New Holland E80MSR Excavators Operation and Maintenance Instruction Manual 604.21.517.00 - PDF

Operation and Maintenance Instruction Manual

E80MSR

Operation and Maintenance Instruction Manual

E80MSR

Print No. 604.21.517.00 English - Printed in Italy

PROVEN PERFORMANCE

PROVEN PERFORMANCE

E80MSR OPERATION AND MAINTENANCE INSTRUCTION MANUAL ENGLISH Print No. 604.21.517.00

Edition 11/2005 English - Printed in Italy Printed by Studio ti - 62705

S WARNING Read carefully this chapter before proceeding with the start, use, maintenance, refuelling operations or other interventions.

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

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

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

IMPORTANT: Data contained in this manual was current at the time of publication. As the Manufacturer improves constantly his products, some information may result as not updated. If variances are observed, contact your Dealer and After-Sales Service.

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

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

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

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

SERIAL NUMBER ENGINE TYPE

ISUZU 4JG1NABGA

ENGINE NUMBER VALID FOR MODELS

LF04-02001~

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

Z

TABLE OF CONTENTS

FOREWORD GENERAL ....................................................................................................................... 0-1 PERIODIC INSPECTIONS ............................................................................................. 0-1 NOTICE........................................................................................................................... 0-1

1. SAFETY PRECAUTIONS 1.1 GENERAL SAFETY INFORMATION ..................................................................... 1-3 1.2 SAFETY PRECAUTIONS....................................................................................... 1-4 1.3 PRE-START SAFETY ............................................................................................ 1-7 1.4 SAFETY DURING OPERATION ............................................................................ 1-11 1.5 INSPECTION & MAINTENANCE SAFETY ............................................................ 1-15 1.6 BATTERY SAFETY ................................................................................................ 1-18 1.7 WARNING LABELS & DECALS ............................................................................ 1-20 1.7.1

NOTICE FOR WARNING LABELS & DECALS............................................... 1-20

1.7.2

LOCATION OF WARNING LABELS & DECALS............................................. 1-20

1.8 PROHIBITED MACHINE OPERATION.................................................................. 1-30 1.9 END OF WORK SHIFT SAFETY ........................................................................... 1-32 1.10 USE FOPS AND FRONT GUARD ......................................................................... 1-33 1.11 USE SAFETY VALVE AND OVERLOAD ALARM.................................................. 1-34

2. MACHINE FAMILIARIZATION 2.1 FAMILIARIZATION................................................................................................. 2-3 2.2 GENERAL MACHINE NOMENCLATURE.............................................................. 2-3 2.3 OPERATOR CAB NOMENCLATURE.................................................................... 2-4 2.4 COMPONENT & CONTROLS NOMENCLATURE................................................. 2-5 2.4.1

RIGHT HAND OPERATOR CONSOLE........................................................... 2-5

2.4.2

LEFT HAND OPERATOR CONSOLE ............................................................. 2-10

2.4.3

REAR PANEL AND OTHERS ......................................................................... 2-15

2.4.4

OPERATING LEVERS AND CONTROLS....................................................... 2-16

2.4.5

GAUGE CLUSTER .......................................................................................... 2-21

2.4.6

OPERATOR CAB AND OPERATOR SEAT .................................................... 2-23

2.4.7

MACHINE ACCESS PANELS AND DOORS .................................................. 2-28

3. BASIC MACHINE OPERATION 3.1 PRE-START CHECK.............................................................................................. 3-3 3.2 STARTING & STOPPING MACHINE ENGINE WITH TEMPERATURE ABOVE 0°C (32°F) ................................................................................................. 3-3 3.2.1

STARTING ENGINE........................................................................................ 3-3

3.2.2

STOPPING ENGINE - NORMAL CONDITIONS ............................................. 3-4 1

TABLE OF CONTENTS 3.2.3

EMERGENCY ENGINE SHUT DOWN ............................................................3-4

3.3 STARTING & STOPPING MACHINE ENGINE WITH TEMPERATURE BELOW 0ºC (32ºF)..................................................................................................3-5 3.3.1

STARTING ENGINE.........................................................................................3-5

3.3.2

STOPPING ENGINE – NORMAL CONDITIONS .............................................3-6

3.3.3

EMERGENCY ENGINE SHUT DOWN ............................................................3-6

3.4 STARTING MACHINE ENGINE WITH BOOSTER CABLES..................................3-7 3.4.1

CONNECTING BOOSTER CABLES................................................................3-7

3.4.2

STARTING BOOSTING MACHINE ENGINE ...................................................3-8

3.4.3

STARTING DISABLED MACHINE ENGINE ....................................................3-8

3.4.4

DISCONNECTING BOOSTER CABLES..........................................................3-8

3.5 MACHINE WARM UP .............................................................................................3-9 3.5.1

ENGINE............................................................................................................3-9

3.5.2

HYDRAULIC OIL ..............................................................................................3-9

3.5.3

HYDRAULIC OIL IN FRIGID ............................................................................3-10

3.6 CONTROLS DECAL ...............................................................................................3-11 3.6.1

OPERATING PATTERN...................................................................................3-11

3.6.2

OPERATING PATTERN DECAL......................................................................3-11

3.7 BASIC OPERATION OF HYDRAULIC CONTROLS...............................................3-12 3.7.1

SAFETY LOCK LEVER ....................................................................................3-12

3.7.2

KPSS (KOBELCO POWER SENSING SYSTEM) WORK MODE SWITCH ....3-13

3.7.3

MACHINE TRAVEL CONTROLS .....................................................................3-14

3.7.4

MACHINE ATTACHMENT & SLEWING CONTROLS .....................................3-17

3.7.5

USING AUTO ACCELERATION ......................................................................3-22

3.7.6

TOWING THE MACHINE .................................................................................3-22

3.8 PRACTICES TO IMPROVE EFFICIENCY..............................................................3-23 3.9 HYDRAULIC BREAKER .........................................................................................3-27 3.9.1

SELECTION OF THE HYDRAULIC BREAKER ...............................................3-27

3.9.2

BEFORE OPERATING THE HYDRAULIC BREAKER ....................................3-27

3.9.3

HYDRAULIC OIL LEVEL CHECK AND CONTAMINATION PREVENTION ....3-27

3.9.4

BASIC OPERATION.........................................................................................3-27

3.9.5

BREAKER AND NIBBLER SELECTOR SWITCH............................................3-28

3.9.6

CONTROL PEDAL ...........................................................................................3-28

3.9.7

SETTING SELECTOR VALVE .........................................................................3-29

3.9.8

SETTING STOP VALVE...................................................................................3-29

3.10 SAFETY PRECAUTIONS .......................................................................................3-30 3.11 MAINTENANCE FOR NIBBLER / BREAKER .........................................................3-32 3.11.1 REPLACEMENT SCHEDULE ..........................................................................3-32 3.11.2 REINFORCEMENT OF ATTACHMENT...........................................................3-32 2

TABLE OF CONTENTS 3.12 DOZER BLADE SAFETY PRECAUTIONS ............................................................ 3-33 3.13 CAUTION ON USING RUBBER SHOES ............................................................... 3-34 3.13.1 PROPER USAGE ............................................................................................ 3-34 3.13.2 PROHIBITED WORK....................................................................................... 3-34 3.13.3 CAUTIONS ON USAGE .................................................................................. 3-36 3.13.4 INSPECTING RUBBER SHOE........................................................................ 3-38 3.13.5 ADJUSTING THE RUBBER SHOE TENSION ................................................ 3-39 3.14 FLAGMAN HAND SIGNALS .................................................................................. 3-40

4. MAINTENANCE 4.1 GENERAL INFORMATION .................................................................................... 4-3 4.2 GENERAL SAFETY ............................................................................................... 4-3 4.3 INSPECTION AND MAINTENANCE CHART ........................................................ 4-7 4.4 FLUIDS AND FILTERS .......................................................................................... 4-11 4.4.1

REQUIRED FLUIDS AND QUANTITIES......................................................... 4-11

4.4.2

REQUIRED FILTERS ...................................................................................... 4-11

4.4.3

FLUIDS AND LUBRICANTS............................................................................ 4-12

4.4.4

LUBRICANT SPECIFICATIONS ..................................................................... 4-13

4.5 PRE-START (EVERY 8 HOURS) INSPECTION & MAINTENANCE ..................... 4-14 4.5.1

ENGINE OIL LEVEL ........................................................................................ 4-14

4.5.2

ENGINE COOLANT LEVEL ............................................................................ 4-14

4.5.3

ENGINE FLUID LEAKS ................................................................................... 4-15

4.5.4

FAN BELT WEAR AND TENSION .................................................................. 4-15

4.5.5

FUEL LEVEL ................................................................................................... 4-16

4.5.6

AIR CLEANER................................................................................................. 4-17

4.5.7

ENGINE ELECTRICAL.................................................................................... 4-18

4.5.8

HYDRAULIC OIL LEVEL ................................................................................. 4-18

4.5.9

BOOM SWING FUNCTIONS........................................................................... 4-20

4.5.10 HYDRAULIC FUNCTIONS .............................................................................. 4-20 4.5.11 HYDRAULIC OIL LEAKS................................................................................. 4-20 4.5.12 MACHINE ELECTRICAL ................................................................................. 4-21 4.5.13 STEPS AND HANDRAILS............................................................................... 4-21 4.5.14 FRAME STRUCTURE ..................................................................................... 4-21 4.5.15 TRACKS AND COMPONENTS....................................................................... 4-22 4.5.16 TRACK TENSION............................................................................................ 4-24 4.5.17 BOOM AND ARM ............................................................................................ 4-25 4.5.18 BLADE, CUTTING EDGE, BUCKET TEETH & SIDE CUTTERS.................... 4-25 4.6 50 HOUR (WEEKLY) & NEW MACHINE BREAK-IN INSPECTION & MAINTENANCE PROCEDURES........................................................................ 4-26 3

TABLE OF CONTENTS 4.6.1

CHANGING ENGINE OIL AND/OR FILTER ....................................................4-26

4.6.2

FUEL TANK DRAIN..........................................................................................4-28

4.6.3

WATER SEPARATOR .....................................................................................4-29

4.6.4

AIR INTAKE SYSTEM......................................................................................4-29

4.6.5

RADIATOR, OIL COOLER AND DEBRIS SCREEN ........................................4-30

4.6.6

HYDRAULIC RETURN FILTERS .....................................................................4-31

4.6.7

BATTERIES......................................................................................................4-32

4.7 100 HOUR (MONTHLY) INSPECTION & MAINTENANCE PROCEDURES ..........4-34 4.7.1

ATTACHMENT LUBRICATION........................................................................4-34

4.7.2

DOZER BLADE LUBRICATION .......................................................................4-34

4.7.3

REPLACEMENT OF CUTTING EDGE (OPT.).................................................4-35

4.8 120 HOUR INSPECTION & MAINTENANCE PROCEDURE .................................4-36 4.8.1

SLEWING MOTOR REDUCTION OIL .............................................................4-36

4.8.2

TRAVEL MOTORS REDUCTION OIL..............................................................4-37

4.9 250 HOUR (3-MONTH) INSPECTION & MAINTENANCE PROCEDURE .............4-38 4.9.1

ATTACHMENT LUBRICATION........................................................................4-38

4.9.2

BOOM SWING LUBRICATION ........................................................................4-39

4.9.3

SLEWING REDUCTION LUBRICATION .........................................................4-39

4.9.4

AIR CONDITIONER FILTERS..........................................................................4-39

4.9.5

INSPECTING COUNTERWEIGHT ATTACHING BOLTS FOR LOOSENING............................................................................................4-40

4.9.6

BELT TENSIONER (FAN & AIR CONDITIONER) ...........................................4-41

4.10 500 HOUR INSPECTION & MAINTENANCE PROCEDURES...............................4-42 4.10.1 ENGINE OIL AND FILTER ELEMENT .............................................................4-42 4.10.2 FUEL FILTER ...................................................................................................4-44 4.10.3 BLEEDING AIR FROM THE FUEL SYSTEM...................................................4-45 4.10.4 BLEEDING AIR IN FUEL SYSTEM (AUTO AIR BLEEDING DEVICE / OPTION)....................................................4-45 4.10.5 GREASING THE SLEWING RING...................................................................4-46 4.10.6 CHECKING SLEWING RING FITTING BOLTS FOR LOOSENING ................4-46 4.10.7 FUEL SYSTEM INJECTION PRESSURE AND NOZZLE CONDITION (ATOMIZATION)...............................................................................................4-46 4.10.8 CHECKING THE AIR CONDITIONER REFRIGERANT ..................................4-47 4.11 1000 HOUR (12-MONTH) INSPECTION & MAINTENANCE PROCEDURES .......4-48 4.11.1 ENGINE VALVE CLEARANCE ........................................................................4-48 4.11.2 ENGINE COMPRESSION PRESSURE ...........................................................4-48 4.11.3 INSPECTION OF STARTER AND ALTERNATOR. .........................................4-48 4.11.4 ENGINE FUEL INJECTION TIMING ................................................................4-48 4.12 2000 HOUR INSPECTION & MAINTENANCE PROCEDURES.............................4-49 4

TABLE OF CONTENTS 4.12.1 CHANGE ENGINE COOLANT ........................................................................ 4-49 4.12.2 CHANGE HYDRAULIC OIL............................................................................. 4-51 4.12.3 CHANGE OIL IN TRAVEL MOTOR REDUCTION UNITS .............................. 4-53 4.12.4 CHANGE OIL IN SLEWING REDUCTION UNIT............................................. 4-54 4.12.5 CHANGE GREASE IN SLEWING RING GREASE BATH............................... 4-55 4.12.6 HYDRAULIC TANK BREATHER..................................................................... 4-55 4.12.7 ATTACHMENT AND DUST SEALS ................................................................ 4-56 4.12.8 WINDSHIELD WASHER RESERVOIR ........................................................... 4-58 4.13 MISCELLANEOUS ................................................................................................. 4-59 4.13.1 FUSES............................................................................................................. 4-59 4.13.2 PERIODICAL INSPECTION ITEMS ................................................................ 4-60 4.13.3 MACHINE STORAGE...................................................................................... 4-64 4.13.4 CARE DURING STORAGE ............................................................................. 4-64 4.13.5 REMOVING MACHINE FROM STORAGE ..................................................... 4-64 4.14 INSPECTION MAINTENANCE CHECK LIST ........................................................ 4-65

5. TRANSPORTATION 5.1 GROUND TRANSPORTATION ............................................................................. 5-3 5.1.1

MACHINE PREPARATION ............................................................................. 5-3

5.1.2

LOADING THE MACHINE............................................................................... 5-4

5.1.3

SECURING MACHINE TO TRAILER .............................................................. 5-6

5.2 LIFTING MACHINE ................................................................................................ 5-7 5.3 LIFTING MACHINE (WITHOUT ATTACHMENT) .................................................. 5-9 5.4 SHIPPING DIMENSIONS....................................................................................... 5-10 5.4.1

MACHINE WITH ATTACHMENTS .................................................................. 5-10

5.4.2

BOOM WITH ARM CYLINDER ....................................................................... 5-11

5.4.3

ARM WITH BUCKET CYLINDER.................................................................... 5-11

5.4.4

ARM WITH BUCKET CYLINDER AND BUCKET............................................ 5-11

5.4.5

DOZER BLADE ............................................................................................... 5-12

5.4.6

BUCKET .......................................................................................................... 5-12

6. SPECIFICATIONS 6.1 GENERAL SPECIFICATIONS ............................................................................... 6-3 6.1.1

MACHINE DIMENSIONS ................................................................................ 6-3

6.1.2

DOZER BLADE SPECIFICATIONS ................................................................ 6-4

6.1.3

WORKING WEIGHTS ..................................................................................... 6-4

6.1.4

STANDARD WORKING RANGES .................................................................. 6-5

6.1.5

BOOM.............................................................................................................. 6-6

6.1.6

ARM................................................................................................................. 6-6 5

TABLE OF CONTENTS 6.1.7

SHOES .............................................................................................................6-6

6.1.8

PERFORMANCE SPECIFICATIONS...............................................................6-7

6.1.9

MACHINE AND COMPONENT WEIGHTS ......................................................6-9

6.1.10 LIFTING CAPACITIES .....................................................................................6-10 6.1.11 LIFTING CAPACITIES .....................................................................................6-11 6.1.12 LIFTING CAPACITIES .....................................................................................6-12 6.2 OPTIONAL ATTACHMENTS -SPECIFICATIONS ..................................................6-13 6.2.1

WORKING RANGES........................................................................................6-13

6.2.2

BUCKET AND ARM COMBINATIONS.............................................................6-14

6.3 TORQUE SPECIFICATIONS ..................................................................................6-15 6.3.1

CAPSCREWS AND NUTS ...............................................................................6-15

6.3.2

ORS JOINT ("O"-RING SEALING TYPE) ........................................................6-16

6.3.3

NUTS AND SLEEVES......................................................................................6-17

6.3.4

FLARE TYPE FITTING JOINTS.......................................................................6-17

6.3.5

N2 (NYLON) TUBE FITTING JOINTS ..............................................................6-17

6.3.6

TORQUE VALUES FOR MOST COMMON BOLTS ........................................6-18

6.4 MISCELLANEOUS INFORMATION........................................................................6-19 6.4.1

TEMPERATURE TABLE ..................................................................................6-19

6.4.2

SPECIAL PIPE WRENCHES ...........................................................................6-19

6.4.3

WEIGHT OF MATERIALS TABLE ...................................................................6-20

6.4.4

CAPS AND PLUGS FOR TUBES AND HOSE FITTINGS ...............................6-20

7. TROUBLESHOOTING 7.1 GENERAL TROUBLESHOOTING ..........................................................................7-3

8. SPECIAL PROCEDURES 8.1 GENERAL ...............................................................................................................8-3 8.2 RELEASING TRAVEL MOTOR BRAKES...............................................................8-3 8.2.1

TOOLS AND EQUIPMENT REQUIRED ..........................................................8-3

8.2.2

PROCEDURES ................................................................................................8-3

8.3 LOWERING ATTACHMENT WHEN SUDDEN ENGINE FAILURE OCCURS .......8-7 8.3.1

HOW TO LOWER ATTACHMENT ...................................................................8-7

8.3.2

HOW TO LOWER ATTACHMENT ...................................................................8-8

8.4 HYDRAULIC TANK PRESSURE ............................................................................8-8 8.5 RELEASING SLEWING BRAKE .............................................................................8-9 8.5.1

TOOLS & EQUIPMENT REQUIRED................................................................8-9

8.5.2

PROCEDURES ................................................................................................8-9

6

FOREWORD

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

GENERAL •

This manual contains procedures to help the operator gain peak performance through effective, economical machine operation and maintenance for the Manufacturer’s Hydraulic Excavators.

•

Before operating the machine, operators must thoroughly read and understand all Safety, Operation and Maintenance instructions found in this manual. Failure to follow the instructions given in this manual may lead to serious injury to persons and or equipment failure.

•

Operators and persons working with this machine should continually study this manual until proper Safety, Operation and Maintenance procedures are completely understood.

•

This manual describes the basic operating techniques. Skill is gained as the operator utilizes these techniques and perfects them with an actual machine.

•

Some illustrated pictures may be different from your machine, as technical improvement is continuous, manuals are periodically updated to reflect these changes.

•

This manual may not contain attachments and optional equipment that are available in your area. Please contact an authorized Dealer for any optional attachments required.

•

Materials and specifications are subject to change without notice.

PERIODIC INSPECTIONS •

After delivery of a machine, the Authorized Dealer will make periodic service inspections. Contact an authorized Dealer for any service related questions not explained in this manual.

NOTICE •

The contents of this manual may not reflect the specifications of the machine delivered. Contact an authorized Dealer to obtain assistance in specifications for machines equipped with options not contained in this manual.

•

Owing to the policy of continual improvement, changes may be made by Manufacturer to any of its products without any obligation on the part of Manufacturer.

