASE

4.9 kg (10.8 lbs)

EP GREASE ASTM D-975 No.2

Fuel tank

Diesel fuel

120 Liters (32 Gal)

ASTM D-975 No.2 ASTM D-975 No.1

Radiator (Reserve tank)

6-10

Engine coolant (Antifreeze)

5.7 L Total volume 8.5 L

50% Mixture

SAE 15W-40 (KOBELCO BRAND) A.P.I clssification for "service GL-4" P/No. KAPSPG90020

(KOBELCO BRAND) Extreme pressure multipurpose grease No.2*2

ASTM D-975 Grade 2-D ASTM D-975 Grade 1-D (KOBELCO BRAND) If commercial coolant is used, the mixing rate should conform with the specified.*1 P/No. KAPLLC95-20 (20 L)

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS BIODIESEL FUEL Fatty Acid Methyl Ester Biodiesel (Biodiesel Fuel) consists of a family of fuels derived from vegetable oils treated with methyl esters.

NOTICE: Biodiesel fuel blends are approved for your engine only if they comply with Specification Standards EN 14214 or ASTM D6751. Do not use biodiesel unless it is approved for your engine.

Check with your authorized dealer for information.

It is imperative that you check which blend is approved for your engine with your local dealer.

Beware that the use of Biodiesel fuel that does not comply with the Standards EN14214 or ASTM D6751 could lead to severe damage to the engine and fuel system of your machine. The use of fuels that are not approved may void warranty coverage.

Biodiesel Fuel Usage Conditions NOTICE: The Biodiesel Fuel must meet the fuel specification mentioned above.

Biodiesel fuel must be purchased from a trusted supplier that understands the product and maintains good fuel quality. Biodiesel fuel must be pre-blended by the supplier. Mixing Biodiesel fuels on site can result in an incorrect mixture which can lead to problems with both engine and fuel system.

Eng in e p er fo r man ce is e ffe cted by the use of biodiesel fue l. Th ere may be up to 12 percent reduction in power or torque depending on the blend used.

NOTICE: DO NOT modify the engine and/or fuel injection pump settings to recover reduced performance.

The reduced power must be accepted if using any biodiesel fuel blend.

Some modification may be required to allow the engine to use biodiesel fuel. Consult your dealer for c o m p l e t e i n fo r m a t i o n r e g a r d i n g a p p r o v e d modifications.

Biodiesel has a higher cloud point than diesel fuel.

NOTICE: The use of high biodiesel fuel blends is not recommended in cold weather conditions.

When handling biodiesel fuel, care must be taken not to allow water into the fuel supply. Biodiesel fuel will actually attract moisture from the atmosphere. Fuel tanks must be kept as full as possible to limit the amount of air and water vapors in them. It may be necessary to drain the fuel filter water tap more frequently.

Potential oxidation and stability could be a problem with the fuel store in the machine.

Biodiesel fuel may degrade natural rubber gaskets and hoses, as it is more solvent than petro-diesel.

Check hoses and other engine components more frequently when using a biodiesel fuel.

DO NOT allow water to collect in the fuel or storage tanks. Keep fuel tanks and storage tanks as full as possible to limit the amount of air and water vapors. It may be necessary to drain the machine fuel filter more frequently. Potential oxidation and stability could cre ate a p roble m with fuel stored in th e machine.

BIODIESEL STORAGE NOTICE: DO NOT store machines for more than three months with biodiesel blends in the fuel system. DO NOT store biodiesel fuel in on-site storage tanks for more than three months.

If long periods of storage are required, run the machine for 20 hours using regular diesel fuel in order to flush the biodiesel fuel from the engine fuel system.

NOTICE: Biodiesel fuel must not be stored in on-site storage tanks for more than 3 months.

Any spillage of biodiesel fuel must be cleaned up immediately before it can cause damage to the environment and/or the paint finish of the machine.

Before using biodiesel fuel blends, you should consult with your dealer to receive full information about the approved blend for your machine and any detailed conditions of its usage.

Be aware that not fulfilling the requirements and conditions of biodiesel fuel usage will void your machine’s warranty.

With biodiesel fuels, it may be necessary to change engine oil, engine oil filters and fuel filter elements more frequently then with diesel fuel. Biodiesel can remove rust and other particles that adhere to the inside of the fuel tank. These par ticles are then tra p p ed by th e ve h icle filte rs a n d m ay ca u s e shortened filter life and/or filter blockages. In cold weather, this is more likely to occur. Consult your dealer for information on cold weather operation and prop er main te nance inter va ls whe n using any biodiesel fuel blend.

6-11

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 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. Synthetic based type is recommended, as the vegetable based oil has a maximum usage temperature of 80°C (176°F). The degradation of vegetable based oil occurs more rapidly and causes reduced service life.

2. Do not mix either type of BIO OIL with the original factory filled mineral oil. If BIO OIL is used, it is required to flush the hydraulic system that was filled with mineral oil twice, before adding bio oil.

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

4. For further information about recommended Bio-degradable oil, please contact local dealer.

Recommended Bio-Degradable Oil Brand: MOBIL EAL Envirosyn 46H Recommended Change Interval The BIO oil change interval is 2,000 hours. For the changing procedure, refer to the Changing Hydraulic Oil section of this manual.

6-12

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

MAINTENANCE PARTS System

Hydraulic oil tank

Part Number

Parts Name

Q'ty

Replacement Interval

YR52V01004R300

Return filter element kit (STD. Breaker)

1

(ZD11G11000)

(O-ring)

1

YT50V00003F1

Suction strainer

1

(ZD11G15500)

(O-ring)

1

YT11P00009S002

Element (Outer)

1

After 6 times of cleaning or one year whichever comes first

After 50 hours (first change) Every 1000 hours (from 2nd change) (Breaker specification : Every 250 hours) Every 2000 hours

YW11P01021P1

Element (Inner)

1

For machines equipped with W (double) element the inner element must be replaced together with the outer element.

Replace the inner element with new one.

Engine oil filter

VI898075-6760

Cartridge

1

After 50 hours (first change)Every 500 hours

Fuel filter

VI897172-5491

Cartridge

1

Every 500 hours

Electromagnetic pump

VI894337-0220

Repair kit

YN50V01015P3

Air-con filter (Outer)

1

YN50V01014P1

Air-con filter (Inner)

1

Every 10 times cleanings When heavy clogging of filter occurs, clean or replace

YN50V00020F1

Line filter

1

Every 2000 hours (Cleaning)

2412N279D1

Side cutter (R, H)

1

2412N279D2

Side cutter (L, H)

1

ZS13C20050

Bolt

6

ZN13C20016

Nut

6

B12P0015F1

Tooth Assy (Inner)

2

2412U111F1

Tooth Assy (Outer)

2

Air cleaner

Air conditioner Pilot line filter

Bucket (STD)

Every 500 hours change

When required

NOTE: Replace parts during periodic maintenance or before the end of service life. The machine can be used economically if parts are changed properly and timely. When you order parts, confirm the parts number using the parts catalog.

NOTE: Items in parentheses ( ) are parts to be changed at the same time.

ENVIRONMENT Before you service this machine and dispose of oil, fluids and lubricants, always remember the environment. Do not drain oil or fluids on to the ground or into containers that leak. Check with your local environmental recycling center or your dealer for correct disposal information.

6-13

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

INSPECTION AND MAINTENANCE CHART Follow the chart for recommended intervals for regular inspection and maintenance. Perform inspection and maintenance according to calendar time or operation time shown by the hourmeter, whichever comes first.

Symbols and their meanings : : Necessary regular inspection item to hour meter : Only first replacing is performed

System

: Inspection and/or maintenance is needed

Maintenance to Perform

Engine oil

Check oil level

Interval (Hours on Hourmeter)

When required

8H

250H

1,000H

Lubricant, etc.

2,000H

5,000H (Replacing part)

O

(First)

*1 (First)

Change Drain

500H

Engine oil

*1

Replecing oil filter

Water separator

100H

O

Change

Fuel filter

50H

O

Cartridge

O

Cartridge

O

Cleaning

Element

O

Filter replacement of electromagnetic pump

O

Filter

Engine

Outer element (When outer ele-

Check/ clean Air cleaner elements

ment is changed,

O

inner element must be replaced

When warning is indicated on multi-display

without fail)

or every 250 HOURS.

Change

After 6 times of cleaning or one

Outer,

O

inner element

year whichever comes first

Coolant level and cleaning of cooling system

Check level

O O

Change/ cleaning

(or every

Hoses in cooling system Checking and cleaning of radiator/oil cooler core/air-cooler and filter

LLC

2 years)

O O

O

NOTE: See Lubricant, Fuel and Coolant Specifications for detailed specifications for lubricants, coolants, and fuel.

6-14

System

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

Maintenance to Perform

Check belt tensioner Radiator cap

Interval (Hours on Hourmeter)

When required

Check

8H

50H

100H

1,000H

O *1

O

(First)

*2 Checking and adjustment of valve clearance

O

*2 Checking and adjustment of compression pressure

O

*2 Checking of intake and exhaust manifold for tightening

(First)

*2 Checking of oil pan and other accessories for tightening

(First)

*1

O

*1

*2 Checking of installing turbo charger for tightening

O

*1

O

(First)

*2 Checking of turbo charger rotor and impeller for rotating

O

*2 Checking of turbo charger rotor for looseness

O O

O

*2 Checking and cleaning of stator brush and commutator

O

*2 Checking of oil pan and for intrusion of water and fuel

O

*2 Checking of fan mounting bolt for

O

tightening *2 Checking of thermostat for func-

O

tion

O

*2 Checking of starter for function *2 Checking of stability, exhaust color and noise

O

*2 Checking of heater plug/intake air heater (Starting aid)

O O

*2 Checking of alternator for function

*2 Checking of each pipe joint for tightening *2 Checking of exhaust pipe and muffler for installation looseness and damage

5,000H (Replacing part)

O

Checking of engine mount bracket for tightening

*2 Checking of turbo charger for lubrication

Lubricant, etc.

2,000H

O

Checking for rubber hose of intake system

Engine

500H

O

Adjust Clean

250H

*1 (First)

*1 (First)

O O

NOTE: Contact the dealer/distributor to check or adjust items marked *2.

NOTE: Items marked *1 require inspection and maintenance at break-in (after first 50, 100, 250, 500 hours).

6-15

Engine

System

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

Maintenance to Perform

Fuel system

8H

50H

100H

250H

500H

*2 Checking and cleaning of alternator brush (If equipped) Checking leakage of fuel system

O

Checking engine oil leakage

O

Check engine electrical

O

Hydraulic oil Hydraulic tank

Check oil level

5,000H (Replacing part)

O

Clean cap and strainer Air bleeding from fuel system

Lubricant, etc.

2,000H

O

Drain water and deposits Fuel tank

1,000H

O

Check/fuel level

Hydraulic system

Interval (Hours on Hourmeter)

When required

O O O Hydraulic oil

O

Change

O

1,000H (Breaker)

Suction strainer

Clean

O O

*1

Return filter

Strainer

O

(Breaker

(First)

attach-

Element

ment)

Check for oil leaks

O

Check hoses/lines

O

Pilot line filter Swing reduction oil level & fill

O

Clean Check oil level

O

Extreme gear oil

(120hr)

*1

Change

Grease slewing ring

Upper frame

O

(First)

O O

Change grease in slewing ring grease bath

O

O

Check bolts/torque (Slewing ring)

O

Grease swing reduction unit

EP grease

O

Greasing of control lever push rod and universal joint

Check bolts/torque (Counterweight)

GL-4 EP grease

Check slewing ring & pinion gear

Check slewing brake

SAE #90

*1 (First)

EP grease

O *1 (First)

O

NOTE: Item marked *3 - dozer blade has to be lubricated every eight hours for the first 50 hours of operation.

After 50 hours of operation, the dozer blade should be lubricated every 250 hours of operation.

6-16

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

Travel reduction unit oil level & fill

Check oil level

O

Change

Lower frame

SAE #90 GL-4

O

Check for oil leaks

O

Check lines for damage

O

Check steps & handrails

O

Check frame structure

O

Check tracks & links

O

Check sprocket wear

O

Check idler wear

O

Check roller wear

O

Check track tension

O O

Grease bucket pins

O EP grease

*3 O

Dozer blade lubrication

O

(50H)

Replacement of backhoe bucket

O

Bucket clearance

O

Check bucket teeth and side cutters

O

Check bolts/torque

Battery

O

Battery electrolyte

O

Battery maintenance

O O

Voltage check Inspect all wiring

O

Check switches/light

O

Check A/C Refrigerant Air conditioner Accessories

O

(First)

Grease for pins

Attachment

oil

*1

Adjust track tension

Electrical

Extreme gear

(120hr)

Check A/C condenser and clean Filter

O O

O O

Clean Change

Check wiper washer fluid level

After 10 times cleaning is done

O

Check frame structure

O

Check bolts/torque

O Check

Seat belt

Change

O O (3 years)

6-17

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

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

M1087

CHECK, CLEAN OR REPLACE THE RADIATOR CAP

1

WARNING To avoid being burned, be careful when removing the radiator cap. Coolant is under high pressure when hot. Do not remove the radiator cap when the system is hot. Allow enough time for the machine to cool down before removing the radiator cap.

TBD

1. Alow the radiator cap and cooling system to cool down so it can be touched with a bare hand. Slowly loosen the radiator cap (1) to release the pressure. After all pressure is released, remove the cap.

UYF00040006J02

1. CAP

2. Check the cap for damage and contamination.

Clean and/or replace if necessary.

3. Securely tighten the cap.

CHECK AND REPLACE WIPER BLADE Check th e wiper blade for wear and damage.

Replace it if necessary.

UYN00040018J01

6-18

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CHECK AND REFILL WINDSHIELD WASHER FLUID RESERVOIR NOTICE: The use of windshield wipers without washer fluid may cause damage to the windshield wiper motor.

1

The windshield washer fluid reservoir (1) is located below the floor plate of the cab.

1. Remove the floor mat.

2. Check the fluid level of the windshield washer fluid reservoir (1).

3. If windshield washer fluid needs to be added, remove the reservoir cap and fill the reservoir to the proper level.

UYF00040007J01

1. WINDSHIELD WASHER FLUID RESERVOIR

4. Replace reservoir cap and reinstall floor mat.

CHECK AND REPLACE BUCKET

7

Removing the bucket

8

1. Before replacing the bucket, position the machine on firm, level ground and rest the bucket on the ground, making sure it is stable.

2,3

1 4 1 5

6

ULC00040005J01

1. O-RINGS

5. PULL PIN

2. RETAINING RING

6. BUCKET

3. PIN

7. ARM

4. PULL PIN

8. BUCKET/BUCKET LINK

2. Roll the O-rings (1) onto the bucket boss (A).

After removing the pins, return them to their original position.

1

3. Extend the retaiing ring (2) and remove pin (3) and pull pins (4) (5) then remove bucket (6).

NOTICE: Keep the pins free from sand, dirt and other contaminants.

NOTICE: Be careful not to damage the dust seals on both ends of the arm (7) and bucket/bucket link (8).

A UYT000400042B01

1. O-RINGS A. BUCKET BOSS

6-19

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS Reinstalling the bucket 1. Clean each pin and pin hole and grease sufficiently.

2. Move the bucket cylinder to match the pin bores of the bucket (6) and bucket link (8) with each other then insert the pin (4).

7 8

2,3

1 4

3. Raise the boom and slightly raise the bucket from the ground.

4. Align bucket (6) with the pin hole of the arm (7).

Move the arm then insert the pin (5).

5

1 6

6

5. Insert the pin (3) and fix retaining ring (2).

NOTICE: If the O-ring (1) is cracked or has lost elasticity, replace it with a new one.

6. Fit O-ring (1) to the normal position.

ULC00040006J01

1.

2.

3.

4.

O-RINGS RETAINING RING PIN PIN

5.

6.

7.

8.

PIN BUCKET ARM BUCKET/BUCKET LINK

7. Apply grease on the grease nipples for the respecti pins until the grease comes out through the gap between the pins and bore.

CHECK AND REPLACE TEETH POINTS AND SIDE CUTTER NOTICE: When replacing the teeth points and side cutter, place a safety block (A) to the bottom face of the bucket.

A

1. Check the teeth points of the bucket for wear and looseness. Tooth poin t life cann ot be determined only by the number of operating ho urs; o pe ratin g c on dition s must a lso be considered.

UYN00040002B02

A. SAFETY BLOCK

6

1 5 4 3

7

2 UYNC0040021J02

1.

2.

3.

4.

6-20

ADAPTER NOSE 5. SIDE CUTTER TOOTH POINT 6. BOLT RUBBER LOCK 7. NUT LOCKING PIN

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS REPLACING THE TOOTH POINTS Short Damaged Rubber

WARNING Wear goggles, safety shoes, hard hat, work clothes and work gloves to perform inspection and maintenance on this machine. Failure to comply could result in death or serious injury.