0-1

FOREWORD

0-2

1. SAFETY PRECAUTIONS

1-1

1. SAFETY PRECAUTIONS

1-2

1. SAFETY PRECAUTIONS

1.1

GENERAL SAFETY INFORMATION

S WARNING DO NOT OPERATE OR PERFORM ANY MAINTENANCE ON THIS MACHINE UNTIL ALL INSTRUCTIONS FOUND IN THIS MANUAL HAVE BEEN THOROUGHLY READ AND UNDERSTOOD. IMPROPER OPERATION OR MAINTENANCE OF THIS MACHINE MAY CAUSE ACCIDENTS AND COULD RESULT IN SERIOUS INJURY OR DEATH. ALWAYS KEEP THIS MANUAL IN THE OPERATOR'S SEAT POCKET. IF IT IS MISSING OR DAMAGED, PLACE AN ORDER WITH AN AUTHORIZED DEALER FOR A REPLACEMENT. IF YOU HAVE ANY QUESTION, PLEASE CONSULT AN AUTHORIZED DEALER. 1. Most accidents, which occur during operation, are due by all persons working with the machine. to neglect of precautionary measures and safety rules. Sufficient care should be taken to avoid these accidents. Erroneous operation, lubrication or maintenance services are very dangerous and may cause injury or death of personnel.

Therefore all precautionary measures, NOTES, DANGERS, WARNINGS and CAUTIONS contained in this manual and on the machine should be read and understood by all personnel before starting any work with or on the machine.

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

3. Messages of safety appear in this manual and on the machine. All messages of safety are identified by the words "DANGER", "WARNING" and "CAUTION". a. DANGER – Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury and is represented as follows:

S DANGER b. WARNING – Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury and is represented as follows:

S WARNING c. CAUTION – Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against possible damage to the machine and its components and is represented as follows:

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

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

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

1-3

1. SAFETY PRECAUTIONS

1.2

SAFETY PRECAUTIONS

S WARNING THE PROPER AND SAFE LUBRICATION AND MAINTENANCE FOR THIS MACHINE, RECOMMENDED BY MANUFACTURER, IS OUTLINED IN THE OPERATOR'S MANUAL FOR THIS MACHINE. IMPROPER PERFORMANCE OF LUBRICATION OR MAINTENANCE PROCEDURES ARE DANGEROUS AND COULD RESULT IN INJURY OR DEATH. READ AND UNDERSTAND THE OPERATOR'S MANUAL BEFORE PERFORMING ANY LUBRICATION OR MAINTENANCE. The serviceman or mechanic may be unfamiliar with many of the systems on this machine. This makes it important to use caution when performing service work. A knowledge of the system and or components is important before the removal or disassembly of any component.

Because of the size of some of the machine components, the serviceman or mechanic should check the weights noted in this manual. Use proper lifting procedures when removing any components. Weight of components table is shown in 6-7 of SECTION VI – SPECIFICATIONS. THE FOLLOWING IS A LIST OF BASIC PRECAUTIONS THAT MUST ALWAYS BE OBSERVED. 1. Read and understand all Warning plates and decals on the machine before Operating, Maintaining or Repairing this machine.

2. Always wear protective glasses and protective shoes when working around machines. In particular, wear protective glasses when using hammers, punches or drifts on any part of the machine or attachments. Use welders gloves, hood/goggles, apron and the protective clothing appropriate to the welding job being performed. Do not wear loose fitting or torn clothing.

Remove all rings from fingers, loose jewelry, confine long hair and loose clothing before working on this machinery.

3. Disconnect the battery and hang a "Do Not Operate" tag in the Operator's Compartment. Remove ignition keys.

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

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

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

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

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

9. To avoid back injury, use a hoist when lifting components which weigh 23 kg (50 lbs) or more. Make sure all chains, hooks, slings, etc., are in good condition and are the correct capacity. Be sure hooks are positioned correctly. Lifting eyes are not to be side loaded during a lifting operation.

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

1-4

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

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

13. Always use the proper tools that are in good condition and that are suited for the job at hand. Be sure you understand how to use them before performing any service work.

14. Reinstall all fasteners with the same part number. Do not use a lesser quality fastener if replacements are necessary.

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

16. Do not damage wiring during removal operations.

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

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

18. The maintenance and repair work while holding the bucket raised is dangerous due to the possibility of a falling attachment.

Do not fail to lower the attachment and place the bucket to the ground before starting the work.

19. Loose or damaged fuel, lubricant and hydraulic lines, tubes and hoses can cause fires. Do not bend or strike high pressure lines or install ones which have been bent or damaged. Inspect lines, tubes and hoses carefully.

Do not check for leaks with your hands. Very small (pin hole) leaks can result in a high velocity oil stream that will be invisible close to the hose. This oil can penetrate the skin and cause personal injury. Use cardboard, wood or metal to locate pin hole leaks.

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

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

22. Be careful when servicing or separating the tracks.

Chips can fly when removing or installing a track pin. Wear safety glasses and long sleeve protective clothing.

Tracks can unroll very quickly when separated.

Keep away from front and rear of machine. The machine can move unexpectedly when both tracks are disengaged from the sprockets. Block the machine to prevent it from moving.

23. Caution should be used to avoid breathing dust that may be generated when handling components containing asbestos fibers. If this dust is inhaled, it can be hazardous to your health. Components in Manufacturer products that may contain asbestos fibers are brake pads, brake band and lining assemblies, clutch plates and some gaskets. The asbestos used in these components is usually bound in a resin or sealed in some way. Normal handling is not hazardous as long as airborne dust which contains asbestos is not generated.

IF DUST WHICH MAY CONTAIN ASBESTOS IS PRESENT, THERE ARE SEVERAL COMMON SENSE GUIDELINES THAT SHOULD BE FOLLOWED. a. Never use compressed air for cleaning. b. Avoid brushing or grinding of asbestos containing materials. c. For clean up, use wet methods or a vacuum equipped with a high efficiency particulate air (HEPA) filter.

1-5

1. SAFETY PRECAUTIONS d. Use exhaust ventilation on permanent machining jobs. e. Wear an approved respirator if there is no other way to control the dust. f.

Comply with applicable rules and regulations for the work place.

g. Follow environmental rules and regulations for disposal of asbestos. h. Avoid areas where asbestos particles may be in the air.

1-6

1. SAFETY PRECAUTIONS

1.3

PRE-START SAFETY

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

OBSERVE SAFETY PRECAUTIONS

GER

DAN

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

OF EAR P CL AREA E E K NG SWI OP M A E R AT MA INTE ION NU NA NC AL E Ap

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abl

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CAUT

ION Bucke t can co d am ag nt e ca act and b w machi CAUTIO h en ne equipp N FOR some ed with attach INTER FERE ments .

C h ec k cl ea ra betwee n ce n bu cket cab be and forre op Exerc ise ca eration. re w operat hen ingBATTERY a buck EXPLOSION PREVENT et near Batteries give off hydrogen gasses that can

WARNING

explode and cause personal injury.

2432 380 Keep sparks, openP3flames and cigarettes awa 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 h h i

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

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

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

1-7

1. SAFETY PRECAUTIONS HOW TO HANDLE LIFE HAMMER A life hammer is provided on the left side of cab. In case of emergency, take the life hammer, break the cab glass, and escape from the cab.

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

HOW TO HANDLE LIFE HAMMER PREPARE FOR EMERGENCIES Have a fire extinguisher and first aid kit ready for emergencies. Know how to operate the fire extinguisher and know where the first aid kit is located for easy access in case of emergency.

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

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

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

PRE-START INSPECTION OF MACHINE

1-8

1. SAFETY PRECAUTIONS ENGAGE SAFETY LOCK LEVER BEFORE LEAVING MACHINE

1

Before leaving the operator's seat, move the safety lock lever to the "LOCKED" (Up) position (1).

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

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

2 PRE-START INSPECTION OF MACHINE 2. UNLOCKED (DOWN POSITION)

SIGNS, SIGNALS & FLAGMEN Install signs on soft shoulders and ground areas, have a flagman direct the operation if necessary.

The operator should note marks and follow signals from the flagman. All personnel should know the meaning of the signs, marks, and signals. Only one flagman should give the signs and signals.

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

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

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

USE CAUTION NEAR NOISE

1-9

1. SAFETY PRECAUTIONS MOUNTING & DISMOUNTING MACHINE

2

When getting on and off the machine, always maintain three point contact by using the handrails and step. Inspect and clean handrails, step, and mounting parts.

Remove slippery materials, such as lubricants, and mud. Always place the cab door entrance parallel to the tracks before stopping the engine for dismounting.

1

1. GRIP BARS AND STEP 2. KEEP STEP CLEAN

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

HOT SURFACES USE THE PROPER OPTIONAL ATTACHMENT Use only optional attachments designed for and approved by Manufacturer. Read, understand and follow all instructions in the manual accompanying the optional attachment. Use of any optional attachment not approved by Manufacturer in writing, can cause serious injury to personnel, damage to the machine and its components and shorten the life of the machine. Contact an authorized Dealer for optional attachments available for the machine.

USE PROPER ATTACHMENT

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

1-10

PREVENT FIRES – CLEAN UP SPILLS

1. SAFETY PRECAUTIONS

1.4

SAFETY DURING OPERATION

STARTING ENGINE Sit in the operator's seat.

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

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

SOUND HORN BEFORE STARTING PASSENGERS This equipment is not intended or designed for the transportation of persons. Never allow persons to ride on the machine. Serious injury or death can result from allowing passengers on or in the machine.

NO PASSENGERS TRAVEL Make certain of the location of the travel motors before operating travel controls. Sound horn before moving the machine to inform persons that the machine is travelling. Position the attachment as shown in illustration before beginning travel.

Move the machine at slow speeds. Do not turn suddenly on rough terrain. Avoid travelling over obstacles.

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

KNOW TRAVEL MOTOR POSITION SWING Make certain the swing area of machine is clear of all persons and obstacles before operating swing controls.

Sound horn before swinging machine. If necessary, have a flagman signal operator during operation to help prevent injury to persons or damage to obstacles and equipment.

ZL11M04116

SWING SAFETY/USE SWING FLASHERS

1-11

1. SAFETY PRECAUTIONS BOOM, ARM & ATTACHMENTS Give the work you are doing your undivided attention.

Make certain the attachment being used is suited for the job at hand. Make certain of obstacles in the work area and operate the machine within those limits. If necessary have a flagman signal the operator to prevent injury to persons or damage to the machine or obstacles in the work area.

ALWAYS PLACE ATTACHMENTS ON THE GROUND AND RAISE THE SAFETY LOCK LEVER BEFORE LEAVING THE CAB. OPERATING ON INCLINES OR SLOPES Operation of this machine on an incline or slope may cause the machine to become unstable or unbalanced.

Work up and down inclines or slopes never across.

Never swing or turn machine around on slopes. Build a level area for the machine to operate. Operate controls carefully to prevent sudden movements which may cause the machine to slide or tip over. Use a flagman to direct the operator.

BUILD BANKING FOR SLOPE OPERATION WORKING AROUND UTILITIES If it is suspected that utility lines such as, gas, water, phone or electrical power are in the work area, contact the local utility authority for line location BEFORE beginning work in the area. Use extreme caution around electrical power lines.

Keep a sufficient distance away from electrical lines during operation. See chart below for minimum distances.

LINE VOLTAGE 0~50,000 50,000~200,000 200,000~350,000 350,000~500,000 500,000~750,000 750,000~1,000,000

Minimum Distance-M (FEET) 3.0M (10) OR MORE 4.5M (15) OR MORE 6.0M (20) OR MORE 7.5M (25) OR MORE 10.5M (35) OR MORE 13.5M (45) OR MORE

KEEP A SAFE DISTANCE FROM UTILITIES

1-12

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

USE PROPER LIFTING DEVICES FROZEN OR SNOW COVERED WORK SITES Use extreme caution when operating the machine on frozen or snow covered work sites. Operate all controls slowly and cautiously to prevent sudden movements that may cause the machine to unexpectedly shift, slide or move. Even on the slightest slope, when snow is present or work area is frozen can allow a machine to unexpectedly move.

Snow on shoulders or snow drifts can be much deeper than expected. The machine can easily become buried under such conditions. Use extreme caution while operating the machine around or in snow.

USE EXTREME CAUTION ON FROZEN OR SNOW

FILLED OR UNSTABLE GROUND Be certain the condition of the work site is stable and capable of supporting the machine during operation.

Do not operate attachment too close to the machine.

Operation of the machine on shoulders or filled areas could cause the machine to become unstable presenting a work hazard.

Position the travel motors to the rear of the machine, allowing for quick reversal, should the work area become unstable.

WORK ON STABLE GROUND

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

BE AWARE OF OBSTACLES

1-13

1. SAFETY PRECAUTIONS PARKING THE MACHINE Always park the machine on a firm, level surface. If no firm level surface is available, block the tracks (1) and lower attachment to the ground to help prevent machine movement.

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

1

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

SEATBELT The fastening of seatbelt is strictly obliged by the possibility of hard blow inside of cab, being hurled out of the cab, or being crushed under the machine when the machine has tipped over. It may cause severe personal injury or death.

2

S WARNING •

•

MAKE SURE THAT THE BRACKET AND BELT ARE FREE FROM DAMAGES BEFORE FASTENING SEATBELT. DEFECTIVE ONES MUST BE REPLACED WITH NEW ONES. BEFORE STARTING MACHINE, TAKE A SEAT AND DON'T FAIL TO FASTEN SEATBELT. 1. BUCKLE 2. RELEASE BUTTON (RED)

1-14

1 FASTEN SEATBELT

1. SAFETY PRECAUTIONS

1.5

INSPECTION & MAINTENANCE SAFETY

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

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

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

STOP THE ENGINE BE CERTAIN TO TURN ENGINE OFF AND PLACE THE SAFETY LOCK LEVER IN THE "LOCKED" (UP) POSITION (1) before attempting any inspection or maintenance procedures to the machine. Failure to stop engine could result in serious bodily injury or death.

1

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

1-15

HYDRAULIC OIL CHECK POSITION

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

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

PRESSURIZED FLUIDS & LUBRICANTS Always release pressure (1) from hydraulic reservoir, engine coolant, fuel system and all systems containing pressure before removing any caps or components. BE CAUTIOUS OF HOT FLUIDS AND GASSES FROM SYSTEMS ON MACHINES THAT HAVE JUST BEEN STOPPED. ALLOW SUFFICIENT TIME FOR SYSTEMS TO COOL BEFORE PERFORMING ANY INSPECTION OR MAINTENANCE PROCEDURES.

KEEP MACHINE CLEAN

1

RELEASE HYDRAULIC TANK PRESSURE SUPPORT THE MACHINE If it becomes necessary to raise the machine for inspection or maintenance, always support (1) the machine by positioning the machine as shown in the illustration and use safety supports or blocks, with a sufficient capacity rating to support the machine, under the tracks. NEVER INSPECT OR PERFORM MAINTENANCE PROCEDURES UNDER A RAISED MACHINE THAT IS NOT SUFFICIENTLY SUPPORTED.

1

SUPPORT THE MACHINE REFUELING Move the machine to a well ventilated area for refueling. Use only specified fuel as described in the MAINTENANCE section of this operator's manual.

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

REFUELING HYDRAULIC PRESSURE Under normal conditions, all circuits of the hydraulic system are under extreme pressure. When inspecting for leaks, use a small piece of cardboard, wood or metal to locate leaks. SMALL (PINHOLE) LEAKS CAN BE DANGEROUS IF CONTACT WITH SKIN OR EYES IS MADE. Wear approved safety glasses or face shield, gloves, hard hat, safety shoes and work clothes during all inspection and maintenance procedures.

1-16

CHECKING FOR HIGH PRESSURE LEAKS

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

USE CAUTION WHEN ADJUSTING TRACKS ELECTRICAL SYSTEM Before performing any inspection or maintenance to the electrical system, or performing any welding procedures, disconnect the negative (–) cables from the battery terminals. Not disconnecting the negative (–) cable could cause extensive damage to the electrical system.

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

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

1-17

1. SAFETY PRECAUTIONS

1.6

BATTERY SAFETY

WEAR PROPER PROTECTIVE CLOTHES Wear long sleeve shirt, gloves and approved safety glasses or face shield when working with or around batteries. Battery electrolyte (acid) will cause severe burns if allowed to make contact with clothing, skin or eyes.

Should electrolyte (acid) come in contact with clothes, skin or eyes, immediately remove effected clothing, flush area with clean water for 15 minutes and get prompt medical attention.

WEAR PROTECTIVE CLOTHES

KEEP AWAY FROM FIRE OR FLAMES Never allow batteries in the vicinity of fire or flames and do not smoke when working with batteries.

Explosive hydrogen gas is produced by the electrolyte (acid) in the batteries. Always work with batteries in a well ventilated area.

KEEP AWAY FROM FIRE OR FLAMES CHARGING BATTERY Charge battery off of and away from machine in a well ventilated area. When charging battery, remove cell covers to allow gasses to escape.

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

1-18

1. SAFETY PRECAUTIONS USING BOOSTER CABLES Wear proper safety equipment when working with batteries.

1

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

Make certain of the positive (+) (2) and negative (–) (1) terminals on the booster battery and the disabled machine before connecting booster cables.

Connect the positive (+) cable first (2), then connect negative (–) (1).

When disconnecting, disconnect the negative (–) cable first (1), then disconnect the positive (+) cable (2).

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

S WARNING IMPROPER BOOSTER CABLE CONNECTIONS CAN CAUSE AN EXPLOSION RESULTING IN PERSONAL INJURY. CONNECT BOOSTER CABLES USING FOLLOWING PROCEDURE. 1. CONNECT BOOSTER CABLE TO POSITIVE (+) BATTERY TERMINAL OF DISCHARGED BATTERY. CONNECT OTHER END OF BOOSTER CABLE TO POSITIVE BATTERY TERMINAL OF NORMAL BATTERY. 2. CONNECT OTHER BOOSTER CABLE TO NEGATIVE (–) BATTERY TERMINAL OF NORMAL BATTERY. CONNECT OTHER END OF BOOSTER CABLE TO UPPER FRAME OF TROUBLED MACHINE. 3. START ENGINE AND REMOVE BOOSTER CABLES IN REVERSE ORDER.

1-19

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

1. SAFETY PRECAUTIONS

1.7

WARNING LABELS & DECALS

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

NOTE: SUPPLEMENTARY EXPLANATION The content of pictograph ISO warning label is explained at the foot of the label. So read and understand it thoroughly.

1.7.1

NOTICE FOR WARNING LABELS & DECALS

•

Do not take away the attached warning labels and decals.

•

Confirm whether labels can be easily read.

If words or illustrations are illegible, clean off or replace the labels.

•

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

•

If labels are damaged, missing or illegible, replace them with new ones.

Contact Dealer for new labels.

1.7.2 1.

LOCATION OF WARNING LABELS & DECALS

SWING-DANGER Located on each side of the rear counterweight.

2.

PRESSURIZED HOT OIL-WARNING Located on each hydraulic tank cover.

S WARNING

Pressurized hot oil can cause burns.

Depress cap slowly with engine off to relieve hydraulic tank pressure.

1-20

1. SAFETY PRECAUTIONS 3.

PRESSURIZED HOT OIL & COOLANT-WARNING Located on top of engine radiator.

4.

DO NOT CLIMB-WARNING Located on top of engine radiator.

5.

STOP ENGINE-WARNING Located on engine radiator.

1-21

1. SAFETY PRECAUTIONS 6.

HANDLING BATTERY-DANGER AND WARNING Located on fuel tank.

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

Connect booster cables (1) using following procedure.

1. Connect booster cable (red) to positive (+) battery terminal of discharged battery (2). Connect other end of booster cable to positive battery terminal of normal battery (3).

2. Connect other booster cable (black) to negative (-) battery terminal of normal battery. Connect other end of booster cable to upper frame of troubled machine (4).

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

1 2

3 4

S WARNING AVOID ACID BURNS • 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.

S

DANGER EXPLOSIVE GASES

Cigarettes, flames or sparks could cause battery to explode. Always shield eyes and face 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 sulphuric acid. Avoid contact with skin, eyes or clothing. In event of accident flush with water and call a physician immediately.

KEEP OUT OF REACH OF CHILDREN

1-22

1. SAFETY PRECAUTIONS

S WARNING PREVENT BATTERY EXPLOSION • Batteries give off hydrogen gasses that can explode and cause personal injury.

• Keep sparks, open flames and cigarettes away from batteries.

• Keep metallic articles away from batteries.

• Keep all ventilation caps tightly secured.

• Never check charge by placing metal articles across battery terminals.

• Leave battery box open to improve ventilation when charging.