No Good

4 The ball push in if it is pressed by hand

3

M1070

Replace the bucket teeth:

Alight the bottom

Good

No Good

• When small holes appear on the teeth points, • When the edges of the teeth points are worn.

1. Using a hammer and punching tool, hammer out the lock pin (4). Be careful not to damage the rubber lock (3).

3 2 Good

No Good

2. Inspect the lock pin (4) and rubber lock (3). replace them if the lock pin (4) is too short or the rubber lock (3) is in poor condition.

3. Clean the surface of the adapter nose (1) with a putty knife to remove the adhered nose (1).

4. Fit the tooth point (2) onto the adapter note (1).

No Good

1

4

No Good

Good

5. Push the rubber lock pin (3) in the hold of the adapter nose (1).

6. Hammer the locking pin (4) until it is aligned with the point surface.

UYN00040003E01

1.

2.

3.

4.

ADAPTER NOSE TOOTH POINT RUBBER LOCK LOCK PIN

6-21

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS REPLACING THE SIDE CUTTER NOTICE: Early replacement of the side cutter is recommended, as a delay in replacement could cause damage to the bucket.

WARNING Wear goggles, safety shoes, hard hat, work clothes and work gloves to perform inspection and maintenance on this machine. Failure to comply could result in death or serious injury.

M1070

1. Remove all sand and soil adhering around the bolts. Use an acetylene torch to cut off the bolts then remove the side cutters.

A UYN00040004B01

A. SAFETY BLOCK

2. Clean the mounting face and install a new side cutter. When replacing the side cutter, also replace the bolts and nuts with new ones.

Tightening torque: 485 to 593 Nm (358 to 437 lb.ft.)

3. After tightening, spot weld the nuts.

A UYN00040005B01

A. SAFETY BLOCK

6-22

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS REVERSING THE BACKHOE BUCKET 1

The backhoe bucket can be reversed 180 degrees for shovelling work. To remove and reverse the bucket, work with one other person, follow signals exactly and pay attention to safety.

NOTICE: Be careful about the use of the bucket for shovelling work because its operation is reversed from that of the backhoe.

NOTICE: When the 2.94 m (9’8” ) arm is used, do not reverse the bucket. If the bucket is reversed, it bumps against the arm during shovelling and this will damage the attachment.

A UYT00040042B01

1. O-RINGS A. BUCKET BOSS

1. Move the machine to a firm, level surface and place the bucket on the ground, making certain that it is stable.

2. Roll the O-ring (1) onto the bucket boss (A).

3. Remove the retaining ring and pin for the bucket pin (2) and link pin (3). Remove bucket pin and link pin.

2

3

A

1

4. Rotate arm 180 degrees with the arm slightly raised and the bucket in place, then lower the arm again and the pin bore position is changed.

5. Clean the pins and pin bores for each part and apply sufficient grease.

6. Fit O-ring in place.

7. Align each pin bore and insert pins. After inserting pins, insert retaining rings and pins.

8. After attaching, rotate bucket softly to the stroke end in engine low idling condition and check that there is no interference of each section.

UYT00040053J01

A. BUCKET BOSS 1. O-RING 2. BUCKET PIN 3. LINK PIN

6-23

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS ADJUSTING THE BUCKET MOUNT GAP WARNING: Unexpected movement of the attachment while adjusting the bucket mounting gap is quite dangerous.

NOTICE: If the clearance of the bucket is not properly adjusted, galling may occur on the contact faces of the bucket and arm, resulting in abnormal noise and damage of the shaft and O-ring.

A

1. Place the bucket on the ground in a stable condition.

ULV00040038B01

A.STANDARD CLEARANCE FOR BUCKET ADJUSTING MECHANISM: 1.2 MM (0.05 INCH) OR LESS

2. Move O-ring (1) from the regular position to the bucket boss position.

1

3. Swing rightward slightly and press the arm top end against the bucket right side. On this side, there is not a lo osen ess ad ju stme nt mechanism.

4. Move the safety lock lever to the LOCKED position, then stop the engine.

B UYT00040042B01

B BUCKET BOSS 1. O-RING

5. Measure clearance (A) between the bucket and arm boss. In the event that the measured value is 1.2 mm or more, carry out the adjustment.

2

3

A

1

6. Three bolts (2) on the clearance adjustment section contain five shims (3) (1 mm average thickness).

7. Tighten each bolt (2) to the specified torque.

Tightening torque: 103 to 127 Nm (76 to 94 lb ft) 8. Return O-ring (1) to place.

UYT00040053J01

A. 1.

2.

3.

6-24

BUCKET BOSS O-RING BOLTS (3) SHIMS (5)

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

DAILY (8 HOUR) INSPECTION AND MAINTENANCE The following procedures are to be performed every 8 hours or daily, before starting the machine.

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

M1087

WARNING To help prevent personal injuries during operation and maintenance, use safety shoes, a hard hat, safety glasses or goggles and good fitting clothing. Failure to comply could result in death or serious injury.

M110B

Before starting the engine, walk around the machine to check for any loose nuts and bolts, any oil, fuel or coolant leakage, and the condition of attachment and hydraulic system.

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

WARNING: The deposit of combustible, fuel leakage and oil leakage in heated area around the engine, muffler and battery may cause fire of machine. Check the area sufficiently, and if the abnormality is found, repair it or contact our dealer/distributor.

1. Check the engine for any oil, fuel or coolant leakage. Repair as required.

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

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

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

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

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

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

8. Check rear view mirror for abnormality, and if abnormality is found, repair it.

9. Clean the surface of mirror and adjust the angle so that the rear sight is visible from the operator seat.

10. Check seat belt and attaching metal for possible damage and if damaged, replace it with new one.

6-25

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CHECK COOLANT LEVEL

WARNING 2

Touching hot surfaces could cause burns. The engine and components will be hot after the machine has been running. Allow the engine and components to cool before servicing the machine.

Failure to comply could result in death or serious injury.

1 A B

M1333

WARNING UYTX2803001B01

Hot coolant can spray out if radiator or deaeration tank cap is removed while system is hot. To remove cap, let system cool, turn to first notch, then WAIT until ALL pressure is released. Failure to comply could result in death or serious injury.

M646

1. Open left side door and check coolant level of reserve tank (1).

2. Open side door of radiator with starter key and check that the coolant level is in the range of FULL (A) - LOW (B) of reserve tank. If not, remove filler cap (2) of reserve tank and fill to FULL (A) level.

3. After supply, tighten the cap securely.

4. When the reserve tank is empty, after checking for oil leakage, check the radiator coolant level.

If shorted, first supply coolant to the engine and then to the reserve tank.

5. Close the side door on the left side face of machine and lock it with starter key.

6-26

A. B 1.

2.

FULL COOLANT LEVEL LOW COOLANT LEVEL RESERVE TANK FILLER CAP

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CHECK ENGINE OIL LEVEL F

WARNING

2

Touching hot surfaces could cause burns. The engine and components will be hot after the machine has been running. Allow the engine and components to cool before servicing the machine.

Failure to comply could result in death or serious injury.

1 A B

M1333

WARNING When handling lubricants (oil, grease etc.,) and other chemical products, always follow instructions for their proper use. Use proper containers to collect fluid. Dispose of fluids and filters in a way that will protect the environment and in accordance with the law. DO NOT smoke or use an open flame during the service procedure. Use eye protection. Failure to comply could result in death or serious injury

G

H

M1303A

L

1. Make sure the machine is on firm, level ground when checking engine oil level.

2. Open engine hood and support it with stay.

3. Pull out oil level gauge (G) and wipe oil with a clean cloth.

4. Insert oil level gauge (G) in oil pan fully.

5. The oil level should be in the range of H - L on the oil level gauge (G). If the level is lower than the L level on the gauge, make up engine oil for the shortage through oil filler cap (F).

P UYRX11003B01

F. A B C

OIL FILLER CAP OIL LEVEL GAUGE OIL LEVEL HIGH OIL LEVEL LOW

P. DRAIN PLUG

6. If the oil is contaminated and deteriorated, change it ahead of schedule.

7. For oil in use, refer to LUBRICANT, FUEL & COOLANT SPECIFICATIONS in this manual.

8. When the oil level is H level or higher, drain the excess engine oil though drain plug (P) and check the oil level again.

9. If the oil level is proper, insert level gauge (G) securely, close engine hood and lock it with starter key.

6-27

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CHECK FUEL LEVEL

1

WARNING

2

Fuel vapors are explosive and flammable. Do not smoke while handling fuel. Keep fuel away from flames or sparks. Shut off engine and remove key before servicing. Always work in a well-ventilated area. Clean up spilled fuel immediately. Failure to comply could result in death or serious bodily injury.

1 A B

M1394

NOTICE: Use diesel fuel only and stop engine before refilling. Do not overflow fuel while refilling. It may cause damage to the fuel system and cause oil spouting. Dispose of all hazardous waste in accordance with government environmental laws and regulations.

ULFX1203003B01

1. FILLER CAP

NOTICE: It is possible to operate machine for 2 days (8 hours a day) in general use when the tank is full. Be sure to fill it up to the top after the work on the second day is finished. Do not overfill. There is a possibility of overflowing because the fuel expands as the outside air temperature rises. Use specified diesel oil for fuel. This engine is equipped with electronic control high pressure fuel injection system to obtain the features like excellent fuel consumption and emission in clean condition. This system requires the parts in high precision and high lubricating ability. Therefore if low viscosity fuel in low lubricating ability is used, the durability may be notably lowered.

1. Check fuel level with fuel gauge by turning starter switch on. The fuel level is low when the fuel gauge reads close to E point.

2. Stop engine with starter key, remove filler cap (1) of fuel tank and fill with fuel making sure of the level. When strainer is fitted to filler port, do not remove it while adding fuel.

3. When dirt adheres on the strainer (2), take it out and clean it with light oil or air gun, and then fit it to filler port again.

2

2

4. Refer to LUBRICANT, FUEL & COOLANT SPECIFICATIONS in this manual.

Fuel tank capacity: 120 L (31.7 gal)

UYN0030018J01

1. STRAINER

5. After refueling, tighten filler cap (1) securely.

6-28

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS DRAIN THE FUEL PRE-FILTER 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 water.

1. The water separator (1) is installed in front of counterweight on the right rear side of machine.

2. Open engine hood and support it with stay.

3. Put container for drain oil under drain hose (2).

4

4. Loosen drain plug (3) and air bleed plug (4) and drain water collected in fuel filter (1) in the container.

1 2

5. After draining, tighten drain plug (3) and air bleed plug (4) securely.

6. Release the stay which is supporting hood, close engine hood and lock engine hood.

3

UYTX2803002B01

1.

2.

3.

4.

WATER SEPARATOR DRAIN HOSE DRAIN PLUG AIR BLEED PLUG

CHECK RADIATOR, OIL COOLER AND FILTER 1. Using starter key, unlock side door on left side of counterweight, and open it.

1

2

2. By visual check, check mud, dust and leaves which contaminate filter (1).

1

3. When filter is contaminated heavily, refer to 250 HOUR (3-MONTH) MAINTENANCE in this manual for procedure to clean these filters.

A B

UYV0030006E02

1. FILTER

6-29

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CHECK HYDRAULIC OIL LEVEL

WARNING For safe operation on inclines, the hydraulic oil level must be maintained between proper level and upper limit mark. DO NOT OPERATE machines on inclined surfaces with a slope greater than 35°. Failure to comply could result in death or serious injury.

M1718

WARNING Hydraulic oil leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: relieve all hydraulic pressure, before disconnecting fluid lines. Before applying pressure, make sure all connections are tight and components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, seek medical attention immediately. Failure to comply could result in death or serious injury.

M587A

1. The hydraulic tank is installed on the right side.

Move the machine to firm level ground and set it in the hydraulic oil level check position.

2. Stop the engine.

UYF0003004E02

HYDRAULIC OIL LEVEL CHECK POSITION

3. Check the oil level through sight level gauge (G) provided on the side of the hydraulic tank.

Hydraulic oil level should be between H and L. Oil level varies depending on oil temperature.

Check the oil level referring to the following.

• Before starting : "L" level oil temp. 10 to 30 C degrees (50 to 86 F degrees) • Normal operation : "H" level oil temp. 50 to 80 C degrees (122 to 176 F degrees)

H G L

ULFX1203004B01

G. BREATHER TOP END CAP A OIL TEMPERATURE LEVEL - “HIGH” B OIL TEMPERATURE LEVEL - “LOW”

6-30

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 4. When removing filler port plug, remove breather top end cap (1) and then release pressure from hydraulic oil tank by pressing the valve head.

5. Avoid overfilling. It causes damages hydraulic equipment or oil spouting.

1

on

6. For make up procedure of hydraulic oil, refer to Change Hydraulic Oil section in this manual. .

WARNING When handling lubricants (oil, grease etc.,) and other chemical products, always follow instructions for their proper use. Use proper containers to collect fluid. Dispose of fluids and filters in a way that will protect the environment and in accordance with the law. DO NOT smoke or use an open flame during the service procedure. Use eye protection. Failure to comply could result in death or serious injury

ULFX1203005B01

1. BREATHER TOP END CAP

M1303A

CHECK BELT TENSION

WARNING Stay clear of rotating machine parts and keep shields installed to help protect from clothing entanglement and injury. Wear close-fitted clothing.

Failure to comply could result in death or serious injury.

M223A

NOTICE: If defects such as cuts or surface separations are found during inspection, replace the belt. Keep oil and grease away from the belt; they may cause the belt to slip and shorten ervice life.

1. Check the fan and alternator belt for insufficient tension, wear, and damage. Insufficient belt tension may cause batter y cha rge failure, engine overheating, or abnormal belt wear. If too much tension is applied to the belt, the bearings or belt may be damaged prematurely.

UYV000300009E02

1. BREATHER TOP END CAP

2. Apply a force of 98 N (22 lb) to the center of belt between pu lleys, a nd m easure the b elt de fle ction . The table b elow sh ows no r ma l condition.

Belt

When new belt replaced mm (in)

When inspected mm (in)

Force N (lbf)

Alternator, Fan

4 to 6 mm (0.16 to 0.24")

7 to 9 mm (0.28 to 0.35")

98 (22)

Air-conditioner

3 to 4 mm (0.12 to 0.16")

5 to 6 mm (0.20 to 0.24")

24 (5.1)

NOTICE: When replacing a belt, there is a lack of initial adaptability of the new belt. Run the engine at idling speed for about three or five minutes. After that, adjust the belt tension again. New belts get complete initial elongation after being run about two hours. See the 250 HOUR (3-MONTH) MAINTENANCE in this manual for details on the inspection and adjustment procedure for the belt.

6-31

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS ADJUST OPERATOR SEAT WARNING: Adjust the operator seat before starting operation or at the time when operator was changed. Be careful not to put hands between handle and seat stand.

Adjust the operator seat position so that the control lever, each control pedal and switch can be easily manipulated in the condition where operator takes seat and has his back fitted to the back seat.

ULV00010016J01

ADJUST MIRROR Two rear view mirrors are equipped at left side of cab and on the hydraulic tank cover. Adjust all mirrors so that the area in the blind spot may decrease most when sitting on the driver's seat.

ULFX1203006B01

CHECK FUNCTION OF GAUGE CLUSTER Before star ting the engine, check the warning display and gauge according with the following procedures: LOW ENG OIL PRESS.

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

2. Make sure all control levers are in the "NEUTRAL" position.

H

3. Insert starter key and start engine.

ULV00010016J01

6-32

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CHECK WORK LIGHT 1. While the key position in the starter key switch is being "ON" position, turn on the work light switch to check the lightening of work light.

2. If it does not lighten, presumably the light bulb is burned out or electrical wire is broken.

3. Contact your dealer/distributor for repair.

ULFX1203016B01

LUBRICATE THE DOZER BLADE

WARNING The machine and attachment should not be moved when lubricating. If a different position is required: clear the area, move attachment, stop the engine and lubricate the attachment. Repeat this procedure until the attachment is completely lubricated. Failure to comply could result in death or serious injury.

A

M1719

NOTICE: The dozer blade must be lubricated every eight hours for the first 50 hours of operation. After 50 hours of operation, it should be lubricated every 250 hours of operation. If the attachment is immersed in water, lubricate it every eight hours.

UYV00020012E02

A.GREASE GUN HOLDER

1. A grease gun is provided inside the side door on the left side of the machine.

6-33

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS Dozer Pin Grease Points 1. Clean the grease fittings before greasing.

1 2

2. Replace any damaged grease fittings.

2

3. Lubricate with a grease gun through the grease fittings shown.

4. Wipe off any grease that leaks out of the pin connection.

WARNING When handling lubricants (oil, grease etc.,) and other chemical products, always follow instructions for their proper use. Use proper containers to collect fluid. Dispose of fluids and filters in a way that will protect the environment and in accordance with the law. DO NOT smoke or use an open flame during the service procedure. Use eye protection. Failure to comply could result in death or serious injury M1303A

6-34

1

UYN00040027J10

1. DOZER CYLINDER ROD AND HEAD 2. DOZER BLADE LINK PIN

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

50 HOUR (WEEKLY) MAINTENANCE Perform the following procedures after 50 hours of operation along with the Daily Maintenance procedures.

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

M1087

WARNING To help prevent personal injuries during operation and maintenance, use safety shoes, a hard hat, safety glasses or goggles and good fitting clothing. Failure to comply could result in death or serious injury.

M110B

CHECK THE BATTERY

WARNING Wear safety clothes, goggles or face shield, gloves and safety shoes when working with batteries.

Work in a well ventilated area.

Battery electrolyte (acid) is corrosive. If it comes in contact with skin, eyes or clothing, flush with large amount of weater and seek immediate medical attention.

Battery electrolyte (acid) produces hydrogen gas that is highly explosive. Keep away sparks, fire or flames and do not smoke when working with batteries. Failure to comply could result in death or serious injury.

A 1 UYV00040003E01

1. DOOR LOCATED AT LEFT REAR OF MACHINE

M144C

1. Stop the engine before maintaining the battery.

2. Using the starter key switch, open the door (1) located at the left rear of the machine and hold it open with stay.

3. Loosen bolts (2) and remove battery protective cover (3).

2

NOTICE: Do not put tools and hardware on protective cover installed on the battery upper section. There is a hazard of explosion because the short-circuit may catch fire.

A

3 UYV00040004E02

2. BOLTS 3. PROTECTIVE COVER

6-35

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS Check the Battery Liquid Level 4. Check the indicator (4) on the battery and make sure it is always at blue (good condition) status.

Red and white status indicate low level of battery fluid and poor battery charge.

(Good condition)

(Refilling liquid)

BLUE

5. Remove the battery cell caps (5) and visually inspect electrolyte (acid) level. Proper level is 10 to 15 mm (0.4 to 0.6 inch) above cell plates.

(Charging liquid)

RED

WHITE

WHITE

RED

RED

A 4

WARNING Sparks or flame can cause hydrogen gas in a battery to explode. To prevent an explosion, do the following: 1. When you disconnect the battery cables, always disconnect the negative (-) battery cable first. 2. When you connect the battery cables, always connect the negative (-) battery cable first. 3.

Do not short circuit the battery posts with metal items. 4. Do not weld, grind or smoke near a battery.

UPW00400007J02

4. INDICATOR

84-109

NOTICE: Remove the battery terminal from the grounding side (negative terminal) first and conversely fit the terminal to the grounding side last.

6. Clean vent of battery cap and tighten cap (5) securely.

A

5

7. Attach protective cover (3) with bolt.

8. Remove stay, close and lock door with key.

10~15 mm

B

NOTICE: Clean battery terminal and apply grease or commercial lube oil rust preventive spray. Call in licensed specialty company for the disposal of used battery. Be careful not to use the hold battery with the new battery - it may reduce the service life of the battery. Replace both batteries if one needs replacement.

C

D ULSX240404B01

Measure Specific Gravity of Battery Fluid

A. B C D

NOTICE: Do not measure the specific gravity of the battery fluid immediately after operation - measure it at ambient temperature.

BATTERY 5. BATTERY CAP UPPER LOWER CELL PLATES

Since the specific gravity of battery fluid varies in respect to the liquid temperature, keep the specific gravity within the range specified in the table. When the specific gravity is lower than the lower limit, it is necessary to charge the battery.

6-36

Charge

20o C degrees (68o F degrees)

0o C degrees (32o F degrees)

-10o C degrees (14o F degrees)

100%

1.26

1.27

1.28

90%

1.24

1.25

1.26

80%

1.22

1.23

1.24

75%

1.21

1.22

1.23

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS Cold Weather Operation In cold weather, a sudden drop in temperature may cause battery fluid to freeze or reduce capacity.

Provide thermal insulation for the battery. Charge the battery earlier.

DRAIN THE FUEL TANK

WARNING Fuel vapors are explosive and flammable. Do not smoke while handling fuel. Keep fuel away from flames or sparks. Shut off engine and remove key before servicing. Always work in a well ventilated area. Clean up spilled fuel immediately. Failure to comply could result in death or serious bodily injury.

1

2

M1394

NOTICE: It is most effective to drain the fuel tank before starting the engine in the morning, since the water and sediment have time to settle after the machine has stopped operating for the night.

UYV00040005E02

1. DRAIN VALVE 2. DRAIN HOSE

1. Park the machine on a firm, level surface with both attachments resting on the ground. Turn the engine off. Place the safety lock lever in the l o c k e d p o s i t i o n . Ke e p a l l u n a u t h o r i z e d personnel clear of the area.

2. Place an empty container under the drain hose (2) to catch the discharged fuel.

4. Loosen the drain valve (1) and drain water and sediment. When clean fuel begins to flow, tighten the drain plug. Check for fuel leakage after tightening drain plug. If fuel is leaking, stop the engine, and consult your authorized dealer for repair.

NOTICE: Be careful not to be showered by flushed fuel.

6-37

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CHECK THE TRACK TENSION

WARNING Grease in track tensioning mechanism is under extreme pressure and can penetrate skin causing severe injury. Keep face and body away from grease fitting area. Never loosen grease fitting more than one (1) complete turn. If grease does not release after one (1) turn of the fitting, call your authorized dealer for assistance. Failure to comply could result in death or serious injury.

M1720

A A 1

NOTICE: Support the lower frame with suitable blocks.

1. Operate swing, arm, bucket and boom controls until the machine is set up as shown.

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

3. Perform Steps 1 and 2 on the right track.

4. To increase track tension, set the machine as shown and use the grease gun to inject No. 2 at extreme pressure the idler adjustment grease n ip p le ( 1 ) u n ti l th e p r o p e r te n s io n ( A) is reached.

UYT00040061J01

1. IDLER ADJUSTMENT GREASE NIPPLE A. SLACK - PROPER TENSION 200 TO 230 MM (7.9 TO 9.1 INCHES)

5. Perform this procedure on both tracks.

NOTICE: After injecting grease, operate the travel control forward and reverse for the track being adjusted. This will balance the tension between the idler and sprocket. Then remeasure, as shown in figure.

6. To decrease track tension, set the machine up as shown in figure.

7. Carefully loosen the adjusting grease nipple (1) to allow grease to escape.

8. Tighten grease nipple (1), measure track tension as shown in figure.

Tightening torque: 49 to 69 Nm (36.6 to 51.4 lb. ft) 9. If necessary, perform steps 6 through 7 on the other track.

1

UYN0040031J02

1. GREASE NIPPLE

6-38

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

100 HOUR MAINTENANCE Perform the following procedures after 100 hours of operation along with the Daily and 50 Hour Maintenance procedures.

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

M1087

WARNING To help prevent personal injuries during operation and maintenance, use safety shoes, a hard hat, safety glasses or goggles and good fitting clothing. Failure to comply could result in death or serious injury.

M110B

LUBRICATE THE BUCKET PIN To lubricate the bucket pin (ciricled area in picture) locate the grease gun on the inside of the side door on the left side of the machine.

NOTICE: If attachment is submerged in water, it is recommended to lubricate it every eight hours.

A

UYTX2804013B01

2

1. Wipe all grease nipples and apply grease until it comes out through the gap of the pin.

3 3 4

1

UYN00040027J12

1. BUCKET LINK PINS 3. IDLER LINK 2. BUCKET CYLINDER ROD PIN 4. ARM TOP PIN

6-39

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

120 HOUR MAINTENANCE Perform the following procedures after 120 hours of operation along with the Daily and 50 Hour Maintenance procedures.

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

M1087

WARNING To help prevent personal injuries during operation and maintenance, use safety shoes, a hard hat, safety glasses or goggles and good fitting clothing. Failure to comply could result in death or serious injury.

M110B

CHECK SWING MOTOR REDUCTION OIL

1

WARNING Touching hot surfaces could cause burns. The engine and components will be hot after the machine has been running. Allow the engine and components to cool before servicing the machine.

Failure to comply could result in death or serious injury.

2

A

M1333

1. Before checking the swing motor reduction oil, park the machine on a firm, level surface, place the bucket on the ground, stop the engine and move safety lock lever to "LOCKED" position.

2. Check gear oil level with the level gauge (1).

3. If necessary to add oil, remove plug (2) from oil fill port and fill to full level with proper gear oil.

4. For specified gear oil, refer to the LUBRICANT, FUEL & COOLANT SPECIFICATIONS section of this manual.

5. Attach level gauge (1).

6. Clean filling plug (2) with light oil, and wind seal tape on tube (3) and install plug securely.

Tightening torque: 64.7 to 73.5 N-m (48 to 54 lbf-ft)

6-40

UYV00040007E01

1. LEVEL GAUGE 2. FILLING PLUG

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CHECK TRAVEL REDUCTION UNIT OIL

2

WARNING Travel reduction gear is under pressure. Keep your face and body clear of drains. Never attempt to service a hot machine. Allow the machine to cool before performing any service. Heat increases travel reduction gear pressure. Loosen plug slowly and wear face protection. Failure to comply could result in death or serious injury.

A

M1721

1

1. Before checking the travel reduction unit oil, park the machine on a firm, level surface, making cer tain the drain por t (1) is on the bottom. Rest the attachment on the ground.

Stop the engine and move the safety lock lever to the LOCKED position. Keep all unauthorized persons clear of the area.

UYN00040033J01

1. DRAIN PLUG 2. LEVEL PLUG

2. Remove level plug (2) and check for short of oil level and contamination. If the oil level is to the top side of level plug, it is in proper level.

3. If shorted, remove level plug (2) and make up short of specified gear oil. For specified gear oil, refer to the section "LUBRICANT, FUEL & COOLANT SPECIFICATIONS".

2

4. Clean level plug (2) with light oil, and then attach it in place.

5. Similarly check on the travel reduction unit on the other side.

A 1 UYN00040034J01

1. BOTTOM PLUG 2. LEVEL PLUG

6-41

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

250 HOUR MAINTENANCE Perform the following procedures after 250 hours of operation along with the Daily and 50 Hour Maintenance and 120 Hour Maintenance procedures.

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

M1087

WARNING To help prevent personal injuries during operation and maintenance, use safety shoes, a hard hat, safety glasses or goggles and good fitting clothing. Failure to comply could result in death or serious injury.

M110B

CHECK FAN, ALTERNATOR, A/C BELTS WEAR AND TENSION

WARNING Entanglement Hazard - Stay clear! Rotating machine parts. Keep shields installed to help protect from clothing entanglement and injury. Wear close-fitted clothing. Failure to comply could result in death or serious injury.

A

M124B

NOTICE: If defects such as cuts or surface separations are found during inspection, replace the belt. Keep oil and grease away from the belt, since they may cause the belt to slip and shorten the service life.

UYV00030009E02

This machine is equipped with belts for alternator, fan and air conditioning.

1. Check these belts for insufficient tension, wear and damage.

2. Check belts for slack, and adjust the tension properly to maintain engine performance and service life. To check the tension of a belt, press your thumb on the center. If the deflection is within the range shown in the table, it is in normal tension.

Belt

When new belt replaced mm (in)

When inspected mm (in)

Force N (lbf)

Alternator, Fan

4 to 6 mm (0.16 to 0.24")

7 to 9 mm (0.28 to 0.35")

98 (22)

Air-conditioner

3 to 4 mm (0.12 to 0.16")

5 to 6 mm (0.20 to 0.24")

24 (5.2)

NOTICE: When replacing a belt, there is a lack of initial adaptability of the new belt. Run the engine at idling speed for about three or five minutes. After that, adjust the belt tension again. New belts get complete initial elongation after being run about two hours.

6-42

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS ADJUST ALTERNATOR AND FAN BELT

2

NOTICE: Keep oil and grease away from the alternator and fan belts, since they may cause the belt to slip and shorten the service life.

1

1. Open engine hood and support it with stay.

2. Loosen attaching nut (1) and adjusting nut (2) slightly and adjust the belt tension.

3. Loosen adjusting bolt (3), adjust the alternator and fan belts to the specified tension, and tighten attaching nut (1) and adjusting nut (2).

3

A

4. After adjustment, start engine and run it at low speed for about 5 minutes.

5. Release the stay which is supporting hood, close engine hood and lock engine hood.

UYV00040011E02

1. ATTACHING NUT 2. ADJUSTING NUT 3. ADJUSTING BOLT

ADJUST AIR CONDITIONING COMPRESSOR BELT

2

WARNING Entanglement Hazard - Stay clear! Rotating machine parts. Keep shields installed to help protect from clothing entanglement and injury. Wear close-fitted clothing. Failure to comply could result in death or serious injury.

A

M124B

NOTICE: Improper belt tension can decrease compressor performance, resulting in damage to the belt and compressor.

1. Open engine hood and support it with stay.

1 UYV00040011E02

1. NUT FOR IDLE PULLEY 2. ADJUSTING BOLT

2. Loosen nut (1) for idle pulley slightly and adjust the belt tension while turning the adjusting bolt (2), and then tighten nut (1).

Tightening torque: 41.2 to 51.0 N-m (31 to 38 lbf-ft) 3. After adjustment, start engine and run it at low speed for about 5 minutes.

4. Stop engine and check tension of fan belt.

5. Release the stay which is supporting hood, close engine hood and lock engine hood.

6-43

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CHECK THE RADIATOR HOSES

WARNING

1

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

Failure to comply could result in death or serious injury.

2

1

A 1

M110B

2

Replacement of radiator hoses is a good maintenance practice.

1. Open engine hood and support it with stay.

1

2. Check the hoses and clamps (1) for cracks, fatique or leakage.

3. Tighten any loose clamps.

UYV00040013E02

4. Replace hosees immediately if cracks, fatigue or water leakage are found. See next section for replacement procedure.

1. CLAMPS (2)

REPLACE THE RADIATOR HOSES

1

WARNING Hot coolant can spray out if radiator or deaeration tank cap is removed while system is hot. To remove cap, let system cool, turn to first notch, then WAIT until ALL pressure is released. Failure to comply could result in death or serious injury.

1

2

A

M646

1. Open engine hood support it with stay.

2. Loosen 6 bolts on the under cover of lower of radiator, and remove under cover.

UYV00040013E02

1. CLAMPS (2) 2. HOSE

3. Loosen drain valve (3) until the radiator coolant level is lower than the replacing hose (2) and drain coolant in container.

4. Loosen drain valve (3) until the radiator coolant level is lower than the replacing hose (2) and drain coolant in container.

2

5. Loosen clamp (1), remove damaged hose (2) and replace the hose with new one.

6. Tighten drain valve.

7. Fill coolant in radiator and then fill reserve tank with coolant.

A 3

1 UYV00040013E02

8. After filling up, tighten radiator cap securely.

9. Release the stay which is supporting hood, close engine hood and lock bonnet catch.

10. Return the under cover to original place.

6-44

1. CLAMP 2. HOSE 3. DRAIN VALVE

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CHECK THE AIR CLEANER RUBBER HOSE

2

WARNING

1

Touching hot surfaces could cause burns. The engine and components will be hot after the machine has been running. Allow the engine and components to cool before servicing the machine.

Failure to comply could result in death or serious injury.

2 2

1

2

A 1

M1333

NOTICE: Immediately after stopping the machine or during the operation, the temperature of the rubber hose is very high.

2

NOTICE: When the rubber hose is replaced, fill the inlet of air intake with clean cloth to prevent the dust from entering.

1. Check the air cleaner rubber hose (1) for damage, deterioration and for looseness around the band (2).

UYV00040009E02

1. AIR CLEANER RUBBER HOSE 2. BAND

2. Replace the damaged or deteriorated rubber hose (1) and the band (2) at the same time with new parts.

CHECK THE AIR COOLER RUBBER HOSE 1. Check the air cooler rubber hose (1) for damage, deterioration and for looseness around the band (2).

2

2. Replace the damaged or deteriorated rubber hose (1) and the band (2) at the same time with new parts.

1 2

A

2 1 2

2 1 2 UYV00040010E02

1. AIR COOLER RUBBER HOSE 2. BAND

6-45

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS SERVICE THE AIR CONDITIONER FILTERS

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

Failure to comply could result in death or serious injury.

1 1

A

M110B

WARNING: Flying debris from compressed air may cause accidents resulting in injury or death. Wear safety goggles and respirator when cleaning the filters of the air conditioner.

UYV00040010E02

1. FRESH AIR FILTER COVER

The fresh air filter should be cleaned every 250 hours and replaced after ten cleanings.

The recirculation air filter should be cleaned every 500 hours and replaced after 10 cleanings.

Maintenance intervals are for reference - in dusty areas, clean and replace earlier than the specified times.

Remove the fresh air filter 1. Remove cover (1) on the left rear side of operator seat and pull it forward.

2. Catch handle grip of fresh air filter (2) through opening from which cover (1) is removed and pull it out upward.

A

2

UYN00040089J02

2. HANDLE GRIP FOR FRESH AIR FILTER

6-46

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS Remove the recirculation air filter 1. The recirculation air filter (3) is located on the left side under the operator seat.