7.

BOOSTER CABLE-WARNING Located on fuel tank.

S WARNING Electric hazard may cause injury when mishandling the cable.

Read operator manual for safe and proper handling.

8.

HOT PARTS-CAUTION Located on counterweight.

1-23

1. SAFETY PRECAUTIONS 9.

STOP ENGINE-WARNING Located on engine radiator.

10. AIR CLEANER-CAUTION Located on engine bonnet.

11. BUCKET TO CAB CONTACT-CAUTION Located inside cab R.H.

S CAUTION 1

Bucket can contact and damage cab (1) when machine equipped with some attachments.

Check clearance between bucket and cab before operation. Exercise care when operating a bucket near cab.

1-24

1. SAFETY PRECAUTIONS 12. SAFETY LOCK LEVER-WARNING Located on control stand.

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

13. LIFTING FRONT WINDOW-WARNING Located inside cab front window.

14. NIBBLER & BREAKER OPERATION-CAUTION Located on right hand operator console.

S CAUTION Do not set this switch to nibbler combined flow operation position when using breaker.

1-25

1. SAFETY PRECAUTIONS 15. READ OPERATOR'S MANUAL-WARNING Located inside cab R.H.

16. ADJUSTING TRACK TENSION-WARNING Located inside cab R.H.

17. ELECTRICAL POWER LINES-WARNING Located inside cab R.H.

1-26

1. SAFETY PRECAUTIONS 18. KEEP CLEAR WORKING AREA-DANGER Located on arm.

19. BOOM TO CAB CONTACT-CAUTION Located inside cab R.H.

LF20T01011P1

1-27

1. SAFETY PRECAUTIONS 20. ENGINE AUTO IDLING STOP-WARNING Located inside cab R.H.

AUTO IDLING STOP A

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

S CAUTION The auto idling stop function for cutting down generating of the useless fuel consumption and an exhaust gas at the time of a stop in this machine is carried. When you use it, be careful of the following things.

Z When you start the engine again after an auto idling stop, please be sure to start after once returning a key switch at ACC or OFF and also returning a throttle potentiometer to Lo. But the engine cannot be again started until a buzzer stops, after engine stops.

Z When you leave from a cab for a long time, please be sure to turn OFF a starter switch.

Z When the engine coolant temperature error are displayed with the LCD or lamp, it does not operate, even if the auto idling stop switch is turned on ON. Please read the operator's manual.

1-28

1. SAFETY PRECAUTIONS 21. ENGINE AUTO IDLING STOP-NOTICE Located on right hand operator console.

AUTO IDLING STOP When an auto idling stop switch is ON, after raising a safety lock lever, engine stops after fixed time progress.

1-29

1. SAFETY PRECAUTIONS

1.8

PROHIBITED MACHINE OPERATION

The following examples of machine abuse and misuse should never be attempted by even the most experienced operator. Such abuse and misuse of this machine and its attachments can result in serious bodily injury, death, severe equipment damage and shortened service life of the machine. Under no circumstance should any of these operations be attempted. Use common sense and follow proper operation procedures found in this operator's manual while operating this equipment.

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

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

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

DO NOT HAMMER WITH ATTACHMENT

1-30

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

USE ONLY FOR INTENDED PURPOSE DO NOT OPERATE BUCKET AND ARM CYLINDERS TO STROKE END REPEATEDLY

1

Extending the bucket and arm cylinders to stroke end to clean debris from the bucket, will cause impact to the bucket cylinder causing cylinder damage. Use high pressure water or manually remove stubborn material from the bucket.

1. ALLOWANCES

DO NOT OPERATE CYLINDER TO STROKE END DO NOT OVER EXERT THE MACHINE'S CAPACITIES. Know the limitations of the machine and its attachments and operate the machine within those specifications.

Do not exceed lift charts. Never tip or raise the machine to obtain power to move material. This could cause extensive damage to the machine and its components as well as result in serious bodily injury or death.

DO NOT OVER EXERT THE MACHINE

1-31

1. SAFETY PRECAUTIONS

1.9

END OF WORK SHIFT SAFETY

Perform all of the following procedures after each shift is complete to insure the machine it in optimal operating condition for the next shift or job site. a. Move the machine to a firm, level surface. b. Lower attachment to the ground. c. Refill fuel tank to full mark to reduce air volume and condensation (moisture). This will decrease the possibility of freezing in the fuel tank, rusting due to moisture and other problems associated with start up and operation. d. Close and secure all windows in place to prevent water or moisture reaching the electrical components of the machine. e. Thoroughly clean and inspect the machine. Perform lubrication maintenance and repair or replace any problem areas found before restarting the machine. f.

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

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

1-32

END OF WORK SHIFT SAFETY

1. SAFETY PRECAUTIONS

1.10

USE FOPS AND FRONT GUARD

For some jobs (e.g. demolition), a safety structure [e.g.

FOPS (1), Front guard (2)] is needed. When your machine does not have this safety structure, you are not allowed to use your machine for this kind of application.

Please check your local dealer in case of doubt.

1

2

USE FOPS AND FRONT GUARD

1-33

1. SAFETY PRECAUTIONS

1.11

USE SAFETY VALVE AND OVERLOAD ALARM

If your machine is used for lifting application and has a maximum rated lifting capacity bigger than 1 ton or an overturning moment bigger than 40000 Nm your machine needs safety valves and an overload alarm according to the EN 474 standard.

Please check your local dealer in case of doubt.

1-34

2. MACHINE FAMILIARIZATION

2-1

2. MACHINE FAMILIARIZATION

2-2

2. MACHINE FAMILIARIZATION

2.1

FAMILIARIZATION

All operators, service mechanics and personnel responsible for operation, inspection and maintenance of the machine should become thoroughly familiar with the controls and components and their functions before working with or on this equipment.

Study the information in this section to become familiar with the controls and components of this machine.

2.2

GENERAL MACHINE NOMENCLATURE

The nomenclature drawing below, points out locations of major components of the hydraulic excavator.

Study these areas and locate these components on the machine. Specific information regarding these components are explained on the following pages of this section.

28

27

25

31

15 29

10

26

9

30

11 6 7 12

32 13

1 5

14 24 8 23 21 18 22 19

2 20

3

16 17 4 No. NAME

No. NAME

No. NAME

No. NAME

1

ISUZU 4JG1NABGA ENGINE

9

17 TRAVEL MOTOR

25 BOOM

2

COUNTERWEIGHT

10 SWING CYLINDER

18

3

ENGINE RADIATOR

11 REAR VIEW MIRROR

19

4

ENGINE AIR CLEANER

12 MAIN CONTROL VALVE

20

5

ENGINE MUFFLER

13 CAB

21

6

FUEL TANK

14 OPERATOR CONTROLS

22

7

HYDRAULIC OIL TANK

15 BATTERIES

23 DOZER BLADE

31 BUCKET CYLINDER

8

HYDRAULIC PUMP

16 SWIVEL JOINT

24 DOZER CYLINDER

32 BUCKET

SLEWING MOTOR

2-3

TRACK IDLER

26 BOOM CYLINDER

(1 EACH SIDE) LOWER ROLLER (5 EACH SIDE) UPPER ROLLER

28 ARM

(1 EACH SIDE) RUBBER

27 ARM CYLINDER

CRAWLER

SHOES (1 EACH SIDE) TRACK SPRING (1 EACH SIDE)

29 IDLER LINK 30 BUCKET LINK

2. MACHINE FAMILIARIZATION

2.3

OPERATOR CAB NOMENCLATURE

The operator cab nomenclature, points out locations of operator controls of the hydraulic excavator operator cab.

Study these areas and locate these components on the machine. Specific information regarding these components are explained on the following pages of section.

7

5

4

6

10 1 16

2

9

8

30

3 15

14 33

31

11

23

17 12

22

18 24 13 19

29

25 28

28 27

No.

NAME

21

26

No.

20 NAME

32 No.

NAME

1

Right hand operator control lever (Horn switch)

13 Key switch

25 Fuse box

2

Left hand operator control lever (Swing & extra select switch)

14 Auto accel switch

26

3

Safety lock lever (for Hydraulics)

15 Reminder lamp for replacing starter 27 Rotary light switch

4

Right travel lever

16 24v cigarette lighter

28 Cap (for optional switch)

5

Left travel lever

17 Auto idling stop select switch

29 Breaker & nibbler select switch

6

Swing & Extra (optional) control ped18 Additional work light switch al

7

Nibbler & breaker control pedal

19 Overload alarm select switch

31 Hour meter

8

Right travel pedal

20 Operators seat (3 way adjustable)

32 Engine emergency stop control

9

Left travel pedal

21 Head rest (adjustable)

33 Dozer blade control lever

10 Gauge cluster

22 Arm rest

11 Switch panel

23 Air-conditioner panel

12 Throttle potentiometer

24 12V power supply

2-4

Slewing switch

parking

brake

release

30 Swing & extra indicator lamp

2. MACHINE FAMILIARIZATION

2.4

COMPONENT & CONTROLS NOMENCLATURE

The following information provides a brief description and function of the components and controls of the hydraulic excavator.

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

2.4.1

RIGHT HAND OPERATOR CONSOLE

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

F

OF

T

AR

HI

LO

HE AT

ON ST

HEAT : This position is used for starting the engine in cold climates. See section III.

ACC

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

F

OF AT HE

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

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

2. KPSS Mode Switch The KPSS mode switch is located on the right hand operator console and has 3 operating functions.

"H" Mode : Use this position for best performance in heavy digging operations.

"S" Mode : Place switch in "S" mode for best performance and control for light duty operations and fuel consumption.

LO

"FC" Mode : Use this position when precision fine control is required.

2-5

HI

ACC

ON T AR ST

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

2. MACHINE FAMILIARIZATION 3. Throttle Potentiometer

HI

LO

LO

HI

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.

F

ACC

ON

OF HE AT

T AR ST

4. Wiper Switch

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

4

5. Washer Switch

Press this switch, and washer fluid is sprayed while it is pushed. Also, washer tank is installed in the front of radiator on the rear left side.

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

2-6

5

2. MACHINE FAMILIARIZATION 6. Working Lights Select Switch

Press this switch, and working lights installed on boom and front right side go on.

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

6

7

7. Buzzer Stop Switch

When the engine coolant temperature is too high, or various sensors of mechatro controller (self diagnosis) fail, the alarm sounds intermittently. To stop sound, press the buzzer stop switch.

NOTE: • Buzzer sounding due to engine cooling water temperature rise can be stopped.

•

To stop buzzer sounding due to finish of the preheating, failure of engine oil pressure turn the key switch “OFF”.

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

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

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

"ON" "OFF"

LO

HI

9. Additional Work Light Switch This switch is located next working lights select switch.

Its basic functions are to turn the additional cab front and rear work lights "ON" and "OFF".

"ON" "OFF"

Depress this side to turn additional cab front and rear work lights "ON".

Depress empty side of switch to turn additional cab front and rear work lights "OFF".

2-7

2. MACHINE FAMILIARIZATION 10. Rotary Light Switch This switch is located on the right hand control console.

Its basic function is to turn the rotary light "ON" and "OFF".

"ON" Depress this side to turn rotary light "ON".

Depress back side of switch to turn rotary light "OFF".

"OFF"

11. Overload Alarm Select Switch The overload alarm select switch is located on the right hand control console. The overload alarm switch is a 2 position rocker switch and used for lifting operations.

"ON" HI

LO

"ON" : Push the symbol side of switch down to turn over load alarm ON when performing lifting operations.

"OFF" : Push the empty side of switch down to turn over load alarm "OFF" when performing other operations.

F

12. 24 Volt Cigarette Lighter The cigarette lighter is located on the right wall of cab.

To use the cigarette lighter the key switch must be in the "ON" position. Push the lighter in and wait approximately 30 seconds for it to "POP" out. Pull lighter from the socket to use. Replace lighter back into its socket after use.

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

13. Swing & Extra Select Indicator Lamp In case of the specifications for extra attachments, each time the switch on the grip of the left control lever is pressed, the circuit is switched to the boom swing and the extra attachment by turns, then when the extra attachment is used, the extra indicator lamp (1) goes on.

(1)

2-8

ACC

ON A ST

EA T

OF

"OFF"

2. MACHINE FAMILIARIZATION 14. Reminder lamp for replacing starter When the number of starting up of starter reaches set value, this lamp is lit continuously.

Replace or overhaul the starter motor as soon as possible.

(1)

NOTE: each time the starter key is turned to start, this reminder lamp is always lit.

15. Auto idling stop select switch Please symbol mark corresponding to this switch to turn "ON", and the engine in operation stops automatically after a constant elapse of time with safety lock lever (1) remaining locked. Consequently the fuel consumption is reduced.

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

"ON" "OFF"

LO

NOTE: 1. Put safety lock lever to "Locked Position", and the rotation changes to the decel rotation about 4 seconds later.

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

1

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

S WARNING WHEN YOU DO THE WORK WHICH HAS FEAR, SUCH AS FALL OF A LOAD, WHEN ENGINE STOPS, PLEASE BE SURE TO TURN OFF AN AUTO IDLING STOP SWITCH.

2-9

HI

2. MACHINE FAMILIARIZATION

S CAUTION •

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

The engine starter motor may be damaged.

•

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

•

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

While keeping the safety lock lever on "LOCKED POSITION".

•

•

When required warm up the engine;

•

When required to operate the air-con continuously;

•

When keeping the working light on;

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

•

2.4.2

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

LEFT HAND OPERATOR CONSOLE

1. 12 Volt Power Supply The 12 Volt power supply is located beside the left hand operator console.

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

S CAUTION Do not use the 12V power supply as a power source for 24V accessories.

MAXIMUM CONTINUOUS OUTPUT – 2.5 Amps

2. Air Conditioner The climate control-AC provides a comfortable indoor environment and adjustable control of cab temperature.

It removes moisture from humid air and reducing window glass fogging.

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

(A)

A. Air outlet selector (A)

Select a preferable air blowout direction moving grille by hand.

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

2-10

(C)

2. MACHINE FAMILIARIZATION B. Control Panel Description

4

6

5

7

9

8

3

2

1

1. MAIN POWER SWITCH 2. AUTO CONTROL SWITCH 3. TEMPERATURE SETTING SWITCH (°C °F SELECTOR SWITCH) 4. AIR OUTLET MODE SELECTOR SWITCH 5. DEFROSTER SWITCH 6. FRESH AND RECIRCULATE AIR SELECTOR SWITCH 7. COMPRESSOR SWITCH 8. FAN SPEED SELECTOR SWITCH 9. LCD DISPLAY NOTE: the LCD display indicates temperature, air outlet mode, compressor “ON” - “OFF”, “AUTO”, recirculate and fresh air and fan speed.

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

C. Fundamental use

2

3

Before turning air-conditioner on, close doors of cab and windows to achieve the best performance.

1. Press control switch "AUTO" (1) to control air capacity and blower outlet automatically, and set the temperature in the range from 18.5°C (65.3°F) to 31.5°C (88.7°F).

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

2. Select proper mode manually through recirculate and fresh air capacity selector switch (2) and compressor switch (3) “ON” - “OFF”.

3. Select preferable fan speed manually through fan speed selector switch (4) when fan speed, selected through auto control, is not preferable.

The indicator lamp of "AUTO" in LCD display goes out. Press "AUTO" switch (1) to return to automatic climate control.

2-11

1

4

2. MACHINE FAMILIARIZATION D. Control Panel Functions

1

D1. Main power switch and display a. LCD display (1) is illuminated when the climate control- AC is operating.

When the climate control-AC is stopped, LCD will be turned off. b. Press main power switch (2), and all functions for the climate control-AC switch “ON” or “OFF”.

Each time when this switch is pressed, the function switches “ON” and “OFF”. When switched “ON”, the climate control-AC starts operating at the point set before switching “OFF” (when it is set to “AUTO”, in auto mode; if NORMAL is selected, then in normal mode).

2

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

D2. Auto Control Switch and Display

2 3

a. Press the main power switch (1) to activate the climate control-AC and the LCD display (2) will illuminate. b. Press control switch “AUTO” (3), and fan speed and air outlet are automatically controlled, and "AUTO" indicator lamp on LCD display (2) is illuminated. c. When the main power switch (1) is “OFF”, the system will retain the previous setting in memory.

Therefore, when the main power switch is pressed again, the climate control AC will come on in the auto control mode. In the auto mode, the fan speed and air outlet openings are operated automatically.

2-12

1

2. MACHINE FAMILIARIZATION D3. Temperature Setting Switch and Display

1

a. The set temperature is indicated in digits on LCD display (1). Temperature set range is 18.5°C (65.3°F) to 31.5°C (88.7°F). b. Press the two temperature set switches (2) simultaneously for 5 seconds to change the display from centigrade (°C) to fahrenheit (°F) or viceversa in the LCD display (Eg.) 25°C → 77°F or 77°F → 25°C

2

c. Press temperature set switch DOWN or UP to change the set temperature.

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

The set temperature may be raised or lowered by continued pressing of the switch. d. The set temperature 18.5°C (65.3°F) is the lowest cooling temperature, and 31.5°C (88.7°F) is the highest heating temperature.

Control beyond either of these limits is not possible.

D4. Air outlet mode selector switch and display a. Air outlet position is indicated by the arrow on LCD display. b. Press Air outlet mode switch (1) in the condition where auto display light is on, and the display mode is fixed., "AUTO" indicator lamp on LCD display goes out, and "AUTO" control of air outlet opening is released.

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

1

LCD DISPLAY Air outlet opening

Vent

Bi-level

Foot

Air outlet opening

Upper half of body

Upper half of body, foot

Foot, front glass

4

3

D5. Defroster switch and display a. Press defroster switch (1), defroster indicator lamp will be displayed. b. Press air outlet mode selector switch (2), and it returns to air outlet mode just before pressing defroster switch (1). c. Press defroster switch (1) in the condition where AUTO display is lighting up, "AUTO" indicator lamp on LCD display (3) goes out and the auto control of air outlet opening is released.

2-13

1

2

2. MACHINE FAMILIARIZATION D6. Recirculate and fresh air selector switch and display

3

4

a. Suction (fresh air intake) mode is indicated on LCD display b. Each time recirculate and fresh air selector switch (4) is pressed, the mode is switched to air recirculate or fresh air intake.

1

2

D7. Compressor switch and display Press compressor switch in the condition where mark on LCD display is unlit, compressor starts operating and indicator lamp of mark on LCD display goes on.

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

2

1. COMPRESSOR SWITCH

4

1

3

2. LCD DISPLAY 3. FAN SPEED SELECTOR SWITCH 4. FAN SPEED DISPLAY D8. Fan speed selector switch and display When it is set to MANUAL mode, fan speed on LCD display is as follows.

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

2-14

LCD DISPLAY FAN SPEED

LOW

MEDIUM

HIGH

MAX.

2. MACHINE FAMILIARIZATION 2.4.3

REAR PANEL AND OTHERS

1. Slewing Parking Brake Release Switch Slewing parking brake is usually locked. The slewing parking brake is released in slewing and arm-in operation. When the slewing function becomes inoperable due to a malfunction, turn toggle switch to "RELEASE LOCK" position, and the parking brake is released.

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

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

2. Breaker and Nibbler Selector Switch This machine is provided with breaker single circuit and nibbler and breaker Bi direction flow circuit. To use breaker or nibbler, select circuit appropriate to the specification through switch on the rear side of operator's seat.

Switch Position Specification

Switch Position

Circuit

Breaker

Single flow

Nibbler

Bi directional flow

S CAUTION Never turn switch on (Bi direction flow) to operate breaker. It may cause damage of machine.

2-15

RELEASE LOCK

NORMAL

2. MACHINE FAMILIARIZATION 3. Travel Speed Select Switch Select high speed (2nd speed) or low speed (1st speed) with this switch located on the right-hand travel lever. When the starter switch is turned from OFF to ON, the speed is automatically set to LOW. After starting the engine, select the desired speed.

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

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

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

2.4.4

OPERATING LEVERS AND CONTROLS

1. Safety Lock Lever The safety lock lever is located on the front outside of the left hand operator console and is red in color. The safety lock lever is used to lock out the hydraulic controls disallowing the use of any hydraulic function. The safety lock lever has 2 operating positions.