2. Turn over the floor mat, catch the handle grip of the recirculation air filter (3) and pull it forward.

Clean the filters C le a n r e cir cu la tio n a n d fr es h a ir filte r s with compressed air.

A

Attach the filters Attach re circulation a nd fresh air filters afte r cle an in g or fo r rep la cemen t by follow in g this procedure in reverse.

3

NOTICE: Insert the recirculation air filter direction the UP side upward.

2 UYN00040089J02

2. FRESH AIR FILTER 3. RECIRCULATION AIR FILTER

AIR CLEANING MAINTENANCE WARNING: Direct contact of the body with compressed air, steam and high pressure water can cause injury.

WARNING: Wear protective glasses, mask, safety cap, safety shoes, etc., to avoid injury.

NOTICE: Stop engine first and clean and replace the air cleaner element.

NOTICE: For machines equipped with double element and the inner element (2) must be replaced together with the outer element (1). Do not fail to replace the inner element (2) with new one.

A

UYF00040019J02

NOTICE: When cleaning outer element, do not remove inner element to avoid dust getting into engine air intake.

Clean and replace outer element Clean when warning is indicated on multidisplay or every 250 HOURS. Replace after six cleanings or one year, whichever comes first.

6-47

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 1. Using starter key, open the engine hood and support it with stay.

2

1

3

2. Remove 3 clamps (3) on the cover and pull out outer element (1).

A

UYH0004008E02

1. OUTER ELEMENT 2. INNER ELEMENT 3. CLAMPS (3)

3. Clean the inside of air cleaner housing.

4. To clean the outer element, blow compressed air (less than 0.2 MPa (29 psi) up and down along the folds of the filter element interior to remove clogged dust or other contaminants.

5. After cleaning, check on element (1) and if pin hole and excessively thinned parts are found, replace with new one.

A

6. Release the stay supporting the hood, close engine hood and lock engine hood.

UYT00040088J01

Clean and replace inner element 1. Remove outer element (1) first and then remove inner element (2).

3

2. Cover air outlet side with clean cloth or sealing tape to prevent intrusion of dust.

3. Clean inside of body and remove the cover attached in Step 2.

4. Fit new inner element (2) to connector.

5. Install outer element (1) and install cover with clamp (3).

NOTICE: Install the air filter so that "ARROW" position mark is faced upward.

6-48

2

A 1 UYF00040037J05

1. OUTER ELEMENT 2. INNER ELEMENT 3. CLAMP

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CHECK RADIATOR AND OIL COOLER DEBRIS SCREEN (FILTER)

1

WARNING Touching hot surfaces could cause burns. The engine and components will be hot after the machine has been running. Allow the engine and components to cool before servicing the machine.

Failure to comply could result in death or serious injury.

Lever

A

M1333

UYF00040037J05

WARNING

1. DEBRIS SCREEN

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

Failure to comply could result in death or serious injury.

M110B

NOTICE: Remove the debris screen (filter) from the machine before cleaning it. If cleaned on the machine, dust and dirt could cause contamination.

1. Open engine hood with starter key.

2. Using starter key, open the door at the left side of the counterweight.

3. Push lever of debris screen (1) toward the front side of the machine to remove the filter.

3

2

4. Check debris screen (1), radiator (2), oil cooler ( 3 ), a ir -c o o le r ( 4 ) a n d c o n d e n s e r ( 5 ) fo r clogging.

4

A

NOTICE: When compressed air or jet water are used for cleaning, do not damage the debris screen by getting too close.

5 UYV00040015E02

2. RADIATOR 4. AIR COOLER 3. OIL COOLER 5. CONDENSER

5. Clean off any mud, dust and leaves found on the debris screen. Use compressed air (0.2 MPa) or water to clean the cores and fins.

NOTICE: If the debris screen is torn or a clog of dirt cannot be removed, or if the aluminum frame is deformed, replace it with a new one.

6. Push the debris screen toward the front of the machine and secure it with lever.

A

7. Close and lock the door at the left side of the counterweight.

8. Release the stay supporting the engine hood, close and lock it.

1

Outside UYV00040017E02

6-49

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS LUBRICATE ATTACHMENT NOTICE: Grease gun is provided inside the side door on the left side of machine.

1. Park the machine on a firm, level surface with both attachments resting on the ground. Turn the engine off. Keep all unauthorized personnel clear of the area.

3

2. Clean the grease fitting before greasing.

Replace any damaged grease fitting.

3. Lubricate with a grease gun through the grease fittin gs show n until the grea se co mes o ut through the gap of pin. Wipe off any grease that leaks out of the pin connection.

1

Attachment Lubrication Points 1. and 2. Boom cylinder and rod pins

2

3. Arm cylinder head pin 4. Boom foot (Center) pin 5. Arm cylinder rod pin NOTICE: Dispose of all waste in accordance with environmental regulations.

4

UYN00040024J04

5. Swing bracket pins

5

ULF00040040E02

6. Swing cylinder head and rod pins

6 6 ULF00040041E02

6-50

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 7. Arm cylinder rod pin 8. Arm to boom pin 9. Bucket cylinder head pin

7

8

9 UYV00040002E03

6-51

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

500 HOUR MAINTENANCE Perform the following procedures after 500 hours of operation along with the Daily, 50 Hour, 120 Hour, and 250 Hour Maintenance procedures.

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

M1087

WARNING To help prevent personal injuries during operation and maintenance, use safety shoes, a hard hat, safety glasses or goggles and good fitting clothing. Failure to comply could result in death or serious injury.

M110B

REPLACE ENGINE OIL AND OIL FILTER

F

WARNING Touching hot surfaces could cause burns. The engine and components will be hot after the machine has been running. Allow the engine and components to cool before servicing the machine.

Failure to comply could result in death or serious injury.

M1333

NOTICE: The engine oil filter on this machine is located remote from the engine on the inside of the door on the right rear side of the machine. When the filter is replaced, idle the machine for several minutes to allow the oil to reach the engine.

NOTICE: Replace engine oil after 50 hours of operation for the first use of a new machine.

NOTICE: Replace the engine oil simultaneously with the engine oil change.

G

P

H

filter L

UYTX2903002B01

F. OIL FILLER CAP H - HIGH LEVEL G. OIL LEVEL GAUGEL - LOW LEVEL P. DRAIN PLUG

6-52

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 1. Loosen the four bolts from the cover located under the engine.

2. Place a container with 15-liter capacity under the engine to collect the drained oil.

3. Clean the oil filler cap (F) area and remove the filler cap.

1

4. Loosen the drain plug (P) of the engine oil pan and drain the engine oil into the container.

5. After draining the engine oil completely, tighten the drain plug (P) securely.

6. Remove the old oil filter (1) with a filter wrench and replace with a new one.

Filter wrench part number: YW01T01014P1

UYN00040042J02

1. OIL FILTER

NOTICE: Check the waste oil for metal chips or powder and contact the dealer/distributor if any are found.

NOTICE: Dispose of all hazardous waste in accordance with government environmental regulations.

7. Remove dust, mud and other contaminants from the seal surface of the oil filter.

8. Apply engine oil to the gasket and fit it in place, turning the filter by hand to the position where it is in contact with the filter seal surface.

9. Tighten is 3/4 to 1 turn with the filter wrench.

BS07N040

A. APPLY CLEAN ENGINE OIL

10. Fill through the oil filler cap (1) with the specified engine oil. See Lubr icant, Fuel & Co olant Specifications in this manual.

11. Attach the oil filler cap (F).

12. Check the oil level using the oil level gauge (G).

It should be between the L and H limits as shown in the diagram. Start and run the engine for five minutes. Stop the engine and check the oil level after 10 minutes. Add oil if necessary.

13. Check the oil filter seal to ensure there is no leakage.

14. Reinstall cover under the engine and close the engine hood.

6-53

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS REPLACING THE FUEL PRE-FILTER The fuel pre-filter is located on the inside of the door on the right rear side of the machine.

WARNING: When handling fuel, make sure there are no open flames or other fire hazards near the engine. Wipe off any spilled fuel completely. Spilled fuel could ignite and cause a fire.

1. Park the machine on a firm, level surface with both attachments resting on the ground. Turn the engine off. Keep all unauthorized personnel clear of the area.

2

2. Clean the area around the water separator.

3. Prepare container for drain oil.

4

4. Close fuel cut valve (1) halfway up the fuel filter line.

3

5. Loosen air bleeder plug (2) and drain valve (3) and drain fuel from fuel pre-filter.

1

6. Fit the specified filter wrench to the lower side of stiffen ing r igs a nd re move ca se ( 4) . Pa r t Number YT01T01008P1

UYTX2804007E01

7. Remove element (5) and float (6) placed in the case (4) and replace element with new one.

8. Replace O-ring (7) with new one.

9. After installing O-ring (7) to case (4) install element into case (4).

7 5

10. Tighten air breather plug (2) and drain plug (3).

4

11. Open fuel cut valve (1).

6

WARNING: AVOID FIRES. Wipe off fuel on any parts of machine. Do not use gasoline to clean filter elements. Dispose of waste fuel promptly in accordance with government environmental regulation.

ULC0040011C02

1.

2.

3.

4.

5.

6.

7.

6-54

HANDLE RING CASE ELEMENT O-RING FLOAT SPRING

A. CLOSED POSITION B OPEN POSITION

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS REPLACING THE FUEL FILTER The fuel filter is located on the inside of the door on the right rear side of the machine.

WARNING: When handling fuel, make sure there are no open flames or other fire hazards near the engine. Wipe off any spilled fuel completely. Spilled fuel could ignite and cause a fire.

1. Park the machine on a firm, level surface with both attachments resting on the ground. Turn the engine off. Keep all unauthorized personnel clear of the area.

2

2. Allow the machine to cool.

4

3. Place a drip pan under the fuel filter.

3

4. Clean the area around the fuel filter.

5. Using a filter wrench, remove the fuel filter.

Part number : YW01T01014P1

1

6. Wipe off fuel on the fuel filter cartridge (1) mounting surface of the filter bracket with a cloth.

7. Check new fuel filters for proper seating of the gasket.

NOTICE: Dispose of all hazardous waste properly according to local environmental regulations.

UYTX2804007E01

1. FUEL FILTER CARTRIDGE

NOTICE: Do not use a filter that has dent on its case. A dented filter could be damaged during operation and leak fuel, resulting in a fire.

8. Apply clean fuel to the gasket on the new fuel filter.

9. Install the fuel filter (1).

10. After installing the new fuel filter, bleed the fuel filter.

11. Start the engine and let it idle for several minutes.

12. Make sure that there is no fuel leakage during the engine operation.

13. For bleeding the fuel filter, refer to the Bleeding the Fuel Filter section of this manual.

BLEEDING AIR FROM THE FUEL SYSTEM The fuel pump on this machine is located under the engine.

1. Fill fuel tank with fuel.

2. Turn starter key switch "ON" and fueling pump starts operating for approximately two minutes and bleed air automatically.

6-55

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS FILTER REPLACEMENT OF ELECTROMAGNETIC PUMP To avoid the engine trouble at starting, replace the filter every 500 hours. And prevent the filter from clogging.

1

1. Clean the area of the electromagnetic pump.

2

2. Remove a hose clamp (1) from the electromagnetic pump and disconnect the hose (2). In this time, prevent the entering of dust and dirt.

3. Loosen mounting bolt electromagnetic pump.

(3)

and

1, 2

3

remove

UYTX2904002E01

1. HOSE CLAMP 2. HOSE 3. MOUNTING BOLT

Disassembly and assembly 1. Using spanner wrench, loosen and remove the cover (4).

2. Remove gasket (5), filter (6) and gasket (7) in order.

7

3. Replace the filter (6), the gaskets (5) and (7) with new ones.

Repair kit number: VI894337-0220 4. Assemble the above parts in the reverse order of disassembling. First, insert the gasket (5) into the cover (4) an d tig hten it to the electromagnetic pump securely by the spanner.

Used tool: Spanner wrench (17 mm)

6

ELECTROMAGNETIC PUMP

5. Install the electromagnetic pump to the specified position, and tighten it by the mounting bolt (3).

Tightening torque: 8.6 to 10.6 N-m (6 to 8 lbf-ft) 6. Install the hose (2) to the electromagnetic pump with the clip (1).

5

4

7 6 5 4 MAGNET

UYT00030001E01

4.

5.

6.

7.

6-56

COVER GASKET FILTER GASKET

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CHECK SLEWING RING FITTING NOTICE: Make sure that the gasket is replaced with new one. Before assembling, clean the cover, magnet and other parts. Check the airtightness of the pump.

1. Check that bolts (1), (2) securing slewing ring are not loosened.

1

2. If loosened, remove bolts (1), (2) once, apply Loctite #262 or equivalent, and tighten them again.

Location

2

Torque specification Nm/lb ft

ULC004003J02

Inner race

279 + 28 (206 + 20)

Outer race

157 + 16 (116 + 12)

1. BOLT 2. BOLT

3. Alternately tighten bolts (1), (2) facing each other in order.

NOTICE: Since the tightening of the slewing ring requires special tools, contact our dealer/distributor for assistance.

Grease the slewing ring 1. Locate the grease nipple at the front of the slewing ring.

NOTICE: Check the Specifications section of this manual for grease specifications.

2. Using grease gun filled with general purpose EP grease, lubricate slewing ring with several shots from grease gun. Grease amount : Max. 30 cc / 1 grease nipple.

3. Slew machine 90 degrees right, and repeat Step 2. See level on frame.

4. Continue to slew machine at 90 degrees increments and lubricating slewing ring until ring has been completely greased.\

ULC004003J02

5. Using grease gun, lubricate through grease nipple until the grease comes out from bearing seal when the direction of the slewing bearing is changed at every 90 degrees.

6-57

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS LUBRICATE PUSH ROD OF CONTROL LEVER 1. Remove rubber boot of pilot valve and apply a small amount of grease to the push rod (1) and top end (2) of rotation sliding section.

2. To remove the boot, insert a flat-blade screwdriver into the space between boot (3) and plastic cover (4), and release the cover from 4 claws one by one.

3. After greasing, attach plastic cover (4) and boot (3).

2

1

3

4

3 Driver

Insert flat-blade screwdriver into this point and push

4 UYN00040054E01

1.

2.

3.

4.

6-58

PUSH ROD TOP END BOOT PLASTIC COVER

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CHECK THE AIR CONDITIONING REFRIGERANT

WARNING

Sight Glass

Never attempt to service the air conditioning system unless you are completely familiar with air conditioning and the safety precautions which must be followed when handling liquid refrigerant. Liquid refrigerant can cause severe and painful frostbite.

Contact your Dealer, who is experienced in servicing and handling of refrigerants.

M143B

WARNING UYF0004002E02

Dangerous gas can form when refrigerant comes in contact with an open flame. Never inhale fumes.

M745

1. Start the engine. Set the engine speed to the middle speed position.

2. Close the doors and windows on the machine.

4

3. Turn the air conditioner switch (1) ON. 4. Turn the fan switch (2) to HI (maximum) 5. Set the Temperature Adjustment Switch (3) to the lower temperature position.

6. Turn the compressor switch ON (lamp is on).

Wh en filling o r ch ang in g re frige rant, u se the specified type. The use of unspecified refrigerant may cause damage to the equipment.

Refrigerant Type and Quantity: R-134a 850 g to 950 g (0.23 to 0.25 lbs)

3

2

1 UYN00040055J01

1.

2.

3.

4.

AIR CONDITIONER ON/OFF SWITCH FAN SWITCH TEMPERATURE ADJUSTMENT SWITCH COMPRESSOR SWITCH

6-59

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 7. 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.

Refrigerant volume A Proper

After the air conditioner is turned ON, littl bubbles appear. The refrigerant becomes transparent, then turns a light milky white

Figure (A) Shows that the refrigerant volume is proper.

Figure (B) Shows that 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.

Figure (C) Shows that the refrigerant is insufficient. Have the refr ige ra nt re cha rged a t you r dealer/distributor.

NOTICE: 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. When oil comes out from the pipe joint, contact our dealer/distributor because it is a sign of gas leaking. Follow the following regulations to conserve global environment. 1. Do not release refrigerant to atmosphere. 2. Extract the sealed refrigerant from unit when disposing this unit.

6-60

Description

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 UYN00040055J01

A. REFRIGERANT VOLUME IS CORRECT B REFRIGERANT OVERCHARGED C REFRIGERANT UNDERCHARGED

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CLEAN THE FUEL TANK CAP AND STRAINER 1. Remove cap with starter key.

1

2. Check cap seal for damage, and if damaged replace it with new one.

ULFX1204007B01

1. FUEL TANK CAP

3. Clean strainer with light oil and attach it in place.

If damaged, replace it with new one.

4. Attach cap and lock it with starter key.

UYT0004009J01

6-61

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

1000 HOUR MAINTENANCE Perform the following procedures after 1000 hours of operation along with the Daily, 50 Hour, 120 Hour, 250 Hour and 500 Hour Maintenance procedures.

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

M1087

WARNING To help prevent personal injuries during operation and maintenance, use safety shoes, a hard hat, safety glasses or goggles and good fitting clothing. Failure to comply could result in death or serious injury.

M110B

REPLACE THE RETURN FILTERS The return filters need special servicing because t hey p lay a n im po r ta nt rol e in r em ov ing contaminants from the hydraulic system.

NOTICE: Change the hydraulic tank return filter on a new machine after the first 50 hours of engine operation, then change filters every 1,000 hours of operation.

NOTICE: If the machine is equipped with a hydraulic breaker, refer to the operator’s manual for the breaker for return filter specifications. Change the filters on the hydraulic breaker every 250 hours.

UYF00030004E02

MACHINE POSITION FOR CHECKING HYDRAULIC OIL

WARNING

1

Hydraulic fluid is under extreme pressure. Make certain all pressure is released in the hydraulic system. Failure to comply could result in death or serious injury.

Push Valve

M1295

1. Park the machine on firm, level ground with both atta chme nts re sting on the grou nd in the position shown. Stop the engine and move the safety lock lever to the LOCKED position. Keep all unauthorized personnel clear of the area.

UYTX2804015B01

2. Clean any dirt from the filter area to avoid contaminating the hydraulic system.

3. Remove the breather cap (1) on the upper surface of the hydraulic tank and release the pressure from the tank by pressing the valve several times.

6-62

1. BREATHER CAP

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 4. Loosen six mounting bolts (2) on the tank upper cover (3). Remove cover.

2 3

5. Remove spring (4), bypass valve (5) and element assembly (A) from tank.

6. Remove O-ring (6) from cover.

4 5

NOTICE: Note the top and bottom direction of filter element (B) and be sure to assemble it directing the side marked TOP upward. The joint (C) must be assembled with special attention, because once fitting, it cannot be disassembled.

7. Assemble long-life return filter element kit (A) and put it in place.

8. Install cover (3) plate and torque attaching bolts (2) to proper value. Refer to Specifications section in this manual for torque values.

B Element Assy A

C B 6

(6)

WARNING

(B)

Touching hot surfaces could cause burns. The engine and components will be hot after the machine has been running. Allow the engine and components to cool before servicing the machine.

Failure to comply could result in death or serious injury.

(C)

M1333

9. Allow the components to cool down before replacing the filter. Use a long-life return filter.

O rd e r R e tu r n Filte r Elem en t Kit Pa r t N o.

YR52V01004R300.

(A)

(B) ELEMENT KIT UYTX2804015B01

A. LONG LIFE RETURN FILTER ELEMENT KIT B ELEMENT C JOINT

1. BREATHER CAP (NOT SHOWN) 2. MOUNTING BOLTS 3. COVER PLATE 4. SPRING 5. BYPASS VALVE 6. O-RING

REPLACE THE AIR BREATHER ELEMENT

WARNING Touching hot surfaces could cause burns. The engine and components will be hot after the machine has been running. Allow the engine and components to cool before servicing the machine.

Failure to comply could result in death or serious injury.

UYX2004010B01

M1333

NOTICE: To keep hydraulic oil clean and extend the life of hydraulic components, replace the filter element at regular intervals. 1000 hours is a guideline. If the machine is operated in very dusty conditions, change the filter sooner.

1. Park the machine on firm, level ground and extend the bucket cylinder. Retract the arm cylinder and lower the bucket to the ground as shown.

6-63

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 1. To release the inner pressure of hydraulic oil tank, remove the breather cap (1) located on the tank, and push the valve several times (5 to 7 times).

ULFX1204008B01

2. After removing the breather cap (1), remove the seal (2), the nut (3), and the seal (4) in order.

1 2 3 4

3. Rotate the cover (5) in a counterclockwise and remove the cover. And then remove the element (6).

4. Install the new element (6) and install the cover (5) along the groove.

5 6

5. Do not allow water and dirt to enter into the air intake and exhaust between the cover (5) and the body (7).

7

6. Install the seal (4) on the cover (5) and tighten the nut (3), and set the seal (2).

UYTX2604006B01

7. Rotate the breather cap (1) in a clockwise tightly by hand. And then install the breather cap (1).

NOTICE: To avoid breaking bolts, do not overtighten. Tightening torque for nut (3) is 10 to 14 Nm (7.37 to 10.32 lb ft).

CHECK THE ENGINE MOUNTING BRACKET 1. Check the engine mounting bracket (1) and the rubber mount (2) for damage, deterioration and for looseness of bolt (3) and nut (4).

2. If damage or deterioration is found on mount bracket (1) or rubber mount (2), contact your dealer/distributor for replacement.

3,4

3,4

1

3

2 3,4 2 3

2

3,4

3. Refer to Specifications section in this manual for tightening torques of bolt (3) and nut (4).

2 1 2 UYV00040027E02

1.

2.

3.

4.

6-64

ENGINE MOUNTING BRACKET RUBBER MOUNT BOLT NUT

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS LUBRICATE THE SWING REDUCTION UNIT

1

WARNING Touching hot surfaces could cause burns. The engine and components will be hot after the machine has been running. Allow the engine and components to cool before servicing the machine.

Failure to comply could result in death or serious injury.

M1333

1. Park machine on firm level ground, and place the attachment to the ground. Stop engine and move safety lock lever to "LOCKED" position.

2. Using grease gun, lubricate about 100 cc grease (about 1/4 cartridges) through grease nipple (1) of the slewing reduction gear or lubricate grease until the grease comes from the relief valve (2).

UYV00040035E02

1. GREASE NIPPLE 2. RELIEF VALVE

NOTICE: Replace at 250 hours operation for the first use of new machine.

6-65

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CHECK THE BATTERY VOLTAGE

WARNING Wear safety clothes, goggles or face shield, gloves and safety shoes when working with batteries.

Work in a well ventilated area.

Battery electrolyte (acid) is corrosive. If it comes in contact with skin, eyes, or clothing, flush with large amount of water and seek immediate medical attention.

Battery electrolyte (acid) produces hydrogen gas that is highly explosive. Keep away sparks, fire or flames and do not smoke when working with batteries. Failure to comply could result in death of serious injury.

M144C

WARNING Sparks or flame can cause hydrogen gas in a battery to explode. To prevent an explosion, do the following: 1. When you disconnect the battery cables, always disconnect the negative (-) battery cable first. 2. When you connect the battery cables, always connect the negative (-) battery cable first. 3.

Do not short circuit the battery posts with metal items. 4. Do not weld, grind or smoke near a battery.

84-109

WARNING: Do not put tools and hardware on protective cover installed on the battery upper section. They could cause a short-circuit and hazard of explosion.

1. Stop the engine before checking the battery.

2. Measure the voltage of the battery and if the measured value does not reach the specified voltage, recharge or replace battery.

NOTICE: Clean battery terminal and apply grease or commercial lube oil rust preventive spray. Call in a licensed specialty company for the disposal of a used battery. Do not use the old battery with the new battery. It may reduce the service life of battery.

If one battery needs replacement, replace the other at the same time.

6-66

2

3 UYV0004004E02

2. BOLTS 3. PROTECTIVE COVER

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

2000 HOUR MAINTENANCE Perform the following procedures after 2000 hours of operation along with the Daily, 50 Hour, 120 Hour, 250 Hour 500 Hour and 1000 Hour Maintenance procedures.

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

M1087

WARNING To help prevent personal injuries during operation and maintenance, use safety shoes, a hard hat, safety glasses or goggles and good fitting clothing. Failure to comply could result in death or serious injury.

M110B

CHANGE THE ENGINE COOLANT

1

WARNING The engine coolant system operates under pressure which is controlled by the radiator pressure cap. It is dangerous to remove the pressure cap while the system is hot. When cool, use a thick cloth and turn the cap slowly to the first stop and allow the pressure to escape before fully removing the cap.

Coolant should be kept off the skin. Adhere to the precautions outlined on the antifreeze and inhibitor containers, where used. Failure to comply could result in death or serious injury.

B097

UYF00040006J02

1. RADIATOR CAP

WARNING Touching hot surfaces could cause burns. The engine and components will be hot after the machine has been running. Allow the engine and components to cool before servicing the machine.

Failure to comply could result in death or serious injury.

M1333

1. Find firm level ground, place bucket on the ground, stop engine, and move safety lock lever to the LOCKED position.

2. Using starter key, open engine hood and hold it with stay.

3. Loosen radiator cap (1) slowly, check that the pressure is released completely, push cap in, and remove the cap by loosening it fur ther.

Prepare hose for pouring water.

6-67

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 4. Remove undercover under the radiator, and prepare container for coolant under drain valve (2) and drain plug (3) on the engine side face.

2

5. After draining, close drain valve (2) and drain plug (3) and fill it with clean soft water.

6. Open drain valve (2) and drain plug (3), and operate engine by low idling, and wash it with flowing water for 10 minutes. During washing with the aid of flowing water, regulate the pouring water volume and discharging water volume to keep the radiator in full condition.

During water flowing, maintain a continual watch for the disconnection of pouring water hose from the radiator water filling port.

UYF00040006J02

2. DRAIN VALVE

7. After flowing water washing, stop engine and stop pouring water, and then after discharging water, close drain valve (2) and drain plug (3).

8. After discharging water, clean it with cleaning solution. Regarding to how to use cleaning solution, follow the instructions in "Instruction Manual" for the cleaning solution in use.

9. After cleaning, open drain valve (2) and drain plug (3) and discharge water completely, and then close the drain valve and drain plug and feed soft clean water close to the feed water port.

10. After water is fed close to feed water port, open drain valve (2) and drain plug (3) and continue flowing water washing until clean water is discharged. During water flowing washing, r e g u la t e t h e p o u r i n g w a t e r vo l u m e a n d discharging water volume to keep the radiator in full condition.

3 UYF00040006J02

3. DRAIN PLUG

11. When clean water is discharged, stop engine and close drain valve (2) and drain plug (3). And then feed "Long Life Coolant" in proper concentration until it is overflowed from the filling port.

12. When the engine coolant is replenished, fill the cooling water after loosening the plug (5) of the EGR cooler (4). Wipe up any spilled fluid.

5,6

4

NOTICE: All air in the engine could not be bled through the plug of EGR cooler. The gasket was fixed in the plug part of air bleeding. If any damage is found on the gasket (6), replace it with a new one.

Air bleed plug Tightening Torque : 24.5 to 30.5 N-m {18 to 23 lbf-ft}

UYF00040006J02

4. EGR COOLER

6-68

5. PLUG 6. GASKET

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 13. Run engine by low idling for 5 minutes to r e m ove a ir c o n t a mi n a t e d in c o o la n t a n d continue low idling operation for 5 minutes further. (During this operation, leave the cap of filling port removed.)

14. Discharge coolant from reserve tank (7) and clean inside of the reserve tank and fill tank with "Long Life Coolant" in proper concentration to the mid point of FULL(A)-LOW(B) marks.

7

15. Stop engine, and after 3 minutes pour soft clean water in radiator to the edge of radiator filler cap, and then tighten radiator cap.

B

A

16. Replace the support of stay, close engine hood and lock hood with starter key.

UYTX280401B01

7. RESERVE TANK

6-69

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CHANGE THE OIL IN THE SWING REDUCTION UNIT

3

WARNING 2

Touching hot surfaces could cause burns. The engine and components will be hot after the machine has been running. Allow the engine and components to cool before servicing the machine.

Failure to comply could result in death or serious injury.

M1333

• Container for drain oil: 2 L {0.5 gal} or more • Changing oil quantity: 1.5 L {0.4 gal} Change the swing reduction unit oil on a new machine after the first 500 hours of engine operation then change every 2000 hours.

1. Prepare container for drain oil.

2. Remove drain plug (1) on the rear lower side of swing reduction unit and drain oil in container.

3. Clean drain plug (1) with light oil, dry it with drain plug.

Tightening torque: 108 N-m {80 lbf-ft} 4. Remove fill plug (2), and fill with the specified gear oil in the specified quantity referring to "4.3 L U B R I C A N T, FUEL & COOLANT SPECIFICATIONS".

5. When the reading is within the specified range of level gauge (3), it is normal level.

6. Clean filling plug (2) with light oil, and wind seal tape on tube (4) and install plug securely.

Tightening torque: 64.7 to 73.5 N-m {48 to 54 lbf-ft} Che ck the metal chips an d pow der in the drained oil. If the oil includes such contaminant, contact our dealer/distributor for repair.

7. Dispose of all hazardous waste in accordance with government environmental regulations.

6-70

1 UYV00040032E02

1. DRAIN PLUG 2. FILLING PLUG

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CHANGE THE OIL IN THE TRAVEL REDUCTION UNITS

2

WARNING Touching hot surfaces could cause burns. The engine and components will be hot after the machine has been running. Allow the engine and components to cool before servicing the machine.

Failure to comply could result in death or serious injury.

M1333

1

WARNING

UYV000400331J01

Travel reduction gear is under pressure. Keep your face and body clear of drains. Never attempt to service a hot machine. Allow the machine to cool before performing any service. Heat increases travel reduction gear oil pressure. Loosen plug slowly and wear face protection. Failure to comply could result in death or serious injury.

1. DRAIN PORT 2. FILL PORT

M1721

1. Park the machine on a firm, level surface with both attachments resting on the ground. Turn the engine off. Keep all unauthorized persons clear of the area.

4. When parking the machine, make certain the drain port (1) is at the bottom.

5. Stop engine and place an empty 3 liter (0.77 gal.) container under the drain plug.

6. Remove drain plug (1) and level plug (2) and drain oil into the container.

7. After draining oil completely, clean the drain plug (1) with light oil and put it back in place.

8. Fill with the specified oil in the specified quantity through the hole for the level plug (2) until oil starts flowing out of the port (3).

9. Clean level plug (2) with light oil and attach it in place.

2

NOTICE: Check the metal chips and powder in the drained oil. If the oil includes such contaminant, contact your dealer/distributor. Dispose of all hazardous waste in accordance with government environmental regulations.

1 UYN00040034J01

1. DRAIN PLUG 2. LEVEL PLUG

6-71

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CLEAN THE SUCTION STRAINER

WARNING Hydraulic fluid is under extreme pressure. Make certain all pressure is released in the hydraulic system. Failure to comply could result in death or serious injury.

M1295

WARNING UYF00040032J03

Touching hot surfaces could cause burns. The engine and components will be hot after the machine has been running. Allow the engine and components to cool before servicing the machine.

Failure to comply could result in death or serious injury.

M1333

1. Park machine on firm level ground in the hydraulic level checking position, stop engine.

1

2. Move safety lock lever to "LOCKED" position.

3. Clean the surface around hydraulic tank to prevent intrusion of foreign matter.

4. Remove breather cap (1) on the upper surface of hydraulic tank and release pressure from hydraulic tank by pressing valve (A) several (5 to 7) times.

A

5. Loosen 6 mounting bolts (2) of tank upper cover, remove cover (3).

NOTICE: Be careful not to drop bolts or tools into the tank while working.

6-72

ULC00040021B01

A. VALVE 1. BREATHER CAP

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 6. Take out suction strainer (4).

2

7. Clean strainer with light oil or washings, dry it and check strainer for damage. If damaged, replace the strainer with new one.

3

8. Check O-rings (5) and (6) on the bottom of stra in e r fo r we ar a nd d ama g e. If wo r n o r damaged, replace the strainer with new one.

9. Insert strainer (4) into suction tube.

4

10. Install cover (3) with bolt (2).

Tightening torque: 41.9 to 51.1 N-m (30.9 to 37.7 lbf-ft)

6 UYF00040025J03

2. BOLT 3. COVER

4. STRAINER 5. O-RINGS

11. Start engine and operate it by low idling for several (5 to 7) minutes. Operate each cylinders and swing, and then return the machine to the hydraulic level checking position. Stop the engine and check the oil level, if the level is low, make up the oil.

5 5 3.

82

m m

UYN00040067J04

6-73

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CHECK THE SWING BEARING TEETH NOTICE: The deterioration of grease may cause damage of pinion shaft and swing bearing of swing reduction unit.

If the grease is white due to moisture content, and the viscosity of grease is lowered, replace the grease. Also, if the grease is contaminated with a large amount of water, replace the grease. In that case, contact our dealer/distributor.

1. Grease may be cloudy due to slight c o n t a m in a t i o n o f w a t e r, bu t t h e r e i s n o malfunction if the viscosity is high. When water is present, loosen bolts (1) and spring washers (2) on the lower side of lower frame, remove cover (3) and packing (4) and drain water.

6-74

4 3 2 1 UYN00040069J02

1. BOLTS 3. COVER 2. SPRING WASHERS 4. PACKING

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CLEAN THE PILOT LINE FILTER

WARNING Touching hot surfaces could cause burns. The engine and components will be hot after the machine has been running. Allow the engine and components to cool before servicing the machine.

Failure to comply could result in death or serious injury.

M1333

3 2 1

NOTICE: Replace the filter after completely releasing internal pressure from hydraulic system.