A

a. "UP"-When placed in the up position (A) the safety lock lever stops all hydraulic controls from functioning and allows the operator to enter and exit the operator seat. b. "DOWN"-When placed in the down position (B), the safety lock lever allows all operating functions of the hydraulic controls to resume and also locks the left hand operating console in operating position.

S WARNING ALWAYS PLACE THE SAFETY LOCK LEVER IN THE LOCKED (UP) POSITION BEFORE LEAVING THE OPERATOR CAB. NEVER LEAVE THE MACHINE UNATTENDED WITH ENGINE RUNNING OR LEVER IN THE DOWN POSITION.

2-16

B

2. MACHINE FAMILIARIZATION 2. Engine Emergency Stop Control (Iso Pattern) The engine emergency stop control knob (1) is located at the lower right hand side of operator's seat. It is used only in an emergency situation to stop the engine quickly. It has 2 operating positions.

1

a. "IN" - Releases the fuel stop lever on the governor to allow normal starting of the engine. b. "OUT" - Activates the fuel stop lever on the engine governor to immediately stop the engine.

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

1. ENGINE EMERGENCY STOP CONTROL KNOB 3. Left Hand Operator Control Lever (Iso Pattern)

A

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

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

Operating speed of function is variable from stop to full stroke depending on how far lever is operated. The left hand operator control lever has 4 basic operational functions.

A."FORWARD" : Variable speed arm out.

B."BACKWARD" : Variable speed arm in.

C."LEFT" : Variable speed left slewing.

D."RIGHT" : Variable speed right slewing.

E."CENTER" : Neutral position.

2-17

C D E B

2. MACHINE FAMILIARIZATION 4. Right Hand Operator Control Lever (Iso Pattern) The right hand operator control lever is located at the top front of the R.H. operator console. Its purpose is to allow the operator to control operations of the boom and bucket. Operating speed of function is variable from stop to full stroke depending on how far lever is operated. The right hand operator control has 4 basic operational functions.

A

D C

A."FORWARD" : Variable speed boom down.

E

B."BACKWARD" : Variable speed boom up.

B

C."LEFT" : Variable speed bucket in (Digging).

D."RIGHT" : Variable speed bucket out (Dump).

E."CENTER" : Neutral position.

5. Left and Right Travel Lever & Pedal The travel lever & pedal are located in front of operator seat. They are used to move the left or right track of the machine either forward or reverse. These controls have 2 basic operational functions.

"FORWARD" : Variable speed forward track movement.

"BACKWARD" : Variable speed reverse track movement.

"CENTER" : Neutral position.

NOTE: these operations are with travel motors positioned behind the operator's cab.

1. RIGHT HAND TRAVEL LEVER 2. LEFT HAND TRAVEL LEVER 3. RIGHT HAND TRAVEL PEDAL 4. LEFT HAND TRAVEL PEDAL

2-18

2

4

1

3

2. MACHINE FAMILIARIZATION 6. Boom Swing & Extra (OPT) Control Pedal

1

The boom swing control pedal are located in right front of operator seat. These controls have 2 basic operational functions.

Release pedal lock on the right side of operators seat to operate pedal.

"FORWARD" : Left swing (Max. 50°) "BACKWARD" : Right swing (Max. 82°) "CENTER" : Neutral NOTE: in case of the specifications for extra attachments, it can be shared with the same circuit of the boom swing pedal (1).

Each time the switch on the grip of left control lever is pressed, the circuit is switched to the boom swing and the extra attachment by turns, then when the extra attachment is used, the extra indicator lamp goes on.

2

To release pedal, push lock rod forward (2).

3

To lock pedal, pull lock rod backward (3).

7. Nibbler & Breaker Control Pedal The nibbler & breaker pedal are located in left front of operator seat. These control have 2 basic operational functions.

Release pedal lock on the left front side of operators seat to operate pedal.

S CAUTION Precaution for pedal operation.

The operation varies in the specifications, so before operating, read Operator Manual carefully.

To release pedal, push lock rod forward (2).

To lock pedal, pull lock rod backward (3).

2

Breaker Foot Pedal Depressing Section

Operating Condition

Pedal in neutral position

Breaker stops operation

Depress heel section

Breaker starts operating

3

Nibbler Foot Pedal Depressing Section

Operating Condition

Depress toe section

Nibbler close

Depress heel section

Nibbler open

2-19

2. MACHINE FAMILIARIZATION 8. Fuse Box The fuse box is located behind the right side of the operator's seat. It contains all necessary fuses for the electrical circuits of the machine. Should it become necessary to inspect or change a fuse, remove the fuse box cover (2) by gently pulling each end away from the box (1). Should a fuse require replacement, use a replacement fuse of the same type and amperage. Turn key switch to "OFF" and wait approximately 4 seconds for all electrical power to stop before removing or replacing a bad or blown fuse. The fuse cover (2) incorporates a fuse puller to remove fuses. Refer to the maintenance section of this manual for a detailed diagram and description of fuse box (1).

2

1

9. Hour Meter

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

10. Holder

1

This cup holder is located the right front of operator.

Place a canned or a bottled drink.

Press lock button : cover open 1. LOCK BUTTON 2. COVER

2

2-20

2. MACHINE FAMILIARIZATION 2.4.5

GAUGE CLUSTER

The monitor displays information sent from sensors positioned at various places on the excavator, making it possible to monitor the excavator's operating working conditions.

2

3 1

6

12

5

13

4

9

7

8

11

10 No. NAME

No. NAME

1

FUEL LEVEL GAUGE

8

ENGINE AIR CLEANER CLOGGING LAMP

2

COOLANT TEMPERATURE GAUGE

9

SWING PARKING BRAKE RELEASE LAMP

3

KPSS WORK MODE LAMP

10 I.T.C.S CONTROLLER CPU LAMP

4

ENGINE OIL PRESSURE LAMP

11 OVERLOAD ALARM LAMP

5

ENGINE COOLANT TEMPERATURE LAMP

12 ENGINE GLOW LAMP

6

BATTERY CHARGE LAMP

13 HIGH (2nd) SPEED TRAVEL LAMP

7

LOW FUEL WARNING LAMP

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

F: Fuel tank is about 100 Liter (26 gal).

E: The remaining fuel oil is about 17 Liter (4 gal).

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

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

3. KPSS Work Mode Lamp Press any of work mode selector switches

H,G,

M on switch panel, and the selected work mode indicator is displayed in green.

Machine is usually in S mode after starting engine.

2-21

2. MACHINE FAMILIARIZATION 4. ENGINE OIL PRESSURE LAMP This lights when the starter switch is turned to the "ON" position, and should turn off after the engine is started.

If a problem arises in the lubricant oil system while the engine is running, a warning lamp lights.

S CAUTION The engine may burn if the excavator is operated with the engine oil pressure lamp on. a. Stop the engine and check the quantity of engine oil. (Refer to 4-14.) b. If the cause is elsewhere, have the excavator inspected at Dealer 5. ENGINE COOLANT TEMPERATURE LAMP If the coolant temperature rises abnormally (above 105°C or 221°F) a warning lamp lights.

The coolant temperature may rise abnormally if the engine is run with an excessive load.

S CAUTION The engine may burn if the excavator is operated with the coolant temperature lamp on. a. The engine is overheating. Stop operation immediately and let the engine run at low speed to let the coolant cool down. b. Once the coolant has cooled down, stop the engine. c. Once the engine has cooled down, inspect the amount of coolant, and check the fan belt for breaks or slack.

6. BATTERY CHARGING LAMP This lights when the starter switch is turned to the "ON" position, and should turn off after the engine is started.

The lamp lights if a problem arises in the charging system while the engine is running.

If this happens, have the excavator inspected at Dealer.

7. LOW FUEL WARNING LAMP When the starter switch is turned to the "ON" position, a warning lamp lights if the fuel is low.

If this lamp lights, please refill fuel tank immediately.

8. ENGINE AIR CLEANER CLOGGING LAMP When the starter switch is turned to the "ON" position, a warning lamp lights if the fuel is low.

If this lamp lights, please refill fuel tank immediately.

2-22

2. MACHINE FAMILIARIZATION 9. SWING PARKING BRAKE RELEASE LAMP When swing parking brake is not released due to trouble of electric system, the release indicator lamp goes on. Turn swing parking brake release switch to "RELEASE" position, move machine to safe area immediately, and contact Dealer.

10. I.T.C.S CONTROLLER CPU LAMP When controller equipped with various electrical and hydraulic control mechanisms fail, this lamp goes on and buzzer sounds.

When being lit up, contact Dealer.

11. OVERLOAD ALARM LAMP The lamp will light and the buzzer will sound if the boom cylinder circuit pressure exceeds the set, specified pressure. If this happens, the operator should be aware that he is operating the machine in a range of low machine stability. The operator should reduce the attachment reach in order to increase machine stability for safer operation.

12. ENGINE GLOW LAMP When the starter switch is moved from the "OFF" to the "HEAT" position, the engine oil and battery charge lamp both turn on.

The lamps also light when the starter switch is set to the "START" position.

13. HIGH SPEED TRAVEL LAMP This lights when the travel speed is switched to high (2nd.) speed.

The travel speed selector switch is located on the grip of the right travel lever.

The speed automatically returns to low (1st.) speed when the starter switch is set "OFF".

2.4.6

OPERATOR CAB AND OPERATOR SEAT

A. Locking/Unlocking Cab Door Use the key switch key to lock or unlock cab door. Insert key into door lock (1) and turn clockwise to unlock or turn counterclockwise to lock cab door.

1

2-23

2. MACHINE FAMILIARIZATION B. Cab Door Latch

1

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

1. DOOR LATCH 2. RELEASE LEVER

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

2

3. Pull release lever (1) near side, and door opens from the inside of cab.

3

3. RELEASE LEVER

C. Opening & Closing Windshield

1

Front window (upper) can be stored in ceiling.

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

1. Pull levers (1) on the right and left sides of front window upper section and levers are unlocked.

1. LEVER (1 EACH SIDE) 2. HANDLE A. FRONT INSIDE OF CAB B. REAR INSIDE OF CAB

2-24

2 A

2. MACHINE FAMILIARIZATION 2. Hold handles on upper central and lower left sides of front window (upper), remove them up and move front window. Lift the front window up and slide overhead all the way to the back end.

Pull down levers (1) to lock the window in place.

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

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

1 B

D. Removing & Storing Lower Front Window 1. After placing upper front window in ceiling and locking it in place, remove lower front window by hand from window frame.

1

2. Store the removed lower front window in holder in the rear of cab, behind the operator's seat.

1

3. To store it, insert the right and left sides of glass in holder (1), and support it with holder (2) on the lower section of window frame.

2 E. Opening and closing door glass 1. Open cab door glass (upper) sliding it to front side after unlocking it.

1

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

1. LOCK

F. Opening and Closing Sunroof

1

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

Close sunroof pulling locks inward, and lock it.

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

1. LOCK (1 EACH SIDE)

(B) (A)

2-25

2. MACHINE FAMILIARIZATION G. Cab Dome Light 1. Turn cab dome light "ON" by pushing the dome light switch (1) rightward.

2. Turn "OFF" by pushing switch leftward.

3. Place dome light switch (1) in the "CENTER" position and the light will be operated by the door switch. When door is opened the light will come "ON" and when the door is closed the light will turn "OFF".

1

H. Storage Compartment The operator and parts manual storage (1) compartment is a pouch located on the back of the operators seat. Keep the operator and parts manual for this machine in this location at all times for quick, easy reference.

1. MANUAL STORAGE

I. Operator Seat Adjustments

1

The operator seat incorporates several adjustment mechanisms to insure operator comfort, ease of operation and operator safety. The adjustment areas are as follows: 1. Operator weight adjustment a. Rotate the adjustment knob (1) until weight close to the operator weight is at the top end of the dial.

1. ADJUSTMENT KNOB

2. Seat height adjustment a. Pull height adjustment lever (1) up to raise or lower rear of seat. b. Push height adjustment lever (1) down to raise or lower front of seat.

1. ADJUSTMENT LEVER

1

2-26

2. MACHINE FAMILIARIZATION 3. Seat reclining adjustment a. Pull reclining adjustment lever (1) up to set desired reclining angle. b. Release reclining adjustment lever (1) to lock seat in position.

1. ADJUSTMENT LEVER

1 4. Seat front to back adjustment

2

a. Pull up on seat adjustment bail and move seat forward or backward to desired position.

1. BAIL : ADJUST OPERATOR SEAT ONLY 2. BAIL : ADJUST CONTROL STAND

5. Arm rest adjustment a. Lower arm rest and with finger, turn adjustment wheel (1) until arm rest is in desired position.

1. ADJUSTMENT WHEEL

1

6. Head rest adjustment a. Move head rest (1) forward or backward to desired reclining angle. b. Raise or lower head rest to desired height.

1. HEAD REST

2-27

1

1

2. MACHINE FAMILIARIZATION 7. Seat belt a. Sitting in operator seat, bring ends of seat belt around waist and insert L.H. end into latch (R.H. end).

1

b. Adjust seat belt until snug around waist by pulling loose end of belt on R.H. side. c. Remove seat belt by pushing red release button on latch end.

1. L.H. end

2

2. R.H. loose end 3. RELEASE BUTTON (RED)

S WARNING

3

ALWAYS WEAR SEAT BELT WHILE SITTING IN OPERATOR SEAT. ALWAYS CHECK CONDITION OF SEAT BELT AND SEAT BELT MOUNTING HARDWARE TO MAKE CERTAIN SEAT BELT IS IN GOOD CONDITION AND PROPERLY SECURE.

2.4.7

MACHINE ACCESS PANELS AND DOORS

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

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

1. ENGINE COOLANT TANK & ENGINE AIR CLEANER ACCESS DOOR 2. Main Pump Access Door Locate on the R.H. side of the machine this door allows access to the main pump.

1. MAIN PUMP ACCESS DOOR

2-28

2. MACHINE FAMILIARIZATION 3. Battery Box Access Cover Located behind swing bracket, this cover allows access to the batteries and battery relay. This access cover is also locked and unlocked by key switch key.

Use stay to leave the cover open.

1

1. BATTERY ACCESS COVER

4. Fuel Cap Stop engine, open hydraulic tank cover, and remove cap on fuel tank, then make it up with fuel seeing level of gauge.

1

1. FUEL CAP 2. LEVEL SIGHT GAUGE

1 2

5. Engine Cover Open engine cover (1) with key switch after stopping engine.

Use stay to support it.

1. ENGINE COVER

2-29

2. MACHINE FAMILIARIZATION

2-30

3. BASIC MACHINE OPERATION

3-1

3. BASIC MACHINE OPERATION

3-2

3. BASIC MACHINE OPERATION

3.1

PRE-START CHECK

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

3.2

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

3.2.1 STARTING ENGINE 1. Move throttle control (1) to "LO" position.

HI

2. Insert key into key switch (2) and turn to the "ON" position.

ACC

ON

T AR ST

F OF

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

HE

AT

LO

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

1

S CAUTION Release key after 20 seconds of cranking if engine does not start.

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

2

3

NOTE: if engine fails to start after 3 attempts, inspect fuel system and correct any problems found.

When cranking engine, the absence of "Blue" or "White" smoke from the exhaust indicates no fuel is reaching the engine cylinders.

AUTO IDLING STOP S

WARNING

S

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

S

CAUTION

S

The auto idling stop function for cutting down generating of the useless fuel consumption and an exhaust gas at the time of a stop in this machine is carried. When you use it, be careful of the following things.

• When you start the engine again after an auto idling stop, please be sure to start after once returning a key switch at ACC or OFF and also returning a throttle potentiometer to Lo. But the engine cannot be again started until a buzzer stops, after engine stops.

• When you leave from a cab for a long time, please be sure to turn OFF a starter switch.

• When the engine coolant temperature error are displayed with the LCD or lamp, it does not operate, even if the auto idling stop switch is turned on ON. Please read the operator's manual.

3-3

3. BASIC MACHINE OPERATION 3.2.2

STOPPING ENGINE - NORMAL CONDITIONS

1. Move machine to a firm, level area and place the attachment in the hydraulic oil check position (1).

1

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

3. Turn key switch to "OFF".

3.2.3

EMERGENCY ENGINE SHUT DOWN

In only cases of emergency should this method be used.

1. Turn key switch to the "OFF" position.

2. Pull out the engine emergency stop control (4) located on the lower right side of control stand until engine stop.

3. Before restarting engine, push emergency engine stop control (4) in.

4

3-4

3. BASIC MACHINE OPERATION

3.3

STARTING & STOPPING MACHINE ENGINE WITH TEMPERATURE BELOW 0ºC (32ºF)

3.3.1

STARTING ENGINE

1. Move throttle control (1) to "LO" position.

HI

2. Turn the key switch (2) to "HEAT" and preheat for 20 seconds to make start-up easier.

F

ACC

ON

T AR ST

OF

3. Turn key switch "ON" and sound horn (3) to warn personnel that the machine is being started.

AT

LO

HE

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

1

S CAUTION

2

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

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

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

When cranking engine, the absence of "Blue" or "White" smoke from the exhaust indicates no fuel is reaching the engine cylinders.

A

3

A. GLOW LAMP

AUTO IDLING STOP S

WARNING

S

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

S

CAUTION

S

The auto idling stop function for cutting down generating of the useless fuel consumption and an exhaust gas at the time of a stop in this machine is carried. When you use it, be careful of the following things.

• When you start the engine again after an auto idling stop, please be sure to start after once returning a key switch at ACC or OFF and also returning a throttle potentiometer to Lo. But the engine cannot be again started until a buzzer stops, after engine stops.

• When you leave from a cab for a long time, please be sure to turn OFF a starter switch.

• When the engine coolant temperature error are displayed with the LCD or lamp, it does not operate, even if the auto idling stop switch is turned on ON. Please read the operator's manual.

3-5

3. BASIC MACHINE OPERATION 3.3.2

STOPPING ENGINE – NORMAL CONDITIONS

1. Move machine to a firm, level area and place the attachment in the hydraulic oil check position (1).

1

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

3. Turn key switch to "OFF".

3.3.3

EMERGENCY ENGINE SHUT DOWN

In only cases of emergency should this method be used.

1. Turn key switch to the "OFF" position.

2. Pull out the engine emergency stop control (4) located on the lower R.H. side of control stand until engine stop.

4

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

3-6

3. BASIC MACHINE OPERATION

3.4

STARTING MACHINE ENGINE WITH BOOSTER CABLES

3.4.1

CONNECTING BOOSTER CABLES

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

ACC

F

ON

OF

HI

RT

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

STA

HEA T

S WARNING

OF

F

ACC

ON

T AR ST

AT

LO

HE

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

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

1

S WARNING WEAR HARD HAT, APPROVED SAFETY GLASSES OR FACE SHIELD, GLOVES AND OTHER SAFETY EQUIPMENT WHEN WORKING WITH BATTERIES. 3. Locate and connect one end of the booster cable to the positive (+) terminal (2) on the battery of the disabled machine.

2

4. Connect other end of positive booster cable to positive (+) terminal (2) of battery being used for boosting.

A

5. Locate and connect second cable to the negative (– ) terminal (1) of the battery being used for boosting.

(3)

6. Connect other end of negative (–) cable (1) to the upper frame of disabled machine as far away from battery as possible.

(1)

(2)

12V

12V

12V

B

12V

C

S WARNING (4) D

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

A. CABLE CONNECTING ORDER B. NORMAL BATTERIES C. DISCHARGED BATTERIES D. UPPER FRAME OF DISABLED MACHINE

3-7

3. BASIC MACHINE OPERATION 3.4.2

STARTING BOOSTING MACHINE ENGINE

1. Start engine of boosting machine in normal manner according to climate conditions. Refer to 3-3 & 3-5 for specific starting instructions.

A

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

(3)

A. CABLE CONNECTING ORDER

12V

B. NORMAL BATTERIES

(1)

(2)

12V

12V

B

12V

C

C. DISCHARGED BATTERIES

(4) D

D. UPPER FRAME OF DISABLED MACHINE

3.4.3

STARTING DISABLED MACHINE ENGINE

1. Start engine of disabled machine in normal manner according to climate conditions. Refer to 3-3 & 3-5 for specific starting instructions.