1. Open side door on the pump side.

2. Remove hose (1), connector (2) and line filter (3).

3. Clean line filter with light oil.

4. Put line filter (3) back in place.

ULFX1204012B01

1. HOSE 2. CONNECTOR

3. LINE FILTER

6-75

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

5000 HOUR MAINTENANCE Perform the following procedures after 5000 hours of operation along with the Daily, 50 Hour, 120 Hour, 250 Hour 500 Hour, 1000 Hour and 2000 Hour Maintenance procedures.

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

M1087

WARNING To help prevent personal injuries during operation and maintenance, use safety shoes, a hard hat, safety glasses or goggles and good fitting clothing. Failure to comply could result in death or serious injury.

M110B

CHANGE HYDRAULIC OIL

WARNING Hydraulic fluid is under extreme pressure. Make certain all pressure is released in the hydraulic system. Failure to comply could result in death or serious injury.

M1295

WARNING UYF00040032J03

Hot oil and/or components can burn. Oil must be at operating temperature when draining. Avoid contact with oil or components. Failure to comply could result in death or serious injury.

M623

NOTICE: Machines equipped with a hydraulic breaker may experience faster deterioration of hydraulic oil. For service instruction, refer to the Checking and Service for Hydraulic Breaker section of this manual.

1. Park the machine on a firm, level surface and swing the upper structure so that the drain plug (1) on the lower section of the hydraulic tank is positioned to the midpoint of the right and left track shoe.

2. Retract the arm cyinder and bucket cylinder, place the bucket and blade (when installed) on the ground and stop the engine.

3. Move safety lock lever to "LOCKED" position.

1

4. Clean the surface around hydraulic tank to prevent intrusion of foreign matter.

ULQX2204002B01

1. DRAIN PLUG

6-76

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 5. Remove breather cap (2) on the upper surface of hydraulic tank and release pressure from hydraulic tank by pressing valve (A) several (5 to 7) times.

2

A

ULC00040023B01

A. VALVE 2. BREATHER CAP

6. Loosen 6 mounting bolts (3) of tank upper cover, remove cover (4).

7. Drain the hydraulic oil into container using oil pump.

Container for drain oil: 48 L {12.7 gal} or more Changing oil quantity: 48 L {12.7 gal} NOTICE: Do not drop bolt or other parts into the tank during the work.

3 4

NOTICE: Dispose of all hazardous waste in accordance with government environmental regulations.

UYTX2804016B01

3. MOUNTING BOLTS 4. COVER

8. Place container for drain oil under drain plug (1) of the hydraulic tank bottom.

9. Loosen drain plug (1) on the bottom of hydraulic tank slowly and drain hydraulic oil completely.

10. Clean drain plug (1) and install it in place.

Tightening torque: 98 to 118 N-m (72 to 87 lbf-ft.

1

UYN00040073J01

1. DRAIN PLUG

6-77

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 11. Fill hydraulic tank with hydraulic oil through filler port. Fill with hydraulic oil watching the level gauge (G) for oil level.

H

12. Attach filler port cover (4) with 6 bolts (3).

Tightening torque: 41.9 to 51.1 N-m (30.9 to 37.7 lbf-ft)

G L

13. Start engine and idle for several (5 to 7) minutes. Operate cylinders and swing, and then re tur n the ma ch ine to th e hyd ra ulic level checking position. Stop the engine and check the oil level, if the level is low, make up the oil.

UYN00040073J01

G. LEVEL GAUGE H = HIGH LEVEL L - LOW LEVEL

6-78

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

SPECIAL MAINTENANCE PROCEDURES AUTOMATIC SPRING BRAKE SYSTEM NOTICE: This machine is equipped with automatically applied spring brake systems in the travel and swing motors. These systems will automatically engage the brakes when the engine is stopped, making it impossible to move the machine.

Attachment on Ground

The following section describes the procedures for releasing the travel motor brakes, the swing motor brake and lowering the attachment to the ground should sudden engine failure occur.

Chock blocks at front tr and rear of each track

WARNING: The procedures found in this section should be performed by a well-trained, experienced service technician who is familiar with the machine.

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.

ULFX1208001E01

1

3

RELEASING TRAVEL MOTOR BRAKES Tools and equipment required:

• • • • • • •

Four chock blocks 5 mm Allen wrench 8 mm Allen wrench 10 mm socket wrench Two 4-liter (1.1 gal) capacity drain pans M8-1/25 x 15 mm lifting eye Overhead lifting device capable of lifting and holding 45 kg (100 lb.)

• Torque wrench (70 to 74 Nm (52 to 55 lb ft) capacity or better

1 2 UYF00080002E01

1. STARTER KEY SWITCH IN “OFF” POSITION 2. THROTTLE IN “LO” POSITION‘

• Thread sealant (for drain and check/fill plugs) • Rubber or soft-faced mallet

6-79

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 1. Place chock blocks at front and rear of each track to prevent machine from moving when brakes are released.

Remove drain plug with 10 mm socket wrench

2. Lower attachment to ground. See Lowering Attach me nt Whe n Sudd en Eng ine Failure Occurs for proper procedure.

3. Turn key switch OFF and remove key.

4. Remove check/fill plug from each travel motor using the 10 mm socket head wrench.

1.35 liter (0.4 gal) capacity drain pan UYV0080001E01

5. Place a clean 4 liter (1.1 gal) capacity drain pan under each travel motor drain plug and remove dra ing plug using the 10 mm socke t head 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.

NOTICE: Before removing these components, prepare a clean area free of dirt and grit to place them during disassembly.

7. Using the 5 mm socket wrench, remove all of the plate mounting bolts from the travel motor reduction unit cover plates.

Remove 12 mounting bolts with 5 mm socket wrench

NOTICE: Be careful not to damage the lips of the cover plates. Any damage to the lips could result in a gear oil leak.

UYV0080002E01

8. Remove the thrustplate and sun gear.

1

3

SUN GEAR

9. Carefully remove the sun gear from the planetary gear assembly and set it aside.

10. Install cover plates onto housings and tighten all bolts securely.

11. Install fill and drain plugs into cover plates. Fill the travel reduction units with gear oil to the proper level through the fill/check port.

12. 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.

13. After repairs are made, reinstall the drive gear in r eve r s e o r d e r. U s e t h e fo ll o w i n g t o r q u e specifications for bolts and plugs.

Torque specifications: Cover bolts (M6) 13.7 + 1.0 Nm (10.1 + 0.7 lb ft) Plugs 49.0 + 4.9 Nm (72.3 + 14.5 lb ft) Thrust plate bolts 35.3 + 2.0 Nm (26 + 1.5 lb ft)

6-80

UYV0080002E01

1

3

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS RELEASING THE SWING BRAKE WARNING: Make certain that the attachment is on the ground to prevent sudden rotation of the upper structure before attempting to release the swing brake. See section on Lowering Attachment When Sudden Engine Failure occurs in this section.

NOTICE: In highly contaminated environments it is recommended to remove the whole swing motor assembly if a hydraulic hand pump is not available.

Refer to the manual for instructions or contact your distributor. When the swing motor is removed, make sure to use caps and plugs on hoses, tubes and fittings to protect the hydraulic system from contamination. Also, use a cover to protect the swing reduction unit. Should the swing reduction unit become contaminated, make sure to flush and clean it. Refer to Lubricant Specifications in this manual for proper oil and component capacity.

1 Remove all hoses, tubes and fittings to gain access

2 UYF00080001E01

WARNING: Use safety protection such as: hard hat, working gloves, safety shoes and safety glasses when needed to perform this job.

Use of a hydraulic hand pump is recommended to release the swing brake manually when the engine fails to start. Refer to the table below and use the proper fitting connector on the P port. Remove the hose and install the proper connector on the P port.

Install the hydraulic hand pump and apply hydraulic pressure at the following specification: Torque specification: 29 Mpa (413 psi)

TOP VIEW

SWING MOTOR

B

SIDE VIEW

A P

Mu

SGo Torque Remarks N·m {lbf·ft} 2-PF1/2 108 10 {80 7} A,B Main port PF3/4 162 15 {120 11} Mu Make-up port Drain port 73.5 5 {54 3.7} PF3/8 Dr Brake release port PF1/4 36.3 2 {27 1.5} P 9.8 {7.2} SGo Gear oil filling port PT1/2 GA PRESSURE MEASUREMENT PT1/4 GB PORTS

Code

Dr

Name

Size

UYTX2808002E01

6-81

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS Tools and equipment required:

• Hand tools to remove hydraulic tubes, hoses and fittings

• • • •

Install proper caps and plugs on hoses,

Plugs and caps for tubes, hoses and fittings

tubes and fittings

10 mm Allen wrench

to help prevent

Lifting eye - P/No. ZE72X12000

contamination entering the system

Overhead lifting device capable of holding 45 kg (100 lb)

UYF000800012E01

• Plenty of clean, dry shop rags and/or paper towels 1. Lower attachment to ground. Refer to Lowering Attachment in this manual for proper procedure.

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 proper plugs and caps on hoses, tubes and fittings to prevent contamination.

NOTICE: Use only plugs and caps designed to properly seal the specific hose, tube or fitting they are to be installed on.

4. Using the 10 mm Allen wrench, loosen the four top plate mounting bolts.

Remove (4) cover mounging bolt

UYV0080006E02

5. Install eye bolts (P/No. ZE72X12000) as shown.

NOTICE: Place a large quantity of clean, dry shop rags around the swing motor to catch any overflow of hydraulic oil from the removal of the top plate.

M12 x 30

6. Remove two top plate mounting bolts from opposite corners.

Lifting position

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.

9. Using the overhead lifting device, carefully lift the swing motor top cover with swing shockless valve assembly and away from the swing motor.

NOTICE: 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.

6-82

Top cover UYV0080005E02

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 10. Carefully remove all brake springs and place in a container filled with fresh, clean hydraulic oil.

Seal the container to prevent contamination.

NOTICE: Do not allow any dirt or debris to enter the swing motor or settle on the top plate.

NOTICE: Avoid oil spills. Use containers, rags and/or paper towels to contain any oil leakage.

Dispose of all waste oils, fluids, lubricants and other hazardous waste properly, according to government regulations.

Remove all springs

UYF00080015E01

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.

Align distributor plate holes towards front and rear of housing

UYF00080016E01

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.

Dowel pins

NOTICE: Make certain the top plate dowel pins and the distributor plate holes mesh together.

13. Carefully and slowly lower the top late into position on the swing motor and install, by hand, the four top plate mounting bolts.

14. After the machine upper structure is positioned for towing, remove cover again and reinstall the swing brake springs. Repeat Steps 11-13 to lock the upper frame into position for proper transportation.

UYF00080017E01

6-83

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS LOWERING ATTACHMENT WHEN SUDDEN ENGINE FAILURE OCCURS NOTICE: When you need to lower the attachment in an emergency, handle the holding valve first, then loosen the port relief valve of the main control valve.

When the engine suddenly fails, the relief valve incorporated in the holding valve mounted on the boom cylinder head side is available to lower the attachment.

WARNING: Be careful when lowering attachment. Do not stand under the boom.

the

Holding valve

1. To manually operate the holding valve, first loosen the lock nut (1).

2. Rotate the thread (2) four turns clockwise to tighten, and the inner spool valve is switched.

Consequently, the holding valve is relieved forcibly.

3. To return the holding valve to active state, rotate the thread (2) counterclockwise fully to the end and tighten the lock nut (1).

1

2

UYF00080019E02

1. LOCK NUT 2. THREAD FOR MANUAL OPERATION

6-84

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS EMERGENCY MANUAL VALVE FOR LOWERING ATTACHMENT This machine is equipped with a reducing valve assembly that can function as an emergency manual valve for lowering the attachment.

The valve is located between the B5 port of the boom cylinder head side and boom lock valve. It is normally blocked to prevent pressure leakage in the boom circuit, but in case of an emergency, it can be used to lower the boom. Pressure in the attachment cylinder can then be released by operating the arm or bucket control lever.

To lower the attachment: 1. Loosen the lock nut first, then loosen the lock screw to the end of contact.

NOTICE: This valve is provided the mechanism of stopper against falling out. But the mechanism might cause break by undue force.

2. The oil on the boom cylinder head side will then flow into the drain passage through the orifice, and the boom will lower slowly. It could take four to eight minutes to lower, depending on machine position and holding pressure.

Function of Actuator Oil pressure of the PC port is reduced by releasing holding pressure of boom cylinder head side to drain passage through orifice. Operation of actuator with remote control valve is possible by leading medium pressure via orifice from PC port to shuttle valve. In this function, the leading of medium pressure ensures primary pressure of remote control (source of pressure). This function ensures that the cylinder movement of boom, arm, bucket and others can be actuated only downward by self weight. Consequently the releasing of pressure becomes possible. But after attachment is lowered to the ground by lowering boom, holding pressure disappears and remote valve is possible.

When the boom cylinder has holding valve, loosen above-mentioned reducing valve assembly together with port relief valve of holding valve, the boom cylinder starts boom lowering. Spool of holding valve moves to open side by back pressure of port relief falve and holding pressure of boom cylinder is led to “Emergency Manual Valve for Lowering Attachment” operation of actuator by remove is possible.

6-85

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

Machine front

Emergency manual valve

4

2

1

3

Remote control valve (PC port) Boom head pressure (B5 port)

6-86

CHAPTER 7 - ELECTRICAL

CHAPTER 7

ELECTRICAL TABLE OF CONTENTS FUSES AND RELAY BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 FUSIBLE LINK (FOR STARTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 MECHATRO-CONTROLLER (CPU) AND ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

7-1

CHAPTER 7 - ELECTRICAL

NOTES

7-2

CHAPTER 7 - ELECTRICAL

FUSES AND RELAY BOX Fuses protect the electrical system from excess c u r r e n t . R e p l a c e a b lo w n f u s e o r a n y f u s e generating white powder.

2

1

WARNING Never replace a faulty fuse with a higher amperage fuse. Never use a jumper in place of a fuse. Never splice accessories directly into fuse terminals.

Failure to comply could result in death or serious injury.

M1728

NOTICE: Spare fuses are stored in the rear of the fuse box cover.

ULFX1202004E01

1. COVER

2. COVER

Replacement Procedure

3

1. Loosen four machine screws (2) used to install cover (1) located on the rear side of operator seat, and remove cover (1).

2. To remove the cover of fuse box, press lock (4) of cover (3) inward to unlock and then lift it up.

3. When replacing the fuse, remove the fuse from the fuse box with fuse remover.

4. After replacement of fuse, attach the cover securely.

FRONT

4 ULFX1202005E01

3. COVER 4. LOCK

7-3

CHAPTER 7 - ELECTRICAL Fuses

1

2

3

4

5

6

7

8

9

10 11 12 13 14 15 16

33 34

35 36

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 UYV00020007E0B

No.

AMPS

1

20A

2

No.

AMPS

Cab Work Light

21

10A

DC-DC Converter

20A

Cab Work Light

22

5A

Option (8)

3

5A

Gauge Cluster

23

15A

Roof Wiper

4

20A

Wiper, Washer

24

20A

Flasher, Alarm

5

20A

Option 1

25

10A

Safety Lever Lock

6

20A

Option 3

26

5A

Mechatro Controller

7

15A

Air Conditioner

27

20A

Mechatro Controller

8

5A

Air Conditioner

28

20A

EGR Rly Glow Timer

9

5A

Option (Hand Control)

29

10A

Alternator Fuel Pump

10

5A

Relay, Hour Meter

30

5A

Gauge Cluster (Back Up)

11

10A

Cigarette Lighter

31

20A

Fuel Supply Pump

12

10A

Horn, Horn Relay

32

5A

Mechatro Controller (Back Up)

13

10A

Tuner

33

5A

Spare

14

20A

Starter Key Switch

34

10A

Spare

15

5A

Room Lamp, Tuner

35

15A

Spare

16

10A

Option 2

36

20A

Spare

17

10A

Option 4

18

10A

Solenoid Valve

19

5A

Air Conditioner

20

20A

Work Light

7-4

FUNCTION

FUNCTION

CHAPTER 7 - ELECTRICAL

FUSIBLE LINK (FOR STARTER) The fusible link protects the electrical system from current overload. It functions like a fuse.

If the electrical power does not come on when the starter key switch is in the on position, the fusible link may be the cause. Inspect and replace the red fusible link (1).

Check and replacement procedure 1. Using starter key switch, unlock and open the side door (1) on left side of counterweight, and hold the door open with stay.

2. Loosen four bolts (3) used to install cover (2), and remove cover (2).

1

3. Remove fusible link (4) and check or replace it with new one.

3

4. After replacement of fusible link (4), install cover (2) with bolts (3).

5. After checking or replacement, remove stay and close the door and lock it securely.

3

4

3

2 UYTX2802011B01

1. SIDE DOOR 2. COVER

3. BOLTS (4) 4. FUSIBLE LINK

MECHATRO-CONTROLLER (CPU) AND ENGINE The mechatro-controller and engine controller are located on the rear side of operator seat.

NOTICE: Be careful not to splash water, mud and drinks on the controllers.

1 2

NOTICE: When an error occurs on the controller, contact your dealer/distributor.

FRONT UYTX2802011B01

1. MECHATRO-CONTROLLER 2. ENGINE CONTROLLER

7-5

CHAPTER 7 - ELECTRICAL

BATTERY The battery is located behind the door located at the left rear of the machine.

See the Battery section in the Maintenance and Adjustments chapter of this manual.

Perform complete battery service on a new machine after the first 50 hours of engine operation. Check electrolyte (acid) every 50 hours.

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

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

If electrolyte contacts skin or eyes, flush affected areas immediately with clean water and seek medical attention.

Failure to comply could result in injury or death.

M4655

ALTERNATOR Ask your Dealer to check the Alternator.

Make sure that the terminal protectors are correctly installed.

Do not use steam cleaning equipment or a cleaning solvent to clean the alternator.

STARTER MOTOR Ask your Dealer to check the Starter Motor.

Make sure that the terminal protectors are correctly installed.

7-6

CHAPTER 8 - SPECIFICATIONS

CHAPTER 8

SPECIFICATIONS TABLE OF CONTENTS GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 SHOE TYPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 WORKING RANGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Backhoe Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Face Shovel Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 BUCKET AND ARM COMBINATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 Front Attachment Variation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 LIFTING CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 Standard Machine with 2.13 m (7’ 0”) arm and 600 mm (23.6” shoes) and 0.29 cu yd (0.22 m3) bucket . . . . 8-8 Standard Machine with 2.13 m (7’ 0”) arm, 600 mm (23.6”) shoes, 029 cu yd (0.22 m3) bucket and add-on counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Special Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cap Screws and Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Metric Coarse Thread Standard Tightening Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Metric Fine Thread Standard Tightening Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ORS Joint (o-ring sealing type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Nuts and Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Joints for Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Split Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-10 8-10 8-11 8-11 8-12 8-12 8-12 8-13 8-13 8-13

8-1

CHAPTER 8 - SPECIFICATIONS

8-2

CHAPTER 8 - SPECIFICATIONS

GENERAL SPECIFICATIONS Item

Unit

E80BMSR

Working Weight

kg (lb)

Bucket Heaped

m3 (cu•yd)

0.22 (0.29)

-

ISUZU DIESEL ENGINE AU-4LE2X Water-cooled, 4 cycle 4 cylinder direct injection type diesel engine with intercooler turbo-charger.

Engine Output-Rating

kW/min-1

41 / 2,200

A

Overall Length

mm (ft-in)

7,060 (23-2)

B

Overall Height

mm (ft-in)

2,920 (9-7)

C

Overall Width of Crawler

mm (ft-in)

2,150 (7-1)

D

Width of Crawler Shoe

mm (inch)

450 (17.7)

E

Height to Top Cab

mm (ft-in)

2,780 (9-1)

F

Ground Clearance of Under Carriage

mm (inch)

360* (14.1)

G

Radius of Rear End

mm (ft-in)

1,790 (5-10)

H

Basic Machine Length

mm (ft-in)

3,880 (12-9)

I

Overall Length of Crawler

mm (ft-in)

2,860 (9-5)

J

Center Distance of Tumblers

mm (ft-in)

2,240 (7-5)

K

Ground Clearance of Rear End

mm (ft-in)

735* (2-5)

L

Width of revolving upper structure

mm (ft-in)

2,230 (7-4)

M

Dozer blade (Down/up)

mm (inch)

305 (12.0) / 475 (18.7)

Ground Pressure

kPa (psi)

37.1 (5.38)

Engine Maker

Swing Speed

min-1

Travel Speed [Low (1st)/High (2nd)]

km/h (mph)

8,620 (19,000)

(rpm)

11.5 (11.5) 2.8 / 5.3 (1.7 / 3.3)

Gradeability % (deg) 70 (35) NOTE: The attachment with the arm measures 2.13 m (7’0”) and bucket “SAE heaped” of 0.22 m3 (0.29 cu.yd.) attached. Marked * dimensions do not include height of shoe lug.

A

L

F

K

E

B

G

J I

D C

H ULFX1206001E01

8-3

CHAPTER 8 - SPECIFICATIONS

SHOE TYPES Grouser Shoes Type

Rubber Shoes

450 mm (17.7")

600 mm (23.6")

450 mm (17.7")

450 mm (17.7")

For General Soil (Standard)

For Soft Soil (Optional)

For Soft Soil (Optional)

For Soft Soil (Optional)

kg

8,490

8,730

8,650

8,400

Height to Top Cab

mm

2,780

2,780

2,780

2,780

Ground Clearance of Under carriage

mm

360*

360*

360*

360*

Basic Machine Length

mm

3,880

3,880

3,880

3,880

Overall Length of Crawler

mm

2,860

2,870

2,860

2,860

Overall Width of Crawler

mm

2,320

2,470

2,320

2,320

kg

38

29

38

37

Use Working Weight

Specific ations

Flat Shoes

Ground Pressure

NOTICE: Do not employ shoes other than 450 mm (17.7”) grouser shoe on rough ground (site covered with rock and gravel). Travelling and digging on rough ground may bend shoe, loosen shoe bolt or damage the under carriage (link, roller, etc.).

NOTE: The attachment with the arm measures 2.13 m (7’0”) and bucket “SAE heaped” of 0.22 m3 (0.29 cu.yd.) attached. Marked * dimensions do not include height of shoe lug.

8-4

CHAPTER 8 - SPECIFICATIONS

WORKING RANGES BACKHOE ATTACHMENT

A A'

E

H D

C

G

L

B J

F

K

LF11Z00090P1 LF11Z00092P1

Unit : mm (ft-in) Attachment Item

1.87 m (6’-2") Arm

2.13 m (6’-12") Arm

+ 0.22 m3 (0.29 cu•yd) Bucket

+ 0.22 m3 (0.29 cu•yd) Bucket

A Maximum digging reach

7,260 (23-10)

7,640 (25-1)

A’ Maximum digging reach at ground level

7,110 (23-4)

7,500 (24-7)

* B Maximum digging depth

4,430 (14-6)

4,700 (15-5)

* C Maximum digging height

6,780 (22-3)

7,240 (23-9)

* D Maximum damping clearance

4,770 (15-8)

5,190 (17-0)

* E Minimum damping clearance

1,970 (6-6)

1,840 (6-0)

* F Max. vertical wall digging depth

3,230 (10-7)

3,810 (12-6)

2,560 (8-5)

3,130 (10-3)

* H Height at min. swing radius

5,400 (17-9)

5,430 (17-10)

* J 8 feet level digging depth

4,000 (13-1)

4,360 (14-4)

3,190 (10-6)

3,250 (10-8)

2,360 (7-9)

2,690 (8-10)

G Minimum swing radius

K Horizontal digging stroke at Stroke L ground level Minimum

NOTE: Marked * dimensions do not include height of shoe lug.

8-5

CHAPTER 8 - SPECIFICATIONS FACE SHOVEL ATTACHMENT

A A'

E

D'

H D

C

G

L

J

B

K

LF11Z00091P1 LF11Z00093P1

Unit : mm (ft-in) Attachment

1.87 m (6’-2") Arm

2.13 m (6’-12") Arm

+ 0.22 m3 (0.29 cu•yd) Bucket

+ 0.22 m3 (0.29 cu•yd) Bucket

7,340 (24-1)

7,720 (25-4)

7,200 (23-7)

7,580 (24-10)

* B Maximum digging depth

4,510 (14-10)

4,780 (15-8)

* C Maximum digging height

6,920 (22-8)

7,350 (24-1)

* D Maximum damping clearance

4,780 (15-8)

5,250 (17-3)

Item A Maximum digging reach A’

Maximum digging reach at ground level

* D' Maximum damping clearance (45°)

4,230 (13-11)

4,460 (14-8)

* E Minimum damping clearance

1,890 (6-2)

1,760 (5-9)

2,560 (8-5)

3,130 (10-3)

* H Max. height at min. swing radius

5,400 (17-8)

5,430 (17-10)

* J 8 feet level digging depth

4,090 (13-5)

4,460 (14-8)

K Horizontal digging L stroke at ground level

Stroke

2,250 (7-5)

2,710 (8-11)

Minimum

4,830 (15-10)

4,750 (15-7)

G Minimum swing radius

NOTE: Marked * dimensions do not include height of shoe lug.

8-6

CHAPTER 8 - SPECIFICATIONS

BUCKET AND ARM COMBINATIONS FRONT ATTACHMENT VARIATION This machine is equipped with attachments in various types in order to comply with various operations.

When large capacity bucket is used, it should be used in combination of short arms to secure the stability of machine and not to be forced to operate machine, front section and each cylinder.

When long boom and arm are used, conversely combine with the small capacity bucket.

Bucket (m3) (cu•yd) Outside width of bucket (mm) Type

Hoe Bucket

SAE

SAE

With side

Without side

(Heaped)

(Struck)

cutters

cutters

—

400

480

0.11

0.09

(0.14)

(0.11)

0.14

0.12

(0.18)

(0.16)

0.18

0.14

(0.23)

(0.18)

0.22

0.18

(0.29)

(0.24)

0.28 (0.37) (STD)

0.21 (0.27)

0.35

0.26

(0.46)

(0.34)

0.35 (0.46) side pin

0.26 (0.34)

Can be turned over

Number of teeth

Arm Weight

1.87

2.13

m Arm

m Arm

3

Yes

Yes

150

410

3

Yes

Yes

160

550

480

3

Yes

Yes

170

650

580

4

Yes

Yes

190

750

680

4

Yes

Yes

210

850

780

4

Yes

Yes

220

850

780

4

Yes

Yes

210

1.87 m

Breaker

—

—

—

—

—

—

—

—

Nibbler

—

—

—

—

—

—

—

—

2.13 m

NOTICE: If any other bucket except for the backhoe bucket is turned over and used for excavation, damage to the arm and bucket may occur. Do not operate the Power Boost Switch when a long arm is installed. When the 2.94 m (9’ 8”) arm is used, do not reverse the bucket. If the bucket is reversed, it bumps against the arm during shovelling and results in damaging the attachment.

NOTICE: : Standard combination : General operation; Excavation or loading of sand, gravel, and clay : Light operation; Mainly loading of loose gravel (e.g., cultivation or loading of sand or gravel) : Prohibited combination; manufacturer’s warranty does not cover any damages resulting from theses combinations. Do not use these combinations.

Install only genuine attachments recommended by the manufacturer on the machine. The manufacturer is not liable for any damages to the machine or attachment arising from the installment of attachment other than the specified attachments.

8-7

CHAPTER 8 - SPECIFICATIONS

LIFTING CAPACITIES STANDARD MACHINE WITH 2.13 M (7’ 0”) ARM AND 600 MM (23.6” SHOES) AND 0.29 CU YD (0.22 M3) BUCKET

5' (1.5m)

10' (3.0m)

A

Lifting capacity specifications are based on the standard machine with 2.13 m (7’ 0”) arm and 600 mm (23.6” shoes and SAE heaped 0.29 cu yd (0.22 m3) bucket.

B ULY000600005E04

15' (4.6m)

20' (6.1m) RADIOUS

A 20' (6.1 m)

lb kg

15' (4.6m)

lb kg

* 3240 * 1470

* 3240 * 1470

10' (3.0m)

lb kg

* 3920 * 1780

3910 1770

2770 1260

5' (1.5m)

lb kg

8100 3670

6620 3000

4220 1910

3580 1620

GROUN D LEVEL

lb kg

7430 3370

6010 2720

3930 1780

3300 1490

-5' (-1.5m)

lb kg

* 6270 * 2840

7360 3330

5950 2700

3810 1730

-10' (-3.0m)

lb kg

* 10690 * 10690 * 4840 * 4840

* 7290 * 3310

6120 2770

3910 1770

* 6270 * 2840

* 3070 * 1390

* 3070 13'–11" * 1390 (4.25m)

* 2600 * 1170

* 2600 18'–11" * 1170 (5.77m)

2370 1070

2460 1110

2100 21'–4" 950 (6.50m)

2640 1200

2250 1020

2210 1000

1880 22'–1" 850 (6.75m)

2520 1140

2130 960

2230 1010

1860 21'–7" 850 (6.58m)

3280 1440

2560 1160

2160 19'–6" 970 (5.96m)

3280 1480

3790 1710

3190 15'–3" 1440 (4.66m)

NOTICE: Do not attempt to lift or hold any load that is greater than these lift capacities at their specified lift point radius and height. Weight of all accessories must be deducted from the above lift capacities.

Lift capacities are based on machine standing on level, firm and uniform round.

User must make allowance for job conditions such as soft or uneven ground out of level conditions, side loads, sudden stopping of loads, hazardous conditions, experience of personnel, etc.

Bucket lift hook is defined as lift point.

The above lift capacities are in compliance with SAE J/ISO 10567.

They do not exceed 87% of hydraulic lift capacity or 75% of tipping load.

Lift capacities marked with an asterisk (*) are limited by hydraulic capacity rather than tipping load.

Operator should be fully acquainted with the operator's machine and rules for safe operation of equipment should be adhered to at all times.

Lift capacities apply to only machine as originally manufactured and normally equipped by the manufacturer.

8-8

CHAPTER 8 - SPECIFICATIONS STANDARD MACHINE WITH 2.13 M (7’ 0”) ARM, 600 MM (23.6”) SHOES, 029 CU YD (0.22 M3) BUCKET AND ADD-ON COUNTERWEIGHT

5' (1.5m)

10' (3.0m)

A

Lifting capacity specifications are based on the standard machine with 2.13 m (7’ 0”) arm and 600 mm (23.6” shoes and SAE heaped 0.29 cu yd (0.22 m3) bucke t a nd ad d-on co un te rweig ht.

Counterweight weighs an additional 260 kg (573 lb).

B ULY000600005E04

15' (4.6m)

20' (6.1m) RADIOUS

A 20' (6.1 m)

lb kg

15' (4.6m)

lb kg

* 3240 * 1470

* 3240 * 1470

10' (3.0m)

lb kg

* 3920 * 1780

3910 1770

2770 1260

5' (1.5m)

lb kg

8100 3670

6620 3000

4220 1910

3580 1620

GROUN D LEVEL

lb kg

7430 3370

6010 2720

3930 1780

3300 1490

-5' (-1.5m)

lb kg

* 6270 * 2840

7360 3330

5950 2700

3810 1730

-10' (-3.0m)

lb kg

* 10690 * 10690 * 4840 * 4840

* 7290 * 3310

6120 2770

3910 1770

* 6270 * 2840

* 3070 * 1390

* 3070 13'–11" * 1390 (4.25m)

* 2600 * 1170

* 2600 18'–11" * 1170 (5.77m)

2370 1070

2460 1110

2100 21'–4" 950 (6.50m)

2640 1200

2250 1020

2210 1000

1880 22'–1" 850 (6.75m)

2520 1140

2130 960

2230 1010

1860 21'–7" 850 (6.58m)

3280 1440

2560 1160

2160 19'–6" 970 (5.96m)

3280 1480

3790 1710

3190 15'–3" 1440 (4.66m)

NOTICE: Do not attempt to lift or hold any load that is greater than these lift capacities at their specified lift point radius and height. Weight of all accessories must be deducted from the above lift capacities.

Lift capacities are based on machine standing on level, firm and uniform round.

User must make allowance for job conditions such as soft or uneven ground out of level conditions, side loads, sudden stopping of loads, hazardous conditions, experience of personnel, etc.

Bucket lift hook is defined as lift point.

The above lift capacities are in compliance with SAE J/ISO 10567.

They do not exceed 87% of hydraulic lift capacity or 75% of tipping load.

Lift capacities marked with an asterisk (*) are limited by hydraulic capacity rather than tipping load.

Operator should be fully acquainted with the operator's machine and rules for safe operation of equipment should be adhered to at all times.

Lift capacities apply to only machine as originally manufactured and normally equipped by the manufacturer.

8-9

CHAPTER 8 - SPECIFICATIONS

TORQUE SPECIFICATIONS SPECIAL TORQUE VALUES Follow the table below and tighten or retighten every bolt and nut. Check for any loose or missing bolt or nuts before daily operation and during periodic inspections. Retighten or supply new part for missing ones as required.