3.4.4

DISCONNECTING BOOSTER CABLES

1. After disabled machine engine is running, disconnect the negative (–) cable from disabled machine upper frame (1).

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

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

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

1

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

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

3-8

3. BASIC MACHINE OPERATION

3.5

MACHINE WARM UP

3.5.1

ENGINE

HI

LO

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

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

1

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

F

ACC

OF

ON

HE AT

T AR ST

1. THROTTLE CONTROL NOTE: in warming up the engine, turn auto idling stop select switch OFF. 3.5.2

HYDRAULIC OIL

1. Move throttle control (1) to "HI" idle position.

I

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

A

D

C

A. BOOM DOWN B. BOOM UP C. BUCKET IN

B

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

L

E

E. ARM OUT F. ARM IN G

G. SLEWING LEFT H. SLEWING RIGHT I.

H

R.H. CONTROL LEVER (ISO PATTERN)

L. L.H. CONTROL LEVER (ISO PATTERN F

3-9

3. BASIC MACHINE OPERATION 3.5.3

HYDRAULIC OIL IN FRIGID TEMPERATURES

1. Perform normal hydraulic oil warm-up procedures.

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

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

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

3-10

3. BASIC MACHINE OPERATION

3.6

CONTROLS DECAL

3.6.1

OPERATING PATTERN

The operating and travel controls of this machine are factory set to ISO standard operating patterns for optimum performance of the machine and its systems.

3.6.2

OPERATING PATTERN DECAL

The figure below is a representation of the "CONTROLS" decal located on the R.H. side window inside the operator cab. Study this decal and understand the directions each control can be operated and the functions associated with each movement of particular control. Detailed instructions for each control and its functions are explained on the following pages of this section.

2

4

3

1

B

A

5

6

A 7 B

NOTE: travel motors are positioned behind the operator's cab.

1.

RIGHT CONTROL LEVER

5.

BOOM SWING & EXTRA (OPT) CONTROL PEDAL

2.

LEFT CONTROL LEVER

6.

NIBBLER & BREAKER CONTROL PEDAL

3.

RIGHT TRAVEL LEVER AND PEDAL

7.

DOZER BLADE CONTROL LEVER

4.

LEFT TRAVEL LEVER AND PEDAL

3-11

3. BASIC MACHINE OPERATION

3.7

BASIC OPERATION OF HYDRAULIC CONTROLS

The following instructions are aimed at providing an operator with the basic function of each hydraulic control.

Use of these instructions, and practice with a machine, will allow a given operator to become more efficient in the operation of this equipment.

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

S WARNING NORMAL POSITIONING OF THE MACHINE FOR THE PURPOSE OF DETERMINING FRONT, REAR, FORWARD AND REVERSE ARE WITH THE TRAVEL MOTORS LOCATED BEHIND THE OPERATOR’S CAB. ALWAYS KNOW THE LOCATION OF TRAVEL MOTORS BEFORE OPERATING ANY HYDRAULIC CONTROLS. A. TRAVEL MOTORS AT REAR OF MACHINE 3.7.1

SAFETY LOCK LEVER

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

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

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

A

B

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

3-12

3. BASIC MACHINE OPERATION 3.7.2

KPSS (KOBELCO POWER SENSING SYSTEM) WORK MODE SWITCH

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

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

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

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

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

1. KPSS WORK MODE FUNCTIONS The KPSS work mode switch allows the operation select and control the operation of the machine and the attachment effectively for a particular job by selecting one of three positions.

"H" Mode : Provides maximum speed and power for digging operations.

HI

LO

"S" Mode : Provides standard power and best fuel consumption.

"FC" Mode : Allows fine control of hydraulic functions for attachment.

F

ACC

OF

ON

HE

AT

T AR ST

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

2. KPSS WORK MODE SELECTION TABLE

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

KPSS WORK MODE SELECTION TABLE WORK TYPE

DIGGING

LOADING

CORRECTION

REFILLING & CORRECTION

WORK REQUIREMENTS MATERIAL

1

2

3

1

2

3

1

2

3

1

2

3

SOFT VISCOUS SOIL

H

S

FC

H

S

FC

FC

FC

FC

H

S

FC

LOOSE SANDY SOIL

H

S

FC

H

S

FC

FC

FC

FC

H

S

FC

TIGHT SANDY SOIL

H

S

FC

H

S

FC

S

FC

FC

GRAVEL & STONE

H

H

S

H

H

S

S

S

FC

TIGHT GRAVEL/ MIXED SOIL

H

H

S

H

H

S

H

H

S

SOFT STONE

H

H

H

H

H

H

H

H

H

CRUSHING

TRANSFER

1

1

2

3

2

Flat Land "S"

H

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

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

3-13

3

3. BASIC MACHINE OPERATION 3.7.3

MACHINE TRAVEL CONTROLS

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

1. Operating Both Travel Levers Together a. Push both travel levers or press the pedals toward front of machine and machine will travel "FORWARD" (A).

A

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

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

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

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

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

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

S CAUTION Use "FAST" (U) travel speed on firm, level surfaces only.

Do not travel continuously for more than two hours.

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

3-14

B

3. BASIC MACHINE OPERATION 3. Turning Machine a. Push the L.H. travel lever toward front of machine to turn machine RIGHT in forward motion (C).

C

b. Pull the L.H. travel lever back toward operator seat to turn machine to the LEFT in reverse motion. c. Push the R.H. travel lever toward front of machine to turn machine to the LEFT in forward motion (D). d. Pull R.H. travel lever toward operator seat to turn machine to the RIGHT in reverse motion.

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

D

b. Pull R.H. travel lever BACK and push L.H. travel lever FORWARD to counter rotate machine to the RIGHT (F).

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

S CAUTION

E

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

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

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

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

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

3-15

F

3. BASIC MACHINE OPERATION 5. Travel Safety a. Make certain travel motor location is known before performing any travel operation.

1. WATER SURFACE A. MAXIMUM WATER DEPTH 620mm {2'- 0"}

1

B. BED MUST BE FIRM & STABLE b. Travel on firm, level surfaces as much as possible. c. When traveling on rough terrain, travel in SLOW

A

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

NOTE: if the machine is operated while the slewing bearing is submerged in water, then the slewing bearing, slewing pinion, and the swivel joint may wear out prematurely. Immediate replacement of grease in grease bath and overhaul of the slewing bearing is required. See maintenance section. l. On soft ground or mud the machine can sink. Stay constantly aware of undercarriage position.

3-16

B

3. BASIC MACHINE OPERATION 3.7.4

MACHINE ATTACHMENT & SLEWING CONTROLS

The following operation instructions are to be used with hoe bucket attachment only. If other attachments are being used, consult the operator’s manual for the particular attachment.

S WARNING READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS DURING ALL OPERATIONS OF THIS MACHINE AND ITS ATTACHMENT(S).

1. Boom Operation Operation of the boom is performed by pushing and pulling the R.H. control lever forward and backward.

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

2. Arm Operation Operation of the arm is performed by pushing or pulling the L.H. control lever forward and backward.

Arm speed is determined by how far the Lever is activated. a. Pushing the L.H. control lever FORWARD moves the arm out. b. Pulling the L.H. control lever BACK moves the arm in. c. Returning the L.H. control lever to the neutral (center) position, stops operation of the arm.

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

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

3-17

3. BASIC MACHINE OPERATION 4. Slewing Operation

A

NOTE: use rotary light during slewing operations.

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

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

3-18

B

3. BASIC MACHINE OPERATION 5. Boom Swing & Extra (OPT) Control Pedals This control pedal is used to operate the boom right and left swing and extra attachments (OPT).

Release pedal lock on the right front side of operators seat to operate pedal.

1

Boom swing operation a. "FORWARD" : Left swing (Max. 50°) b. "BACKWARD" : Right swing (Max. 82°) c. "CENTER" : Neutral position Minimum slewing radius : 2,220 mm (Case of max. swing angle) Extra operation (OPT) a. "FORWARD" : Extra suction

2

b. "BACKWARD" : Extra return c. "CENTER" : Neutral position NOTE: in case of the specifications for extra attachments, it can be shared with the same circuit of the boom swing pedal (1).

Each time the switch (S mark) on the grip of left control lever is pressed, the circuit is switched to the boom swing and the extra attachment by turns, then when the extra attachment is used, the extra indicator lamp goes on.

To release pedal, push lock rod forward (2).

To lock pedal, pull lock rod backward (3).

3-19

3

3. BASIC MACHINE OPERATION 6. Nibbler & Breaker Controls The nibbler & breaker pedal is located in front of operators seat. This pedal has 2 basic operational functions.

Release pedal lock on the left front side of operators seat to operate pedal.

S CAUTION Precaution for pedal operation.

The operation varies in the specifications, so before operating, read Operator Manual carefully.

To release pedal, push lock rod forward (2).

2

To lock pedal, pull lock rod backward (3).

Breaker Foot Pedal Depressing Section

Operating Condition

Pedal in neutral position

Breaker stops operation

Depress heel section

Breaker starts operating

3

Nibbler Foot Pedal Depressing Section

Operating Condition

Depress toe section

Nibbler close

Depress heel section

Nibbler open

3-20

3. BASIC MACHINE OPERATION 7. Dozer Blade Control Lever Blade is attached on lower frame with pin, and is used for backfilling and leveling after digging works by operating dozer cylinder through the aid of dozer control lever in cab and moving blade up and down.

S WARNING

A

READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS AND OPERATION PROCEDURES FOUND IN THIS MANUAL BEFORE OPERATING THE MACHINE OR ANY ATTACHMENT.

1 B

The dozer blade control lever (1) is located on the right side of the right hand operator console basic function is to lift (B) or lower (A) the dozer blade.

2

a. Start machine and place the safety lock lever in the "UNLOCKED" (Down) position. b. Move throttle control (2) to the "HI" idle position. c. Using boom, arm and bucket controls set the attachment to desired position. d. Pull the blade control lever to lift up the blade. e. Push the blade control lever forward to lower the blade.

S WARNING

B

•

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

•

DOZER BLADE CONTROL FUNCTION IS LIVE AT ALL TIMES. THAT IS, EVEN WITH THE SAFETY LOCK LEVER IN LOCKED UP POSITION.

S CAUTION Don't move the dozer lever downward when the engine is not running. If the dozer blade is lifting, the dozer blade drops. This causes serious injury.

3-21

A

3. BASIC MACHINE OPERATION USING AUTO ACCELERATION

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

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

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

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

3.7.6

TOWING THE MACHINE

Where you can't get the machine out of soft soil, place wire slings as shown on the right and pull it by an other machine. Always place wire slings around the frame section and put pads on each corner to prevent the wire slings from being damaged.

NOTE: do not pull the machine utilizing the holes provided for pulling lightweight objects.

Otherwise the holes may break.

3-22

"ON" "OFF"

LO

3.7.5

HI

3. BASIC MACHINE OPERATION

3.8

PRACTICES TO IMPROVE EFFICIENCY

Use Arm In Action Operate the bucket at shallow depths and use the arm in action to fill the bucket. Setting the bucket too deep will decrease the machine’s efficiency.

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

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

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

90° ~ 110

3-23

3. BASIC MACHINE OPERATION Cleaning Sand & Soil from Bucket Operate arm to a near level position and bring the bucket to a dumping position. If sand and soil do not fall out, move the bucket lever right and left a few times.

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

Stop Slewing Motion Early To stop slewing action, release the slewing lever before you get to your final point of digging or dumping.

Back Filling & Leveling For back filling and leveling work after digging, move the bucket back and forth horizontally.

NOTE: do not push or pull material with the bucket like a bulldozer when using the machine to level material. a. In leveling ground toward machine, pull the arm gently, lift the boom a little and when the arm has passed the vertical point, lower the boom gently and manipulate the machine so the bucket moves horizontally. b. For leveling ground away from machine, reverse operation in step 1 above. c. ln the above operation, bucket motion may be used together with the boom. By controlling the action of the boom work lever, you can dig a slope- like, slope facing operation. d. Never travel with attachment touching the ground.

Severe structural damage could occur.

3-24

3. BASIC MACHINE OPERATION Operating the Shovel Digging with the shovel differs slightly from digging with backhoe. a. Using the arm cylinder, scrape the ground. b. Scrape the ground at 2 ~ 3° to improve draining in areas near the groundwater level. c. Be careful not to bump the reversed bucket into the cab.

1 2° ~ 3°

d. The excavating power during shovel operations is less than that during backhoe operations. e. If machine bucket is equipped with a lifting eye (1), check to make sure that the eye (1) will clear arm with bucket cylinder in full extended (full dump) position.

MACHINE OPERATION IN ADVERSE WEATHER CONDITIONS 1. Operation in Extreme Cold a. Follow procedures on 3-5 as starting engine may be difficult due to extremely cold temperatures. b. Use an engine oil, hydraulic oil and diesel fuel designed for use in cold climates. See maintenance section, 4-13 for reference. Also, keep battery fully charged. c.Make certain to perform machine warm-up procedures as described on 3-9 to prevent premature wear or damage to pumps, motors and other components.

NOTE: in extremely frigid climates, covering the radiator is a method to aid the machine warm-up. IF NECESSARY TO MAINTAIN OPERATING TEMPERATURES, COVER THE OUTER EDGES OF THE RADIATOR, LEAVING AN OPENING IN THE CENTER PART OF THE COVER - THUS AVOIDING FAN OVERLOADING. Keep a close watch on the gauge cluster for warning icons during operation. It may be necessary to use a coolant heater, fuel heater, engine heater jacket, and/or additional battery power to aid engine starting. d. Make certain that the engine coolant mixture is sufficient to keep the machine safe. Take into consideration wind chill factors when mixing coolant ratios.

NOTE: mix coolant to a protection temperature of 5°C (9°F) lower than the machine will experience during operation, storage or transport. e. Keep battery terminals free of ice and snow. Ice and snow could cause the terminals to short circuit and cause extensive damage to the machine systems. Check the battery electrolyte (acid) level frequently and fill as necessary with distilled water. If the machine will be left outside overnight, it is recommended to remove the batteries and store in a warm area.

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

S CAUTION Do not allow dirt and debris to accumulate in the radiator fins, oil cooler fins or debris screen. c. Keep all belts properly tensioned. d. Make certain that the engine coolant mixture is sufficient to keep the machine safe. e. If the machine becomes overheated, idle the machine to help cool the engine, turn engine "OFF" and check coolant level. After filling to proper level the machine continues to over heat, stop engine, allow to cool, drain and flush entire cooling system and refill with the proper mixture of fresh, clean coolant.

3-25

3. BASIC MACHINE OPERATION f.

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

g. Keep a close watch on the gauge cluster for warning icons during operation. Avoid unnecessary low speed running of the engine during operation.

During slow, or no work periods, place throttle potentiometer in "LO" idle position.

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

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

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

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

3-26

3. BASIC MACHINE OPERATION

3.9

HYDRAULIC BREAKER

3.9.1

SELECTION OF THE HYDRAULIC BREAKER

When mounting the breaker on the hydraulic excavator, it is necessary to match stability, hydraulic pressure, and the oil level for each breaker. To select hydraulic breakers, call your Dealer.

3.9.2

BEFORE OPERATING THE HYDRAULIC BREAKER

Consult your Dealer for the piping or enforcement of the arm when installing the hydraulic breaker.

REPLACE THE HYDRAULIC RETURN FILTER ACCORDING TO THE REPLACEMENT SCHEDULE TABLE LISTED ON 3-32. Thoroughly read the hydraulic breaker operation manual and SAFETY PRECAUTIONS from this section, as well as the safety precaution's section on this manual to avoid damaging the machine or hydraulic breaker during operation. SELECT THE APPROPRIATE HYDRAULIC FLOW FOR THE BREAKER BY FOLLOWING THE INSTRUCTIONS DETAILED IN 3-28.

3.9.3

HYDRAULIC OIL LEVEL CHECK AND CONTAMINATION PREVENTION

When the hydraulic breaker is not installed on the machine, attach the blank plugs to the tube end on the arm top end and the hose end on the hydraulic breaker side to prevent dust and water from entering into the piping.

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

3.9.4

BASIC OPERATION

S WARNING READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS AND OPERATION PROCEDURES FOUND IN THIS MANUAL BEFORE OPERATING THE MACHINE OR ANY ATTACHMENT. 1. Start machine and place the safety lock lever in the "UNLOCKED" (down) position (1).

2. Move throttle control to the "HI" idle position.

3. Using boom, arm and bucket controls set the breaker or nibbler to desired position.

4. Control pedal is locked when lock rod is pulled backward (2).

5. Push lock rod forward to release control pedal (3).

6. Make certain breaker or nibbler is in desired position and against material to be broken.

7. Place left foot on pedal and depress with toe (4) to activate breaker or nibbler.

8. Operate breaker or nibbler for one minute then release pedal.

1

3

S WARNING

2

OPERATION OF BREAKER OR NIBBLER LONGER THAN ONE MINUTE INTERVALS COULD CAUSE PREMATURE WEAR OR DAMAGE TO THE ATTACHMENT AND THE MACHINE. IF MATERIAL IS NOT BREAKING, REPOSITION BREAKER OR NIBBLER AND REPEAT OPERATION IN ONE MINUTE INTERVALS. NEVER LEAVE THE OPERATOR CAB WITH ENGINE RUNNING.

3-27

4

3. BASIC MACHINE OPERATION 3.9.5

BREAKER AND NIBBLER SELECTOR SWITCH

This machine is provided with breaker single circuit and nibbler and breaker Bi direction flow circuit. To use breaker or nibbler, select circuit appropriate to the specification through switch on the rear side of operator's seat.

1. Switch Position Specification

Switch Position

Circuit

Breaker

Single flow

Nibbler

Bi directional flow

S CAUTION Never turn switch on (Bi direction flow) to operate breaker. It may cause damage of machine.

3.9.6

CONTROL PEDAL

1. Nibbler and Breaker Combined (Conflux) Circuit Release pedal lock on the left front side of operator's seat to operate pedal (1).

S CAUTION Precaution for pedal operation.

The operation varies in the specifications, so before operating, read the operator's manual carefully.

Breaker Foot Pedal Depressing Section

Operating Condition

Pedal in neutral position

Breaker stops operation

Depress heel section

Breaker starts operating

1

Nibbler Foot Pedal Depressing Section

Operating Condition

Depress toe section

Nibbler close

Depress heel section

Nibbler open

S CAUTION

S WARNING

1

NEVER LEAVE THE OPERATOR CAB WITH ENGINE RUNNING.

The accumulator, mounted on boom, can contact and damage opened cab skylight (1) 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.

3-28

3. BASIC MACHINE OPERATION 3.9.7

SETTING SELECTOR VALVE

For machines provided in nibbler and breaker specification, the selector valve installed on the back of boom is required to be switched to the position corresponding to the specification.

NOTE: • Inappropriate switching of the selector valve may cause decrease of work efficiency and machine damage.

•

Be sure to switch selector valve once or twice a month to avoid valve from sticking.

1. Tools Used SELECTOR VALVE

CIRCUIT

(A)

Main Circuit

TOOLS Spanner (24 mm) Allen Wrench (5 mm)

2. Setting Procedure

A

D

A

D B

N

B

B. Breaker

A

N

1. Use an allen wrench to loosen and remove the socket bolt.

2. Use a spanner to turn the selector valve to the proper position.

3. After the valve is in the proper position, tighten the socket bolt.

4. Markings of the selector valve are shown below.

N. Bi direction flow of Nibbler A. TO ATTACHMENT

C

C. TO CONTROL VALVE A6 PORT

C B

N

D. TO TANK 3.9.8

SETTING STOP VALVE

Stop valve on arm top end is used to stop hydraulic oil flowing.

Free (1) : Hydraulic oil flows.

Stop (2) : Hydraulic oil stops flowing.

Before removing attachment, set stop valve to "STOP" position.

B

1. Tools Used STOP VALVE

CIRCUIT

TOOLS

(B)

Main circuit

Spanner (24 mm) mm

24

1

3-29

2

3. BASIC MACHINE OPERATION

3.10

SAFETY PRECAUTIONS

The following safety precautions should be used in conjunction with all other safety precautions found in this MANUAL.

S WARNING READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS AND OPERATING PROCEDURES FOUND IN THIS MANUAL BEFORE OPERATING THE MACHINE OR ANY ATTACHMENT. USE FOR INTENDED PURPOSE Use the attachment only for its intended purpose. If not used in accordance with the manufactures instructions, the excessive pressure exerted on the boom, arm and frame structure of the machine will cause premature failure of the components.

PASSENGERS Never allow passengers on the attachment or machine.

PROTECTIVE EQUIPMENT Install protective guards on the machine and close the all window (1) to protect the operator from flying debris.

Also the operator and all personnel in the vicinity of the machine should wear protective gear such as safety shoes, hard hat, gloves and face shield or goggles.

1 CYLINDERS Do not operate boom, am or bucket cylinders to stroke ends when using a breaker attachment. Doing this can cause undue stress on the cylinder rods and result in damage.

3-30

3. BASIC MACHINE OPERATION AVOID CONTINUOUS OPERATION Operate the breaker or nibbler in one minute intervals.

Operation for longer than one minute at a time can cause high oil temperatures and damage the accumulators, cylinder seals and possibly pump damage.

HOSE SURGE Should the hydraulic hoses begin to surge or vibrate abnormally during operation of a breaker or nibbler, immediately stop operation and contact Dealer for assistance. This problem often is a result of damaged accumulators and can also result in valve failure.

DO NOT USE DROPPING FORCE Never use the dropping force of the attachment to break or drive objects. This will cause extensive damage to the attachment and machine structure.

DO NOT USE SLEWING FORCE Never use the slewing force of the machine for pushing or sliding objects. This will cause premature failure of the attachment and other machine components.

DO NOT LIFT Never use an optional attachment to lift or transport objects or material. Doing so can cause extensive damage to the attachment, the machine structures and cause injury or death.

3-31

3. BASIC MACHINE OPERATION WORKING RANGES

A

Never operate an optional attachment over the sides of the machine. Only operate over the front or rear of the tracks.

A. UNACCEPTABLE WORK RANGE

B

B

B. ACCEPTABLE WORK RANGE

A

3.11

MAINTENANCE FOR NIBBLER / BREAKER

3.11.1

REPLACEMENT SCHEDULE

It is necessary to perform the following maintenance schedule in regard to hydraulic oil and filters along with normal inspection and maintenance as described in Section 4 of this manual for the nibbler / breaker optional attachment.

REPLACEMENT SCHEDULE LOCATION

1st MAINTENANCE

2nd MAINTENANCE

REGULAR MAINTENANCE

Change Hydraulic Oil

Hydraulic tank

—

—

Every 600 hours

Return Filter Element Kit

Hydraulic Tank

50 hours

250 hours

Every 250 hours

COMPONENT

3.11.2

REINFORCEMENT OF ATTACHMENT

The use of machine with breaker and nibbler may cause damage of attachment. So contact your Dealer to reinforce arm.

3-32

3. BASIC MACHINE OPERATION

3.12

DOZER BLADE SAFETY PRECAUTIONS

Precaution on blade Be careful that blade does not contact boom cylinder and bucket while working with blade front side.

Precaution when placing attachment near side Be careful so that bucket and blade do not contact when placing front attachment near side in travel or transportation position.

Precaution on blade so as not to collide with rock, etc.

It may cause premature failure of blade and cylinder.

3-33

3. BASIC MACHINE OPERATION

3.13

CAUTION ON USING RUBBER SHOES

3.13.1

PROPER USAGE

The rubber shoe offers excellent features which a iron shoe does not possess.

However, if it is used the same way as the iron shoe, then its advantages can not be fully taken. Operation of the machine varies upon working site and conditions.

Comparison between rubber and iron shoes Rubber shoe

Iron shoe

Less vibration Smooth run Low noise Harmless for paved road Easy handling Not damageable Large traction force : Excellent,

: Good,

: Ordinary

Although the rubber shoe displays many advantages because of its material properties, it has disadvantages in terms of strength. It is therefore necessary to get fully familiar with the characteristics of the rubber shoe and observe what are prohibited and cautioned against, in order to extend the service life of the rubber shoe and have it fulfill its advantages to a maximum possible extent. Read thoroughly "CAUTIONS ON USAGE" before use.

GUARANTEE OF RUBBER SHOE Guarantee does not cover such damages done to the rubber shoe that result from improper working and/or operation as; execution of work in such places where there are steel plates, U-drains, block corners, sharp slashed gravel and stones, ferroconcrete debris, metal scraps and others which may tear off the rubber shoe, and neglect to observe prohibited operations.

3.13.2

PROHIBITED WORK

Do not carry out the following operations: 1. Do not operate and/nor travel in gravel-mixed land, rugged and solid rock bed, ferroconcrete, iron scraps, edges of iron plates.

2. Do not operate and/nor travel in such places as river beds where there are lots of stones of different sizes.

The rubber shoe tends to be damaged or come off from the rollers as the result of being caught in the grooves on the rubber shoes. The service life of the rubber shoe will be reduced if soil is pushed by force when the rubber shoe is slipping.

3-34

3. BASIC MACHINE OPERATION 3. Do not let oil, fuel, solvents, etc., come in contact with rubber shoes. If it does, wipe it off with a cloth immediately.

Do not travel on a puddle of oil, etc. on the road surface.

4. Do not enter such hot places as an open-air fire, steel plate left in the open sun.

Do not work in asphalt leveling.

5. When storing the machine for long period (more than three months), keep it indoors which will not be exposed to direct sunshine and rain.

6. If the machine travel using one side crawler, with the crawler of another side floating, the rubber shoe may come off from the rollers or be damaged.

3-35

3. BASIC MACHINE OPERATION 3.13.3

CAUTIONS ON USAGE

Use care of the following when working.

1. Rubber shoes slip easily on icy surfaces.

Take the necessary safety precautions, such as not driving on snowy/icy slopes.

2. Avoid making a spin turn on a concrete road.

3. Avoid abrupt change of directions because it will cause early wear or chipping of the rubber shoe.

4. Exercise care so the rubber shoe is not damaged by the bucket while working.

5. Do not operate the machine by pressing the bucket against concretes and walls.

6.

When the machine is lifted up by the attachment, lower it slowly.

7. If the machine is operated in salty corrosive places, the adhesion of the core metal of the shoe will get water after use.

8. The rubber shoe should be used within -25°C ~ +55°C (-13°F ~ 131°F), considering the physical properties of rubber.

NOTE: use the rubber shoe under proper tension to prevent it from coming off from the rollers. Operate the rubber shoe carefully even when tensioning is proper.

9. Avoid changing direction of the machine on ground with difference in level (about 20 cm/8 in). When crossing over a place where there is a difference in level, do it at right angles to the difference in level.

20 cm

3-36

3. BASIC MACHINE OPERATION 10. When climbing back on a slope, avoid changing direction of the machine while climbing on a point between a level ground and the slope.

11. If you travel on a slope or a concave with one side of the machine lifting, it will damage the rubber shoe.

Always travel with both sides of the machine in level.

12. Do not change direction of the machine with the rubber shoe on ground with high spots, as shown in the figure as it will cause the rubber shoe to come off or be damaged.

3-37

3. BASIC MACHINE OPERATION 3.13.4

INSPECTING RUBBER SHOE

Repair or replace rubber shoe if it falls into the following condition.

(Contact Dealer for repair or replacement of rubber shoes.)

1. The Height of Lug a. If the lug of height (A) wears off, traction force decreases. Replace the shoe with a new one if (A) gets down below 5 mm (0.2 in).

1

b. If the lug wears out at an extent that the steel cord in the shoe is exposed over two links, replace the shoe with a new one.

1. RUBBER SHOE

2

A

2. METAL CORE 3. STEEL CORD

4

3

4. LUG A. HEIGHT

3

2. Breakage of Steel Cord If the steel cords of the rubber shoe are broken (1) by more than one half of one side row, replace the shoe with a new one.

1 3. Crack of Rubber Shoe If a crack which has developed to about 60 mm (2.4 in) length is seen between the lug of rubber shoe, repair the shoe (1).

However, repair the shoe immediately if the steel cord inside is seen exposed even though a crack is small and short.

NOTE: for repairs or replacement of rubber shoes, contact Dealer.

A. REPAIR IS NEEDED B. REPAIR IS NOT YET NECESSARY

3-38

1 A

B

3. BASIC MACHINE OPERATION 3.13.5

ADJUSTING THE RUBBER SHOE TENSION

1. Adjust Every 50 Hours (After 30 Hours the First Time) a. Wash the area around the rubber shoes, then place the machine on the level ground. b. Lift the machine body by the use of the attachment.

90° 㨪 110

c. Measure the clearance "A" between the bottom surface of the frame and top surface of the clawler at the center of the crawler frame.

Standard clearance (A): 140 ~ 150 (5.5” ~ 5.9”)

S CAUTION

A

The rubber shoes have a joint (marked "M").

Bring the joint at the top center of the frame. If this is not does, the shoe will be too loose, and readjusting will be necessary.

S WARNING BECAUSE HIGH PRESSURE IS APPLIED TO THE GREASE CYLINDER, GREASE MAY SPOUT OUT WHEN THE GREASE NIPPLE IS LOOSENED, CAUSING A SERIOUS INJURY. KEEP YOUR FACE AWAY FROM THE GREASE NIPPLE AND LOOSEN IT GRADUALLY. THE GREASE NIPPLE MAY SPRING OUT BECAUSE OF THE INTERNAL HIGHPRESSURE GREASE. DO NOT LOOSEN THE GREASE NIPPLE MORE THAN ONE ROTATION.

3-39

M

3. BASIC MACHINE OPERATION

3.14

FLAGMAN HAND SIGNALS

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

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

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

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

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

3-40

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

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

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

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

3-41

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

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

COUNTER ROTATE LEFT 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.

COUNTER ROTATE RIGHT 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.

3-42

3. BASIC MACHINE OPERATION TRAVEL FORWARD Face machine operator, bend both elbows in, make fists and rotate fists one over the other in a reverse circular motion.

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

CLOSE BUCKET (BUCKET IN OR DIG) 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 reverse circular motion.

OPEN BUCKET (BUCKET OUT OR DUMP) Face machine operator, hold left hand in,open 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.

3-43

3. BASIC MACHINE OPERATION TURN LEFT 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.

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

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

MOVE SLOWLY 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.)

3-44

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

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

3-45

3. BASIC MACHINE OPERATION

3-46

4. MAINTENANCE

4-1

4. MAINTENANCE

4-2

4. MAINTENANCE

4.1

GENERAL INFORMATION

S CAUTION READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS CONTAINED IN THIS MANUAL BEFORE PERFORMING ANY INSPECTION OR MAINTENANCE PROCEDURES TO THIS MACHINE, ITS SYSTEMS OR COMPONENTS. 1. It is recommended by Manufacturer that an inspection and maintenance schedule be developed and maintained on a regular basis for this machine. Developing and maintaining such a schedule, helps to keep the machine in optimum operating condition.

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

NOTE: the inspection and maintenance charts provided give only general time intervals. It may be necessary to develop a custom schedule to perform machine maintenance at more frequent intervals based on the work conditions.

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

4.2

GENERAL SAFETY

DISPOSAL OF HAZARDOUS WASTE Dispose of waste oils, fluids, lubricants, filters and other hazardous waste properly.

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

4-3

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

HOT SURFACES & FLUIDS Use caution and wear the proper safety equipment when working around hot areas. Never change oils, engine coolant or filters immediately after a machine has been stopped. Allow machine to cool before performing maintenance procedures.

WARM ENGINE OIL Engine oil should have a temperature of 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.

"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.

INSPECT WASTE OILS AND FILTERS Before disposal, inspect all waste oils, fluids and filters for debris and foreign material (1).

It is recommended to cut open the oil filters to determine any abnormal wear.

1

4-4

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

S CAUTION Never allow a hydraulic line or component to become contaminated. This could cause severe system damage. Contact an authorized Dealer to obtain the proper caps and plugs to be used on this machine. Refer to specification’s section, 6-13, for proper part numbers.

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.

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

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

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

S WARNING NEVER USE GASOLINE, DIESEL FUEL OR OTHER FLAMMABLE SOLVENTS TO CLEAN PARTS. ALWAYS CLEAN PARTS IN A WELL VENTILATED AREA.

4-5

4. MAINTENANCE HYDRAULIC TANK PRESSURE

1

Always release the internal pressure of the hydraulic tank before performing inspection or maintenance procedures.

1. Push rubber cap "DOWN" to release air pressure in the reservoir (1).

S CAUTION Gasses from hydraulic tank may be hot.

Wear safety equipment.

HI

LO

WELDING SAFETY 1. Turn key switch to "OFF" position (1). Wait 4 seconds for electrical power to disconnect.

1

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

HE AT

OF

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

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

RELEASING HYDRAULIC SYSTEM

1

S WARNING NEVER CHANGE OILS OR FILTERS ON A MACHINE THAT HAS JUST FINISHED WORKING. ALLOW MACHINE TO COOL FIRST UNTIL OILS AND FLUIDS ARE WARM NOT HOT. RELEASE HYDRAULIC TANK PRESSURE BEFORE WORKING WITH ANY HYDRAULIC COMPONENT. 1. Select the hard and flat area and place the machine in the position (1).

2. Stop the engine.

3. Immediately after the engine stops, shift the R.H. and L.H. travel control levers shift forward and backward, operate the R.H. and L.H. control levers in full stroke several times, and release the internal pressure remaining in the hydraulic system.

4-6

F

ACC

ON T AR ST

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

4. MAINTENANCE

4.3

INSPECTION AND MAINTENANCE CHART

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

S WARNING

ENGINE

SYSTEM

READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS FOUND IN THIS MANUAL BEFORE PERFORMING INSPECTION & MAINTENANCE. INTERVAL (HOURS ON HOURMETER)

MAINTENANCE TO PERFORM

COMPONENT LOCATION

CHECK OIL LEVEL

REAR SIDE OF ENGINE

8

50

120

250

500

1,000 2,000

REF. PAGE # 4-14

CHECK COOLANT LEVEL RESERVOIR

4-14

CHECK FOR FLUID LEAKS COMPLETE ENGINE

4-15

CHECK BELT TENSION

FRONT OF ENGINE

4-15

CHECK FUEL LEVEL

GAUGE CLUSTER

4-16

CHECK AIR CLEANER

AIR CLEANER

4-17

CHECK ENGINE ELECTRICOMPLETE ENGINE CAL

4-18

DRAIN WATER FROM FUEL

FUEL TANK BOTTOM

4-28

CHANGE ENGINE OIL

OIL PAN

4-26, 4-42

CHANGE OIL FILTER

R.H. SIDE OF ENGINE

4-26, 4-42

CHANGE FUEL FILTER

L.H. SIDE OF ENGINE

4-44

DRAIN WATER SEPARATOR

SIDE OF FUEL TANK

4-29

CHECK AIR INTAKE SYSHOSES & CLAMPS TEM CHECK FAN ASSEMBLY

4-29

FRONT OF ENGINE

—

CHECK BELT TENSIONER FRONT OF ENGINE

4-41

CLEAN RADIATOR

RADIATOR

4-30

CLEAN DEBRIS SCREEN

BETWEEN RADIATOR AND OIL COOLER

4-30

CHANGE ENGINE COOLRADIATOR ANT

4-49

CHANGE AIR CLEANER ELEMENTS

AIR CLEANER

4-17

ADJUST VALVE CLEARANCE

ENGINE TOP

4-48

CHECK ENGINE COMPRESSION

ENGINE

4-48

CHECK INJECTION PRESENGINE SURE

4-46

4-7

ELECTRICAL

HYDRAULIC

SYSTEM

4. MAINTENANCE INTERVAL (HOURS ON HOURMETER)

MAINTENANCE TO PERFORM

COMPONENT LOCATION

HYDRAULIC OIL LEVEL

SIDE OF HYD TANK

4-18

CHECK HYDRAULIC FUNCTIONS

OPERATOR'S CONTROLS

4-20

CHECK FOR OIL LEAKS

HYDRAULIC SYSTEM

4-20

CHECK HOSES / LINES

HYDRAULIC SYSTEM

4-20

SWING FUNCTIONS

HYDRAULIC SYSTEM

4-18

CLEAN SUCTION SCREEN

HYDRAULIC TANK

4-51

CHANGE RETURN FILTERS

HYDRAULIC TANK

CHANGE HYDRAULIC TANK BREATHER

HYDRAULIC TANK

4-55

CHANGE HYDRAULIC OIL HYDRAULIC TANK

4-51

CLEAN HYDRAULIC TANK HYDRAULIC TANK

4-51

INSPECT ALL WIRING

4-21

8

50

120

250

500

1,000 2,000

REF. PAGE #

4-31 (Breaker)

COMPLETE MACHINE

BATTERY ELECTROLYTE BATTERIES

4-32

BATTERY SERVICE

4-32

BATTERIES

4-8

UPPER FRAME

SYSTEM

4. MAINTENANCE INTERVAL (HOURS ON HOURMETER)

MAINTENANCE TO PERFORM

COMPONENT LOCATION

HYDRAULIC FUNCTION OPERATION

OPERATOR'S CONTROLS

4-20

CHECK SWITCHES

OPERATOR CONSOLE

4-21

CHECK SLEWING BRAKE

OPERATOR'S CONTROLS

8

50

120

250

500

1,000 2,000

REF. PAGE #

—

CHECK WARNING LIGHTS CAB/FRAME/BOOM

4-21

CHECK BUZZER

OPERATOR'S CONTROLS

4-21

CHECK GAUGES

GAUGE CLUSTER

4-21

CHECK HORN

HORN SWITCH

4-21

CHECK GAUGE CLUSTER GAUGE CLUSTER

4-21

CHECK SLEWING REDUCTION OIL LEVEL & FILL

UPPER FRAME

4-36

SLEWING REDUCTION LUBRICATION

SLEWING REDUCTION

4-39

CHECK BOLTS/TORQUE

SLEWING RING

4-40

CHECK SLEWING RING & SIGHT WINDOW IN BATPINION GEAR TERY BOX

—

CHECK SLEWING RING SEAL

SLEWING RING

—

CHECK SWIVEL JOINT SEALS

SWIVEL JOINT

—

DRAIN WATER FROM LOWER FRAME CAVITY SLEWING RING GREASE DRAIN PORT BATH

4-53

GREASE SLEWING RING SLEWING RING

4-46

GREASE BOOM SWING

SWING CYLINDER & SWING BRACKET

4-39

CHANGE GREASE IN SLEWING RING GREASE REMOVE UPPER FRAME BATH

4-55

CHANGE SLEWING REDUCTION UNIT OIL

SLEWING MOTOR

4-54

CHECK BOLTS/TORQUE

COUNTERWEIGHT

4-40

4-9

ATTACHMENT

LOWER FRAME

SYSTEM

4. MAINTENANCE INTERVAL (HOURS ON HOURMETER)

MAINTENANCE TO PERFORM

COMPONENT LOCATION

CHECK FOR OIL LEAKS

COMPLETE SYSTEM

8

50

120

250

500

1,000 2,000

REF. PAGE # 4-20

CHECK LINES FOR DAMFRAME CAVITY AGE

4-20

CHECK STEPS

FRAME RAILS

4-21

CHECK FRAME STRUCTURE

ENTIRE FRAME

4-21

CHECK TRACKS & LINKS TRACKS

4-22

CHECK SPROCKET WEAR

REAR OF TRACKS

4-22

CHECK IDLER WEAR

FRONT OF TRACKS

4-22

CHECK ROLLER WEAR

TRACKS

4-22

CHECK TRACK TENSION RAISE TRACKS

4-24

ADJUST TRACK TENSION FRAME RAILS

4-24

CHECK TRAVEL REDUCTION UNIT OIL LEVEL & TRAVEL MOTORS FILL

4-37

CHANGE TRAVEL REDUCTRAVEL MOTORS TION UNIT OIL

4-53

CHECK BOLTS/HARDWARE

ENTIRE MACHINE

CHECK BOOM & ARM STRUCTURE

BOOM & ARM

— 4-25

CHECK BUCKET TEETH & BUCKET SIDE CUTTERS

4-25

GREASE BOOM PINS

BOOM

4-38

GREASE ARM PINS

ARM

4-38

GREASE BUCKET PINS

ARM & BUCKET LINK

(100h)

CHECK BLADE CUTTING BLADE EDGE GREASE DOZER BLADE PINS

4-34 4-25

DOZER BLADE

(100h)

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

4-10

4-34

4. MAINTENANCE

4.4

FLUIDS AND FILTERS

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

4.4.1

REQUIRED FLUIDS AND QUANTITIES TYPE OF FLUID

HYDRAULIC

ENGINE OIL

GEAR OIL

HYDRAULIC TANK

55 Liters (14 GAL)

HYDRAULIC SYSTEM

78 Liters (20 GAL)

ENGINE OIL PAN (H LEVEL)

9.2 Liters (2.4 GAL)

ENGINE OIL PAN (L LEVEL)

6.8 Liters (1.8 GAL)

UPPER ROLLER

20cc × 2 (1.2cu.in × 2)

LOWER ROLLER

90cc × 10 (5.5cu.in × 10)

IDLER

160cc × 2 (9.8cu.in × 2)

SWING MOTOR REDUCTION UNIT

1.5 Liter (0.4 GAL)

TRAVEL MOTOR REDUCTION UNIT

1.3 Liter × 2 (0.34 GAL × 2)

OPERATING LEVER JOINT EP GREASE

QUANTITIES REQUIRED

LOCATION OF USE

"U" JOINT EACH SIDE

ATTACHMENT PINS

13 PLACES 1 PLACE 90° × 4

SLEWING RING GEAR TRACK TENSION ADJUSTMENT

2 PLACES AS REQ’D

WITH LITHIUM BASE MoS2 GREASE SLEWING GEAR SUMP (BATH)

5 kg (11.0 lb)

RADIATOR

3.8 Liters (1.0 GAL)

ENGINE COOLANT

COOLING SYSTEM TOTAL VOLUME

10 Liters (2.6 GAL)

FUEL

FUEL TANK

85 Liters (22.5 GAL)

4.4.2

REQUIRED FILTERS SYSTEM

LOCATION OF FILTER USE RETURN FILTER ELEMENT KIT (STD & NIBBLER)

HYDRAULIC

TANK SUCTION STRAINER TANK BREATHER FILTER ELEMENT ENGINE OIL FILTER CARTRIDGE

ENGINE

AIR CLEANER INNER ELEMENT AIR CLEANER ELEMENT

FUEL OPERATOR CAB

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

4-11

4. MAINTENANCE 4.4.3

FLUIDS AND LUBRICANTS DESCRIPTION

ENGINE OIL-SAE 15W/40 (1 GALLON) ENGINE OIL-SAE 15W/40 (5 GALLON) ENGINE OIL-SAE 15W/40 (55 GALLON) HYDRAULIC OIL-AW 46 (5 GALLON) HYDRAULIC OIL-AW 46 (55 GALLON) GREASE EP/2-14 OUNCE GREASE EP/2-35 POUNDS GREASE EP/2-120 POUNDS GEAR OIL 80W90-5 GALLONS

4-12

4. MAINTENANCE 4.4.4

LUBRICANT SPECIFICATIONS

The following information is designed to allow usage of the proper oils, greases, fuels and coolants in various climates and certain working conditions.