Size (M) M5 M6

M8

M10

M12

M14

M16

M20 5/818UNF

8-10

Q’ty

Opposing flats mm

5

–

• Sending unit mounting (fuel tank)

• 1.96±0.2 {1.4±0.14}

4

10

• A/C condenser mounting

• 9.7±1.0 {7.2±0.7}

4

10

• Water subtank mounting

• 9.6±1.0 {7.1±0.7}

4

13

• Muffler mounting (Nut-Upper)

• 10.8±1.9 {8.0±1.4}

4

13

• Muffler mounting (Nut-Lower)

• 8.8±0.8 {6.5±0.6}

2

13

• Air cleaner mounting

• 19.6±2.0 {14.5±2.1}

Apply Loctite #262

3

10

• Slewing grease bath inspection cover mounting

• 19.6 {4.5}

Apply Loctite #242

16

17

• Floor plate rubber mounting

• 46.5±4.6 {34±3.4}

8

17

• Power take-up bracket mounting

• 64.7±6.4 {47±4.3}

12

17

• Hydraulic oil tank cover mounting

• 46.5±4.6 {34±3.4}

2

17

• Lower frame grease cover mounting

• 10.8±0.98 {8.0±0.7}

6

17

• Fuel tank bottom cover mounting

• 46.5±4.6 {34±3.4}

4

17

• Engine muffler bracket mounting

• 64.7±6.5 {47±4.8}

Apply Loctite #262

10

17

• Engine mounting

• 46.5±4.6 {34±3.4}

Apply Loctite #262

4

19

• Engine mounting

• 80±8 {59±5.9}

Apply Loctite #271

4

19

• Radiator mounting

• 120.6±12 {89±8.8}

Apply Loctite #262

2

19

• Radiator stay mounting

• 120.6±12 {89±8.8}

6

19

• Cab mounting

• 80±8 {59±5.9}

Location

Tightening torque N•m {lbf•ft}

Recommended sealant

Apply Loctite #262

Apply Loctite #262

4

10

• Hydraulic pump mounting

• 67±6.7 {49±4.9}

3

19

• Swivel joint mounting

• 107.8±10.8 {79.5±8.0}

4

19

• Idler & Idler adjust setting bolt

• 115±12 {85±8.8}

Apply Loctite #262

8

19

• Travel motor cover mounting

• 83.4±8.4 {62±6.2}

Apply Loctite #262

24

22

• Sprocket mounting

• 181±18 {134±13}

Apply Loctite #262

40

22

• Lower roller mounting

• 181±20 {134±15}

Apply Loctite #262

156

22

• Shoe bolt mounting

• 294±29 {217±21}

14

22

• Guide mounting

• 181±18 {133±13}

4

24

• Floor plate rubber mounting nut

• 191±19 {141±14}

4

24

• Hydraulic tank mounting

• 191±19 {141±14}

2

24

• Upper roller mounting

• 279±29 {206±20}

Apply Loctite #262

24

24

• Travel motor mounting

• 279±28 {206±20}

Apply Loctite #262

Apply Loctite #262 Apply Loctite #262

24

24

• Slewing bearing outer mounting

• 157±16 {116±12}

Apply Loctite #262

30

24

• Slewing bearing inner race mounting

• 279±28 {206±20}

Apply Loctite #262

4

24

• Fuel tank mounting

• 191±19 {141±14}

Apply Loctite #262

8

24

• Slewing reduction unit mounting

• 279±29 {206±21}

Apply Loctite #262

6

30

• Side cutter mounting

• 539±54 {398±40}

3

30

• Counterweight mounting

• 490±48 {362±35}

2

19

• Idler adjuster grease nipple mounting

• 59±10 {44±7.4}

Apply Loctite #262

CHAPTER 8 - SPECIFICATIONS CAP SCREWS AND NUTS METRIC COARSE THREAD STANDARD TIGHTENING TORQUE VALUES The following Torque Specifications are provided for use when actual torque value of a fastener is not known.

Check the machine for loose nuts and bolts daily before starting work and at scheduled maintenance intervals.

Replace missing bolts and nuts with equivalent parts. Make certain to tighten all capscrews and nuts to proper torque values.

NOTICE: The torque values in the table do not apply for bolts used with plastic covers. For the tightening torque for such bolts, consult with dealer/distributor. Over-tightening may cause damage on the parts.

NOTICE: Check if the torque is specified in a specific section of this manual. If provided, use the torque in the specific section. Metric hardware with thread size diameter of M5 or greater have a number on the top indicating the strength of the bolt.

Metric Coarse Thread (Not plated) Torque value Unit : N•m {lbf•ft} Classification Nominal size

4.8T

7T

10.9T

No lubrication Oil lubrication No lubrication Oil lubrication No lubrication Oil lubrication

M6

P=1

4.4±0.5 {3.2±0.4}

3.7±0.4 {2.7±0.3}

9.6±1.0 {7.1±0.7}

8.1±0.8 {6.0±0.6}

17.4±1.8 {12.8±1.3}

14.7±1.5 {10.8±1.1}

M8

P=1.25

10.7±1.1 {7.9±0.8}

9.0±0.9 {6.6±0.7}

23.5±2.0 {17.3±1.5}

19.6±2.0 {14.5±1.5}

42.2±3.9 {31.1±2.9}

35.3±3.9 {26.0±2.9}

M10

P=1.5

21.6±2.0 {15.9±1.4}

17.9±1.8 {13.2±1.3}

46.1±4.9 {34.0±3.6}

39.2±3.9 {28.9±2.9}

83.4±8.8 {61.5±6.5}

70.6±6.9 {52.1±5.1}

M12

P=1.75

36.3±3.9 {26.8±2.9}

31.4±2.9 {23.2±2.1}

79.4±7.8 {58.6±5.8}

66.7±6.9 {49.2±5.1}

143±15 {105±11}

121±12 {89.2±8.9}

M14

P=2

57.9±5.9 {42.7±4.4}

49.0±4.9 {36.1±3.6}

126±13 {92.9±9.6}

106±10 {78.2±7.4}

226±20 {167±15}

191±19 {141±14}

M16

P=2

88.3±8.8 {65.1±6.5}

74.5±6.9 {55.0±5.1}

191±20 {141±15}

161±16 {119±12}

343±39 {253±29}

284±29 {209±21}

M18

P=2.5

122±12 {90.0±8.9}

103±10 {75.8±7.2}

265±29 {195±21}

226±20 {167±15}

481±49 {355±36}

402±39 {297±29}

M20

P=2.5

172±17 {127±13}

144±14 {106±10}

373±39 {275±29}

314±29 {232±21}

667±69 {492±51}

559±59 {412±44}

M22

P=2.5

226±20 {167±15}

192±20 {142±15}

500±49 {369±36}

422±39 {311±29}

902±88 {665±65}

755±78 {557±58}

M24

P=3

294±29 {217±21}

235±29 {173±21}

637±69 {470±51}

520±49 {383±36}

1160±118 {856±87}

941±98 {694±72}

M27

P=3

431±39 {318±29}

353±39 {260±29}

941±98 {694±72}

765±78 {564±58}

1700±167 {1250±123}

1370±137 {1010±101}

M30

P=3.5

588±59 {434±44}

490±49 {361±36}

1285±127 {948±94}

1079±108 {796±80}

2300±235 {1700±173}

1940±196 {1430±145}

M33

P=3.5

794±78 {586±58}

667±69 {492±51}

1726±177 {1270±131}

1451±147 {1070±108}

3110±314 {2290±232}

2610±265 {1930±195}

M36

P=4

1030±98 {760±72}

863±88 {637±65}

2226±226 {1640±167}

1863±186 {1370±137}

4010±402 {2960±297}

3360±333 {2480±246}

8-11

CHAPTER 8 - SPECIFICATIONS METRIC FINE THREAD STANDARD TIGHTENING TORQUE VALUES (NOT PLATED) Tighten all capscrews and nuts to proper torque values.

Torque value Unit : N•m {lbf•ft} Classification Nominal size

4.8T

7T

10.9T

No lubrication Oil lubrication No lubrication Oil lubrication No lubrication Oil lubrication

M8

P=1.0

11.3±1.1 {8.3±0.8}

9.5±1.0 {7.0±0.7}

24.5±2.0 {18.1±1.5}

20.6±2.0 {15.2±1.5}

44.1±3.9 {32.5±2.9}

37.3±3.9 {27.5±2.9}

M10

P=1.25

22.6±2.0 {16.7±1.5}

18.7±1.9 {13.8±1.4}

48.1±4.9 {35.5±3.6}

41.2±3.9 {30.3±2.9}

87.3±8.8 {64.4±6.5}

73.5±6.9 {54.2±5.1}

M12

P=1.25

39.2±3.9 {28.9±2.9}

33.3±2.9 {24.6±2.1}

85.3±8.8 {62.9±6.5}

71.6±6.9 {52.8±5.1}

154±16 {114±12}

129±13 {95.2±9.6}

M16

P=1.5

92.2±8.8 {68.0±6.5}

77.5±7.8 {57.2±5.8}

196±20 {145±15}

169±17 {125±13}

363±39 {268±29}

304±29 {224±21}

M20

P=1.5

186±19 {137±14}

155±16 {114±12}

402±39 {297±29}

333±29 {246±21}

726±69 {535±51}

608±59 {448±44}

M24

P=2

314±29 {232±21}

265±29 {195±21}

686±69 {506±51}

569±59 {420±44}

1240±118 {915±87}

1030±98 {760±72}

M30

P=2

637±59 {470±44}

530±49 {391±36}

1390±137 {1030±101}

1157±118 {853±87}

2500±255 {1840±188}

2080±206 {1530±152}

M33

P=2

853±88 {629±65}

706±70 {521±52}

1860±186 {1370±137}

1550±155 {1140±114}

3350±334 {2470±246}

2790±275 {2060±203}

M36

P=3

1070±108 {789±80}

892±88 {658±65}

2330±226 {1720±167}

1940±196 {1430±145}

4200±422 {3100±311}

3500±353 {2580±260}

TORQUE SPECIFICATIONS FOR JOINTS AND HYDRAULIC HOSES ORS JOINT (O-RING SEALING TYPE) Nominal Size Hose mouth ring and coupling

1–14 UNS 1–3/16–12 UN 1–7/16–12 UN

Wrench Size (mm) 30 32

Torque Value N•m {lbf•ft}

177±18 {130±13}

41

206±21 {152±15}

46

O-ring

Nipple

137±14 {101±10}

36 41

Connector

206±21 {152±15}

Nut

NUTS AND SLEEVE

8-12

Sleeve

Torque Value N•m {lbf•ft}

10 × 1.5

19

49±9.8 {36±7}

15 × 2.0

27

118±12 {87±9}

18 × 2.5

32

147±15 {108±11}

22 × 3.0

36

216±22 {159±16}

28 × 4.0

41

275±27 {202±20}

35 × 5.0

55

441±44 {325±33}

B

Nut O.D. ( )

Wrench Size B (mm)

O.D. ( )

Tube Size O.D. × Thickness (mm)

CHAPTER 8 - SPECIFICATIONS JOINTS FOR PIPING

Nominal Screw Size (PF)

Wrench Size (mm)

Torque Value N•m {lbf•ft}

1/8

14

15±2 {11±1.5}

1/4

19

36±2 {27±1.5}

3/8

22

74±5 {54±4}

1/2

27

108±9.8 {80±7}

3/4

36

162±9.8 {119±7}

1

41

255±9.8 {188±7}

1–1/4

50

392±40 {289±30}

1–1/2

55

485±49 {358±36}

O-RING

HYDRAULIC HOSES Nominal Screw Size (PF)

Wrench Size (mm)

Torque Value N•m {lbf•ft}

1/8

14

15±2.0 {11±1}

1/4

19

29±4.9 {22±4}

3/8

22

49±4.9 {36±4}

1/2

27

78±4.9 {58±4}

3/4

36

118±9.8 {87±7}

1

41

137±15 {101±11}

1–1/4

50

167±15 {123±11}

Connector

O-ring

Nipple

Nut

SPLIT FLANGE

Size

Working Pressure MPa {kgf/cm2} 20.6 {210}

Working Pressure MPa {kgf/cm2} 41.2 {420}

Torque Value N•m {lbf•ft}

Bolts Size (M)

Torque Value N•m {lbf•ft}

Bolts Size (M)

3/4

33.9±5.6 {25±4.1}

10

39.5±5.6 {29±4.1}

10

1

42.4±5.6 {31±4.1}

10

62.2±5.6 {46±4.1}

12

1–1/4

55.1±7.1 {41±5.2}

10

93.3±8.4 {69±6.2}

14

1–1/2

70.6±8.4 {52±6.2}

12

169±11 {125±8.1}

16

2

81.9±8.4 {60±6.2}

12

282±11 {208±8.1}

20

Flange Head

Half Clamp

NOTICE: These tightening torques are available in the case of tightening without lubricant.

8-13

CHAPTER 8 - SPECIFICATIONS

8-14

CHAPTER 9 - INDEX

Chapter 9

INDEX A Alternator ............................................................. 7-6

Lifting Capacities ..................................................8-8 Lifting Machine .....................................................5-8 Locking/Unlocking Cab Door ................................3-3

B Back Filling & Leveling with Front Attachment .. 4-23 Basic Operation of Hydraulic Controls ............... 4-13 Before Operating the Machine ............................. 4-3 Burn Prevention ................................................... 2-8 Buzzer Stop Switch ........................................... 3-19

C Cab Dome Light ............................................ 3-5, 3-6 Cab Door Latch ................................................... 3-3 Components & Controls Nomenclature ............. 3-10 Connecting Booster Cable ................................... 4-6 Control Decal ..................................................... 4-12

D Decals ................................................................ 2-10 Disposal of Hazardous Waste ............................. 6-4 Document Pouch ................................................. 3-3

E Engine ................................................................. 1-4

F Fire Extinguisher .................................................. 2-9 Fire Prevention .................................................... 2-9 Fuel Handling Precautions .................................. 2-8

G General Information ............................................. 1-1 Guidelines to Replace Ground Tools ................. 6-14

H Hand Signals ..................................................... 2-22 Hazardous Chemical Precautions ....................... 2-8 How to Handle Life Hammer ............................... 2-9 Hydraulic Oil Cumulative Time .......................... 3-24

I Identification Numbers ......................................... 1-4

K Key Switch ......................................................... 3-30

L

M Machine Components ..........................................1-3 Machine Operation in Adverse Weather Conditions .

4-27 Machine Travel Controls ....................................4-14 Machine Warm Up ........................................ 4-7, 4-9 Maintenance Precautions .....................................2-7 Metric Coarse Thread Standard Tightening Torque Values ..........................................................8-11 Metric Fine Thread Standard Tightening Torque Values ..........................................................8-12 Model, Serial Number, and Year of Manufacture .1-4 Mounting and Dismounting Precautions ...............2-5

N N2 (Nylon) Tube Fitting Joints ............................8-13

O Opening and Closing Windshield .........................3-5 Operating Pattern ...............................................4-12 Operating Pattern Decal .....................................4-12 Operating Precautions ..........................................2-6 Operating the machine .........................................4-4 Operation at Seashore or Salty Climate .............4-27 Operation in Extreme Cold .................................4-27 Operation in Extreme Heat .................................4-27 Operation in High Altitudes .................................4-27 Operation in Humid Climate ...............................4-27 Operation in Sandy and Dusty Areas .................4-27 Operator Cab Nomenclature ..............................3-10 Operator Precautions ...........................................2-5 Operator Seat Adjustments ..................................3-7 Operator’s Compartment Controls and Accessories .

3-9

P Personal Safety ....................................................2-3

R Removing and Storing Lower Front Window ........3-5 Removing Machine from Storage .......................5-13 Right, Left, Front, and Rear of the Machine .........1-2 Roll-Over Protective Structure (If equipped) ........2-8

L.C.D. Display ........................................... 3-22, 3-23 9-1

CHAPTER 9 - INDEX

S Safety Area .......................................................... 2-3 Safety Rules ........................................................ 2-3 Screen Change Switch ...................................... 3-17 Seat Belt Precautions .......................................... 2-9 Seat Height Adjustment ....................................... 3-7 Selection of the Hydraulic Breaker .................... 4-28 Specific Precautions to this Machine ................... 2-9 Starter Motor ........................................................ 7-6 Starting & Stopping Machine Engine with Temperature above 0°C (32°F) ..................... 4-5 Starting and Stopping Precautions ...................... 2-5 Starting Engine .................................................... 4-5 Stopping Engine - Normal Conditions ... 4-5, 4-7, 4-8

T Throttle Potentiometer ....................................... 3-30 Torque Specifications ........................................ 8-10 Transportation ..................................................... 5-3 Transporting Precautions .................................... 2-8 Travel Independent Mode Display ..................... 3-27 Travel Speed Select Switch ............................... 3-20

U Use of Optional Attachment ................................. 5-3 Utility Safety ......................................................... 2-4

W Warming of Hydraulic Oil .......................... 4-10, 4-11 Warming Up of Engine ........................................ 4-9 Wiper Switch ...................................................... 3-19 Work Mode Switch ........................... 3-16, 4-10, 4-11

9-2

Dealer’s stamp

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

Specifications, descriptions, and illustrative material herein are as accurate as known at time of publication, but are subject to change without notice.

Availability of some models and equipment builds varies according to the country in which the equipment is being used. For exact information about any particular product, please consult your New Holland dealer.

Printed in U.S.A.

Copyright © 2010 CNH America LLC. All Rights Reserved. New Holland is a registered trademark of CNH America LLC. Racine Wisconsin 53404 U.S.A.