LUBRICANT

CLIMATE ZONE

Hydraulic Oil FRIGID FRIGID (Anti-wear, antioxidant and non-foaming) -30°C ~15°C -20°C ~ 30°C *Note: Machines are shipped from factory (-22°F~59°F) (-4°F~86°F) with ISO VG32S hydraulic oil ISO VG22 ISO VG32

FRIGID ~ WARM -25°C ~ 40°C (-13°F~104°F) ISO VG32S*

LUBRICANT

CLIMATE ZONE

ENGINE OIL* A.P.I. classification for "service CD" *All engines shipped from factory with SAE30 or SAE15W40 oil according to ambient temperature in engine oil pan.

LUBRICANT

FUEL

LUBRICANT

GEAR OIL LUBRICANT GREASE

LUBRICANT ENGINE COOLANT (50% MIXTURE)

FRIGID -30°C ~ 30°C (-22°F~86°F) SAE10W30

WARM -5°C ~ 40°C (23°F~104°F) SAE15W40

VERY HOT 30°C and Above (86°F and Above) SAE15W50

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

WARM -5°C ~ -15°C (23°F~5°F)

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

ASTM D975 No.2

ASTM D975 No.2

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

ENGINE OIL (For general purpose lubrication) LUBRICANT

WARM VERY HOT -5°C ~ 40°C 5°C ~ 55°C (23°F~104°F) (41°F~131°F) ISO VG46 ISO VG68

For swing motor reduction unit and travel motor reduction Units Extreme pressure gear oil #90 grade GL-4 BY A.P.I. classification GENERAL LUBRICATION

SLEWING GEAR SUMP (BATH)

Extreme pressure multipurpose GREASE No.2 N.L.G.I. No.2 lithium base with MoS2 GREASE EP type grease Antifreeze (LLC) -34°C ~ (-29.2°F) Mixture ratio should prospect to 5°C (41°F) lower than the coldest temperature the machine will experience. Take into consideration wind chill factors.

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

1. There are two types of BIO OIL available; vegetable-based and synthetic-based. You are recommended to use the synthetic-based type, because the vegetable-based oil has a maximum usage temperature of 80°C (176°F).

Because of this, the degradation of vegetable-based oil occurs more rapidly, and caused reduced service life.

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

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

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

4-13

4. MAINTENANCE

4.5

PRE-START (EVERY 8 HOURS) INSPECTION & MAINTENANCE

The following procedures are to be performed every 8 hours or daily, before the machine is started.

S WARNING BE CAUTIOUS OF HOT FLUIDS AND SURFACES. WEAR GOGGLES, SAFETY SHOES, HARD HAT, WORK CLOTHES AND WORK GLOVES TO PERFORM INSPECTION AND MAINTENANCE ON THIS MACHINE. 4.5.1

ENGINE OIL LEVEL

1. Stop engine and raise engine bonnet.

2

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

3. If necessary to add oil, remove oil filler cap (1) and fill engine oil to proper level (2 liter) (3). Refer to 413 for oil specifications.

3 H L

NOTE: • In case of closed ventilation type (Ventilation valve and intake manifold are connected by hose), oil enters in cylinder through hose by rapid oiling in the condition where the filler port is blocked when oiling, causing engine trouble and accident.

•

1

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

4.5.2

ENGINE COOLANT LEVEL

1. Open radiator access cover and inspect coolant level in engine coolant reservoir (1) .

1. ENGINE COOLANT RESERVOIR

1 A

2. RADIATOR CAP A. PROPER LEVEL

2

2. Proper coolant level is between "FULL" (2) and "LOW" (3) marks.

3. If necessary to add coolant, remove reservoir cap and fill to proper level (A) with fresh coolant mixture.

Refer to 4-13 for proper coolant specifications.

4-14

3

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

2

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

4.5.3

ENGINE FLUID LEAKS

1. Inspect complete engine for signs of fluid leaks.

2. When inspecting around pressure lines and hoses use a stiff piece of cardboard (1).

1

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

4.5.4

FAN BELT WEAR AND TENSION

1. Inspect fan belt for excessive wear or damage.

2. Measure belt tension on the span of belt. Belt deflection should be 8 mm ~12 mm (0.3" ~0.5").

1 3

Force : Approx. 98N(22lbf,10kgf) 3. Loosen attaching nut (5) and adjusting nut (6), and adjust tension of belt.

4. Loosen adjusting bolt (7), adjust fan belt to the specified tension, and tighten attaching nut (5) and adjusting nut (6).

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

4

2 NOTE: when moving the alternator, try not to damage the stator coil section between the front and rear brackets or the bolts.

6

1. ALTERNATOR 2. CRANK PULLEY

7

3. IDLER PULLEY 4. COMPRESSOR 5. ATTACHING NUT 6. ADJUSTING NUT 7. ADJUSTING BOLT

5

4-15

4. MAINTENANCE 4.5.5

FUEL LEVEL

1. Turn key switch to "ON" position.

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

3. The fuel tank can be filled through the fuel filler cap located on top of the fuel tank or by using the auxiliary fuel pump located inside the battery access door. a. Filling tank through fuel filler cap 1. Open battery access cover with key switch key and fill tank to proper level with diesel fuel. Refer to 4-13 for fuel specifications. b. Filling tank using auxiliary fuel pump 1. Open battery access cover, remove the filter end of the fuel pump suction hose (1) from its storage housing and insert the fuel suction hose into fuel supply reservoir.

2. Locate the auxiliary fuel pump switch (2) inside the storage box access door.

Place the switch in the "ON" position. Place pump switch in the "OFF" position when fuel tank is full.

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

1

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

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

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

4-16

2

4. MAINTENANCE 4.5.6

AIR CLEANER

S CAUTION Wear protective glasses or goggles when using compressed air.

NOTE: •

Filter elements should not be changed until the engine air cleaner lamp lights on the gauge cluster panel.

•

The removal and cleaning of inner element are not allowed. It may cause engine trouble due to the entry of dust.

NOTE: cleaning and replacement of outer element.

Cleaning : When warning is indicated on gauge cluster.

Replacement : After cleaning of 6th time or an elapse of 1 year.

1. Cleaning or replacement of Outer Element

1

a. Open engine air cleaner access door (1) with starter switch key. b. Release clamp from the air cleaner cover (2). c. Remove the air cleaner outer element (3) from the housing. d. Clean the inside of air cleaner housing. e. To clean the outer element, blow compressed air (less than 0.7 MPa {100 psi}) up and down along the folds of the filter element interior (4) to remove clogged dust or other contaminants. f. After cleaning, use a light to check the inside of the element for tearing, pinholes, or packing damage. Replace with a new element if necessary. g. Set outer element, and install cover.

S CAUTION Carefully hold the O-ring, water inside cause engine failure. h. If the engine air cleaner warning lamp lights on the gauge cluster within the 6 times cleaning of outer element, replace the element with new one.

4-17

2

3

4

4. MAINTENANCE 2. Replacement of Inner Element

3

a. Remove the inner element (4).

4

b. Set new inner and outer elements (3), and install the cover.

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

4.5.7

ENGINE ELECTRICAL

1. Visually and manually inspect all engine electrical wiring, connectors and components for signs of damage and malfunction.

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

S WARNING OPERATING THE MACHINE WITH DAMAGED OR MALFUNCTIONING ELECTRICAL COMPONENTS CAN CAUSE SERIOUS DAMAGE TO THE MACHINE AND SERIOUS INJURY TO PERSONNEL. REPAIR OR REPLACE FAULTY COMPONENTS IMMEDIATELY. 4.5.8

HYDRAULIC OIL LEVEL

1. Place the machine in the oil check position on a firm surface.

2. Open hydraulic oil tank access cover and view the hydraulic oil level in the sight glass (1) on side of hydraulic oil tank. If low, add oil (4).

1

S WARNING FOR SAFE OPERATION ON INCLINES, THE HYDRAULIC OIL LEVEL MUST BE MAINTAINED BETWEEN "PROPER LEVEL" (3) AND "UPPER LIMIT" (2) MARK.

4-18

2 3 4

4. MAINTENANCE 3. Use the following instructions to add hydraulic oil :

1

a. Release hydraulic tank pressure (1).

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

b. Remove the six mounting bolts from the hydraulic suction screen cover plate (2).

2

c. Add hydraulic clean oil (4) through the suction screen, filling hydraulic tank to the proper level.

3

d. Before replacing filter cover, replace "O"-ring (3). e. Place new "O"-ring in seat. Place cover (5) over opening and install mounting bolts (6) with lockwashers. f. Torque mounting bolts to proper value. Refer to torque specifications table.

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

4-19

5

6

4

4. MAINTENANCE 4.5.9

BOOM SWING FUNCTIONS

1. Before starting the engine, check the installation of the swing unit, and swing cylinder, swing bracket, hoses, etc. for possible defect.

2. Start the engine, and ensure the operation while swinging.

1 4.5.10

2

HYDRAULIC FUNCTIONS

1. Check all hydraulic controls for proper functionality (1) before operating the machine.

1

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

4.5.11

HYDRAULIC OIL LEAKS

1. Check complete hydraulic system for leaks. Use a small piece of cardboard when checking areas with high pressure (1).

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

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

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

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

4-20

1

4. MAINTENANCE 4.5.12

MACHINE ELECTRICAL

1. Check all switches for proper operation.

3

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

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

4. Check all gauges and warning lamps on the gauge cluster panel for proper operation.

1

1

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

2

1

1. WARNING LAMPS 2. TRAVEL SPEED (2nd) 3. KPSS WORK MODE LAMPS

4.5.13

STEPS AND HANDRAILS

1. Inspect daily all mounting steps and handrails (1) on the machine to make sure they are clean and in safe working condition.

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

2

S CAUTION Use steps, and handrails when mounting and dismounting the machine. Keep steps, handrails and step rails clean and in safe working condition (2).

4.5.14

1

FRAME STRUCTURE

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

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

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

S WARNING DISCONNECT BATTERIES BEFORE WELDING ON THIS MACHINE. CONNECT WELDER GROUND CABLE 1M (3’3") AWAY FROM AREA TO BE WELDED.

4-21

4. MAINTENANCE 4.5.15

TRACKS AND COMPONENTS

1. Track shoes a. Visually inspect track shoes for signs of excessive wear or damage or bend (1 and 2).

12

1

b. Have all repair or replacement work done by Dealer. c. Check tightness of shoe attaching bolts and nuts.

If loose, torque to 294 ± 29 N•m (217 ± 22 lbf•ft) (3).

3

2. Track links a. Inspect links (4) for signs of excessive wear or damage. b. Have all repair or replacement work done by Dealer.

4

3. Sprockets a. Inspect sprockets (5) for excessive wear and damage. b. Should the sprockets require service, contact Dealer.

5

4-22

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

INSPECT THESE SURFACES

5. Rollers

A

a. Inspect rollers (6) for excessive wear and damage.

6

b. Should the rollers require service, contact Dealer.

A. LOWER ROLLER B. UPPER ROLLER

6

4-23

B

4. MAINTENANCE 4.5.16

TRACK TENSION

1. Operate slewing, arm, bucket and boom controls until machine is set up.

S WARNING SUPPORT BLOCKS.

LOWER

FRAME

WITH

SUITABLE

2. Measure the sag in the center of the track, between the bottom of the track frame and the track shoe surface.

3. To increase track tension, set machine and with grease gun inject extreme pressure No. 2 grease into idler adjustment grease nipple until proper tension is reached, frame opening to grease nipple (2).

Perform this procedure on both tracks.

200~230 mm (7.9"~9.1")

4. To decrease track tension, set machine up and carefully loosen grease nipple to allow grease to escape.

5. Tighten grease nipple.

1

S WARNING GREASE IN TRACK TENSIONING MECHANISM IS UNDER EXTREME PRESSURE AND CAN PENETRATE SKIN CAUSING SEVERE INJURY. KEEP FACE AND BODY AWAY FROM GREASE NIPPLE AREA. NEVER LOOSEN GREASE NIPPLE MORE THAN ONE COMPLETE TURN. IF GREASE DOES NOT RELEASE AFTER ONE TURN OF THE NIPPLE, CALL AN AUTHORIZED SERVICE DEALER FOR ASSISTANCE. 6. Start engine and operate the travel motor for the track being adjusted, back and forth. Recheck track tension and adjust if needed.

7. Perfome steps 1 through 6 on the opposite track if needed.

4-24

1

4. MAINTENANCE 4.5.17

BOOM AND ARM

1. Inspect boom and arm structures for signs of excessive wear and damage (1).

2. Should repair or replacement be necessary, contact Dealer.

1

S WARNING DISCONNECT BATTERIES BEFORE WELDING ON THIS MACHINE. CONNECT WELDER GROUND CABLE 1M (3’-3") AWAY FROM AREA TO BE WELDED.

4.5.18

BLADE, CUTTING EDGE, BUCKET TEETH & SIDE CUTTERS

1. Inspect bucket teeth and side cutters for signs of excessive wear and damage (1).

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

1

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

3. Inspect cutting edge for signs of excessive wear and damage (2).

4. Should repair or replacement be required, contact Dealer for proper advice.

4-25

2

4. MAINTENANCE

4.6

50 HOUR (WEEKLY) & NEW MACHINE BREAK-IN INSPECTION & MAINTENANCE PROCEDURES

Change the engine oil and filter on a new machine after the first 50 hours of operation. Then change the engine oil at every 500 hours of operation.

NOTE: one new oil filter is shipped with the machine in the support kit. This is to be used at the 50 hour oil & filter change.

4.6.1

CHANGING ENGINE OIL AND/OR FILTER

S WARNING DO NOT CHANGE OIL ON A MACHINE THAT HAS JUST STOPPED WORKING. THE OIL WILL BE EXTREMELY HOT. ALLOW THE ENGINE TO COOL UNTIL OIL IS JUST WARM BEFORE CHANGING. 1. Move machine to firm level ground.

2

2. Remove the four bolts on the under cover directly below the engine (2).

3. Prepare container to receive drain oil.

• Container capacity : 11 litter or more.

4. Open engine cover with engine key.

5. Clean around oil filler cap (1), remove cap and loosen drain plug of oil pan to drain oil.

When oil drain hose connecting type is used, loosen drain cap by hand, connect drain hose to oil drain and put the other top end of hose in container, and then start draining.

2

1

NOTE: • Check the waste oil. If there are metal chips or powder mixed in the oil, contact Dealer.

• The oil filter can not be reused because it is cartridge type.

1. OIL FILLER CAP 2. DRAIN PLUG 3. DRAIN PORT 4. ENGINE OIL FILTER

3

5. FILTER WRENCH 6. RATCHET HANDLE 7. MUFFLER 6. Tighten drain plug securely.

When oil drain hose connecting type is used, remove drain hose and attach drain cap (3).

7. Prepare container to receive drain oil.

• Container capacity : 300 ml or more

4-26

4. MAINTENANCE 8. Loosen plug (2) of filter base and drain oil contaminated in filter through drain port (3).

9. Tighten drain plug (2) securely.

2

3 10. Attach filter wrench (5) to engine oil filter (4).

5

6

11. Attach ratchet handle (6) to filter wrench (5) and remove oil filter (4) turning the handle in counterclockwise direction.

NOTE: be careful not to spill oil remained in filter when removing filter.

4

12. After cleaning filter base, apply clean engine oil (8) on gasket section of new oil filter (4) and turn it in clockwise direction by hand until the gasket comes into touch to seal surface. Partially fill filter with oil before installing.

13. Tighten it 1 and 1/4 turns with filter wrench (5) from this condition.

4-27

8

7

4. MAINTENANCE 14. Draw out oil level gauge and supply the specified engine oil through oil filler port gradually taking care not to block the filler port.

Identify the appropriate oil type and oil quantity referring to pages 4-13.

• Total oil quantity to be changed: 10.3 liters (2.7 Gal)

A NOTE: in case of closed ventilation type (Ventilation valve and intake manifold are connected by hose), oil enters in cylinder through hose by rapid oiling in the condition where the filler port is blocked when oiling, causing engine trouble and accident.

15. Attach oil filler cap (1) and clean spilled oil completely. Do not block the oil filler with mouth jug and pour oil in slowly (A).

16. Check that oil level is between the upper and lower limits of level gauge, and then start engine.

Keep idling for several minutes, and check that oil filter attaching face is free from oil leak.

17. Stop engine and identify the oil level in about 30 minutes.

When shortage, make up the specified engine oil.

18. Close engine cover and lock it with engine key.

19. Attach under cover with four bolts.

4.6.2

FUEL TANK DRAIN

1. Locate and open fuel tank drain valve (1) on bottom of fuel tank.

2. Allow all water and sediment to drain from fuel tank into a waste container, then close the drain valve.

1

4-28

4. MAINTENANCE 4.6.3

WATER SEPARATOR

The water separator isolates water that mixes in with the fuel. The case is equipped with a float (1). When water accumulates, the float (1) rises. When the float (1) rises to the level line (2), drain the water.

1. Loosen the drain plug (3) to drain the water.

1. FLOAT 2. LEVEL LINE (RED) 3. DRAIN PLUG 4. GAUGE FILTER (IN)

2

5. GAUGE FILTER (OUT) 2. When the float (1) comes down to the bottom, close the drain plug (3).

1

3. Check that fuel is not leaking.

Drain water whenever the float (1) rises to the level line, regardless of inspection time.

3

S CAUTION Clean up all spilled fuel to avoid a fire.

Dispose of all hazardous waste in accordance with government environmental regulation.

4 5

NOTE: remove the gauge filter and clean it with light oil.

Cleaning interval is every 1,000 hours of operation.

4.6.4

AIR INTAKE SYSTEM

Inspect all hoses and clamps of the air intake system on a new machine after the first 50 hours of operation.

Then at every 500 hours of engine operation.

1. Inspect all hoses for damage and tighten all hose clamps.

2. Replace any hose found to be damaged before allowing any operation of the machine.

A. HOSE & CLAMPS FROM AIR CLEANER HOUSING B. HOSE & CLAMPS FROM AIR CLEANER

4-29

A

B

4. MAINTENANCE 4.6.5

RADIATOR, OIL COOLER AND DEBRIS SCREEN

1. Clean radiator after every 50 hours of operation using pressurized water.

S CAUTION Do not use high pressure water as it will bend the radiator fins. Use standard water pressure.

2

2. Open engine air cleaner access door (1) and engine cover (2) for cleaning the radiator and oil cooler.

1 3. Open engine cover (2) and remove the wing bolts (3) retaining the debris screen (4). Carefully remove debris screen (4) and clean with pressurized water.

4

3

4

4. Remove wash out access cover (5), bolts (6) from bottom of machine.

5

5. Rinse all dirt and debris from engine compartment.

Reinstall debris screen and wash out access cover (5).

S CAUTION Be careful not to bend or damage cooling fins of the radiator or oil cooler. Replace debris screen if damage is found. Repair damaged cooling fins of radiator and oil cooler.

4-30

6

4. MAINTENANCE 4.6.6

HYDRAULIC RETURN FILTERS

Change the hydraulic tank return filters on a new machine after the first 50 hours of engine operation then change every 1,000 hours.

NOTE: • One new hydraulic return filter is shipped with the machine in the support kit. This is to be used at the 50 hours filter change.

•

Move machine to firm leveled ground and place attachment in oil level check position.

•

Long-life return filter is used. Place an order of return filter element kit.

1. Release hydraulic tank pressure (1).

1

S WARNING NEVER CHANGE OILS OR FILTERS ON A MACHINE THAT HAS JUST FINISHED WORKING. ALLOW MACHINE TO COOL FIRST UNTIL OILS AND FLUIDS ARE WARM NOT HOT. RELEASE HYDRAULIC TANK PRESSURE BEFORE WORKING WITH ANY HYDRAULIC COMPONENT. 2. Remove the cover and the six mounting bolts (1) (2) and spring washer (2) from the hydraulic return cover (3).

2

S CAUTION Slowly remove the mounting bolts. The filter cover plate is under spring tension.

3. Remove "O"-ring (6), spring (4) and bypass valve (5).

4. Remove the filter assy (A) from the housing.

5. Replace "O"-ring (6) fitted to mating surface of cover (3) with new one.

(1) (2)

6. Assemble long-life return filter element kit (A) and place it in.

NOTE: 1. The top and bottom direction of element (B) is previously given.

Don’t fail to assemble the kit directing the side marked "TOP" upward.

2. The joint (C) must be assembled giving a special attention, because the joint (C) fitted once cannot be disassembled.

7. Install cover (3) plates and torque attaching bolts (1) to proper value. Refer to specifications section for torque value.

4-31

(3)

(6) (B)

(6)

(C) (A)

(4) (5)

(B) (B) (C) (B)

(A)

4. MAINTENANCE 4.6.7

BATTERIES

Perform complete battery service on a new machine after the first 50 hours of engine operation.

Then, check electrolyte (acid) every 50 hours.

S WARNING 1. WEAR SAFETY CLOTHES, GOGGLES OR FACE SHIELD, GLOVES AND SAFETY SHOES WHEN WORKING WITH BATTERIES. 2. WORK IN A WELL VENTILATED AREA. 3. BATTERY ELECTROLYTE (ACID) IS CORROSIVE. IF IT COMES IN CONTACT WITH SKIN, EYES OR CLOTHING, FLUSH WITH LARGE AMOUNTS OF WATER AND SEEK IMMEDIATE MEDICAL ATTENTION. 4. BATTERY ELECTROLYTE (ACID) PRODUCES HYDROGEN GAS THAT IS HIGHLY EXPLOSIVE. DO NOT ALLOW NEAR SPARKS, FIRE OR FLAMES AND DO NOT SMOKE WHEN WORKING WITH BATTERIES. 1. Open battery box access cover (1).

2. Remove battery cell caps (4) and visually inspect electrolyte (acid) level (2). Proper level is 10 ~ 15 mm (0.4" ~ 0.6") above cell plates (3).

3. If necessary, fill each cell to proper level with distilled water only.

4. Remove cables from terminals and clean with hot water. Coat each terminal with a thin layer of petroleum jelly. Clean cables in the same manner and reinstall onto battery.

5. If cables are found to be in poor condition, replace with new parts immediately.

S WARNING PREVENT BATTERY EXPLOSION

1

•

Batteries give off hydrogen gasses that can explode and cause personal injury.

•

Keep sparks, open flames and cigarettes away from batteries.

•

Keep metallic articles away from batteries.

•

Keep all ventilation caps tightly secured.

•

Never check charge by placing metal articles across battery terminals.

•

Leave battery box open to improve ventilation when charging.

6. Use a hydrometer to check the specific gravity of each cell. Compare readings to the chart below.

2 10 ~ 15 MM (0.4" ~ 0.6")

3

NOTE: use hydrometer according to its manufacturer’s instructions.

4

4-32

4. MAINTENANCE 7. When disconnecting batteries, remove the negative (–) cable first. When connecting batteries, connect the negative (–) cable last.

8. When the battery requires charging; a. Disconnect battery cables from terminals. b. Remove all cell caps. c. Check for proper electrolyte (acid) level. d. Connect charger leads to the proper battery terminals.

S CAUTION

AMBIENT TEMPERATURE

Make certain not to cross positive and negative terminals when connecting charger.

CHARGE

20°C (68°F)

0°C (32°F)

-10°C (14°F)

e. Stop charge if battery overheats.

100 %

1.26

1.27

1.28

f. Periodically check the specific gravity of the batteries with a hydrometer. Stop charging batteries when 100% charged.

90 %

1.24

1.25

1.26

80 %

1.22

1.23

1.24

75 %

1.21

1.22

1.23

NOTE: battery life can be shortened by over discharging of the battery. Replace any battery that will not hold charge or is difficult to charge.

4-33

4. MAINTENANCE

4.7

100 HOUR (MONTHLY) INSPECTION & MAINTENANCE PROCEDURES

NOTE: perform all pre-start (Every 8 hour and 50 hour) inspection & maintenance procedures along with the following 100 hour inspection and maintenance procedures.

4.7.1

ATTACHMENT LUBRICATION

Use extreme pressure multi-purpose grease No.2 EP type grease. Lubricate all points until grease purges.

NOTE: if attachment is sank in water, it is recommended to lubricate it every 8 hours.

1.Idler link and bucket pin.

2.Bucket cylinder rod end.

3.Arm top pin.

4.Bucket link pins.

2

5.Bottom bucket link pin.

4 1 3 5

4.7.2

DOZER BLADE LUBRICATION

Lubricate dozer blade pins every 100 hours of engine operation. Use extreme pressure multipurpose No. 2 EP type grease. Lubricate all points until grease purges.

1.Dozer cylinder rod and head.

2.Dozer blade link pin.

4-34

4. MAINTENANCE 4.7.3

REPLACEMENT OF CUTTING EDGE (OPT)

Check cutting edge of the blade for damage. If severe damage or wear is detected, replace it.

1. Remove sand and soil adhered around mounting capscrews, and then cut capscrews by means of gas cutting and remove cutting edge.

2. Clean contact surface of it and install new cutting edge.

Don't fail to replace capscrews and nuts with new ones at the same time when the cutting edge is replaced.

Torque value : 279 ± 29 N•m {206 ± 21 lbf•ft} Apply loctite #262 or equivalent.

NOTE: the delay of replacement may cause damage of blade.

We recommend to replace it a little ahead of schedule.

4-35

4. MAINTENANCE

4.8

120 HOUR INSPECTION & MAINTENANCE PROCEDURE

4.8.1

SLEWING MOTOR REDUCTION OIL

Check the oil level of the swing motor reduction unit on a new machine after the first 50 hours of engine operation.

Then check every 120 hours.

1. Locate the dipstick (2) on the side of the slewing motor (1) . Pull dipstick (2) , wipe clean and reinsert all the way in.

1

1. SLEWING MOTOR 2. DIPSTICK 3. FILL PLUG

2

4. DRAIN PORT 2. Pull dipstick (2) and read oil level.

3. If necessary to add oil, remove plug (3) from oil fill port and fill to full level with proper oil. Refer to 4-13 for oil specifications.

3

S CAUTION Reduction unit may be under pressure.

Remove plug slowly.

4.

To drain oil from swing motor reduction unit;

4

a. Locate drain port (4) under rear of machine. b. Place a 2 liter (0.5 gallon) container under drain port (4) and remove plug allowing oil to drain into container. c. Replace plug and tighten securely after all oil is drained. d. Fill through fill port using proper oil. Refer to 413 for oil specifications.

S WARNING NEVER CHANGE OILS OR FILTERS ON A MACHINE THAT HAS JUST FINISHED WORKING. ALLOW MACHINE TO COOL FIRST UNTIL OILS AND FLUIDS ARE WARM NOT HOT.

4-36

4. MAINTENANCE 4.8.2

TRAVEL MOTORS REDUCTION OIL

Inspect oil level of travel motor reduction unit on a new machine after the first 50 hours of engine operation. Then check every 120 hours.

1. Move machine to a firm, level surface. Operate travel until "FILL" plugs (1) on travel motors are at top.

1

2. Stop engine and remove the travel motor reduction unit oil level plug (2). If oil just seeps from the port, oil level is correct.

2

S WARNING TRAVEL REDUCTION UNIT COULD BE UNDER PRESSURE. CAREFULLY LOOSEN PLUG AND REMOVE SLOWLY FILL AIR PRESSURE IS RELEASED. 3. To add oil, remove the oil fill plug (1) and add extreme pressure gear oil #90 grade GL-4 until oil just begins to flow from this plug.

NOTE: capacity of each travel motor reduction unit is 1.3 liters (0.34 Gallons).

4. To drain oil, remove fill plug (1) and drain plug (3).

Allow oil to drain into a 2 liter (0.5 Gal) capacity container. Replace drain plug (3), remove lever plug (1) and fill through fill port using extreme pressure gear oil #90 grade GL-4.

5. Replace all plugs and tighten securely.

NOTE: to replace oil in travel motors, please refer to 2,000 hour maintenance in this section.

4-37

3

4. MAINTENANCE

4.9

250 HOUR (3-MONTH) INSPECTION & MAINTENANCE PROCEDURE

NOTE: perform all pre-start (Every 8 hour and 50 hour) inspection & maintenance procedures along with the following 250 hour inspection and maintenance procedures.

4.9.1

ATTACHMENT LUBRICATION

Lubricate attachment pins every 250 hours of engine operation. Use extreme pressure multi-purpose No. 2 EP type grease. Lubricate all points until grease oozes.

NOTE: if attachment is sank in water, it is recommended to lubricate it every 8 hours.

1. Boom cylinder head and rod pins.

1. BOOM 2. BOOM CYLINDER ROD PIN 3. BOOM CYLINDER HEAD PIN

1

4. ARM CYLINDER HEAD PIN 5. BOOM FOOT PIN (CENTER)

2

6. ARM TO BOOM PIN 7. ARM CYLINDER ROD END 8. BUCKET CYLINDER ROD END 2. Boom foot pin (5).

3

3. Arm cylinder head pin (4).

4. Arm cylinder rod end (7).

5. Arm to boom pin (6).

6. Bucket cylinder head end (8).

5 4 6

7 8

4-38

4. MAINTENANCE 4.9.2

BOOM SWING LUBRICATION

Lubricate boom swing pins every 250 hours of engine operation. Use extreme pressure multipurpose No. 2 EP type grease. Lubricate all points until grease purges.

NOTE: if attachment is sank in water, it is recommended to lubricate it every 8 hours.

(2)

1. Swing cylinder head and rod pins.

2. Swing bracket pins.

(1) (1)

4.9.3

SLEWING REDUCTION LUBRICATION

Apply the following grease through the grease nipple of the slewing reduction unit after 250 hours 1st time, and every 1,000 hours thereafter.

1. Grease it through the grease nipple until the grease is extruded through the relief valve.

1. GREASE NIPPLE 2. RELIEF VALVE

2 1 4.9.4

AIR CONDITIONER FILTERS

A. Cleaning recirculate and fresh air filters.

Recirculate air filter ......... Every 500 hours Fresh air filter ................. Every 250 hours

4-39

4. MAINTENANCE 1. Cleaning fresh air filter a. Loosen 3 bolts under operator’s seat, and remove cover (1).

1

1. COVER 2. COVER 3. FRESH AIR FILTER 4. RECIRCULATE AIR FILTER A. MACHINE FRONT b. Remove cover (2), and take fresh air filter (3) out. c. Blow compressed air to clean fresh air filter (3).

NOTE: water washing is not allowed to clean air filter because it is paper filter.

4 3

d. Cleaning about 10 times is allowed, or replace it with new one every two years.

2

A

2. Cleaning recirculate air filter a. Raise recirculate air filter (4) slightly, and pull it out. b. Clean it with water or compressed air blow.

NOTE: washing with organic solvent (gasoline, trichlene, thinner, etc.) is strictly prohibited. c. When frequently clogged, or damage is serious, replace it with new one. d. After drying, set outside and recirculate air filters (4) and install cover (2).

4.9.5

INSPECTING COUNTERWEIGHT ATTACHING BOLTS FOR LOOSENING

Check bolts and nuts for loosening (1). Correct torque is 490 ± 49 N•m (361 ± 36 lbf•ft).

S CAUTION Striking counterweight against obstruction may cause loosening of bolts. Check bolts for loosening after 50 hours the first time, and every 250 hours after that.

1

TORQUE SPECIFICATION (Apply Loctite #262): 490 ± 49 kgf·m (361 ± 36 lbf·ft)

4-40

4. MAINTENANCE 4.9.6

BELT TENSIONER (FAN & AIR CONDITIONER)

Inspect belt tensioner assembly on a new machine after the first 50 hours of operation. Then at every 250 hours of engine operation.

1. Measure belt tension on longest span of belt. Belt deflection should be 8 mm to 12 mm.

2

Force : Approx. 98 N (22lbf, 10kgf)

3 BELT

DEFLECTION

Fan belt

8 mm to 12 mm (0.3” to 0.5”)

Air Conditioner

10 mm to 12 mm (0.4” to 0.5”)

1. ATTACHING NUT

1

2. ADJUSTING NUT 3. ADJUSTING BOLT 4. ADJUSTING BOLT

4

5. IDLER PULLEY

5

6. COMPRESSOR 2. Loosen attaching nut (1) and adjusting nut (2) , and adjust tension of belt.

3. Loosen adjusting bolt (3) , adjust fan belt to the specified tension, and tighten attaching nut (1) and adjusting nut (2).

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

5. Adjust the tension of belt of air conditioner turning adjusting bolt (4) of idler pulley (5).

4-41

6

4. MAINTENANCE

4.10

500 HOUR INSPECTION & MAINTENANCE PROCEDURES

Perform all other inspection & maintenance procedures as previously described in this section.

4.10.1

ENGINE OIL AND FILTER ELEMENT

S WARNING DO NOT CHANGE OIL ON A MACHINE THAT HAS JUST STOPPED WORKING. THE OIL WILL BE EXTREMELY HOT. ALLOW THE ENGINE TO COOL UNTIL OIL IS JUST WARM BEFORE CHANGING. 1. Move machine to firm level ground.

2

2. Remove the four bolts (2) on the under cover directly below the engine.

3. Prepare container to receive drain oil.

• Container capacity : 11 litter or more.

4. Open engine cover with engine key.

2 5. Clean around oil filler cap (1), remove cap and loosen drain plug of oil pan to drain oil.

When oil drain hose connecting type is used, loosen drain cap by hand, connect drain hose to oil drain and put the other top end of hose in container, and then start draining.

1

NOTE: • Check the waste oil. If there are metal chips or powder mixed in the oil, contact Dealer.

• The oil filter can not be reused because it is cartridge type.

1. OIL FILLER CAP

3

2. DRAIN PLUG 3. DRAIN PORT 4. ENGINE OIL FILTER 5. FILTER WRENCH 6. RATCHET HANDLE 7. MUFFLER 6. Tighten drain plug securely.

When oil drain hose (3) connecting type is used, remove drain hose (3) and attach drain cap.

7. Prepare container to receive drain oil.

• Container capacity : 300 ml or more

4-42

4. MAINTENANCE 8. Loosen plug (2) of filter base and drain oil contaminated in filter through drain port (3).

9. Tighten drain plug (2) securely.

2

3 10. Attach filter wrench (5) to engine oil filter (4).

5

6

11. Attach ratchet handle (6) to filter wrench (5) and remove oil filter (4) turning the handle in counterclockwise direction.

NOTE: be careful not to spill oil remained in filter when removing filter.

4

12. After cleaning filter base, apply clean engine oil (8) on gasket section of new oil filter (4) and turn it in clockwise direction by hand until the gasket comes into touch to seal surface. Partially fill filter with oil before installing.

13. Tighten it 1 and 1/4 turns with filter wrench (5) from this condition.

4-43

8

7

4. MAINTENANCE 14. Draw out oil level gauge and supply the specified engine oil through oil filler port gradually taking care not to block the filler port.

Identify the appropriate oil type and oil quantity referring to pages 4-13.

• Total oil quantity to be changed: 10.3 liters (2.7 Gal)

A NOTE: in case of closed ventilation type (Ventilation valve and intake manifold are connected by hose), oil enters in cylinder through hose by rapid oiling in the condition where the filler port is blocked when oiling, causing engine trouble and accident.

15. Attach oil filler cap (1) and clean spilled oil completely. Do not block the oil filler with mouth jug and pour oil in slowly (A).

16. Check that oil level is between the upper and lower limits of level gauge, and then start engine.

Keep idling for several minutes, and check that oil filter attaching face is free from oil leak.

17. Stop engine and identify the oil level in about 30 minutes.

When shortage, make up the specified engine oil.

18. Close engine cover and lock it with engine key.

19. Attach under cover with 4 bolts.

4.10.2

FUEL FILTER

S WARNING CLEAN UP ALL SPILLED FUEL. FUEL OIL IS HIGHLY FLAMMABLE. SPILLED FUEL CAN CAUSE FIRES. 1. Use the filter wrench to remove the fuel filter (1) and replace it with a new one.

NOTE: The fuel filter is cartridge type, and so cannot be reused.

1

1. FUEL FILTER A. REMOVAL B. INSTALLATION 2. Clean the seal face of the filter base. Before installing the fuel filter (1), apply clean fuel oil to the sealing face.

3. Install the fuel filter (1) and screw it by hand until it contacts the filter base. Then use the filter wrench to tighten the filter 2/3 turn.

4-44

A

B

4. MAINTENANCE 4.10.3

BLEEDING AIR FROM THE FUEL SYSTEM

S WARNING CLEAN UP ALL SPILLED FUEL. FUEL OIL IS HIGHLY FLAMMABLE. SPILLED FUEL CAN CAUSE FIRES. If air contaminates the fuel system, the engine may become hard to start or it malfunction. Bleed the air whenever the fuel tank is empty, the water separator (1) is drained, or the fuel filter element is replaced.

1. Air bleeding procedure

2

a. Fill fuel tank with fuel. b. Check that air bleed plug (2) on upper part of water separator (1) and drain plug (3) are tightened.

1

c. Loosen air bleed screw (4), turn upper section of pump counterclockwise, and move feed pump (5) up and down until fuel mixed without foams flows out.

NOTE: never loosen plug on upper section of water separator when bleeding air.

Loosening of the plug does not allow bleeding of air.

3

d. Tighten air bleed screw (4).

Tighten air bleed screw (4) after moving feed pump (5) up and down until the movement becomes heavier.

4

e. After starting engine, check fuel system for leakage.

5

4.10.4

BLEEDING AIR IN FUEL SYSTEM (AUTO AIR BLEEDING DEVICE / OPTION)

This machine is equipped with fuel pump (1) under the engine.

1. Air bleeding procedure a. Fill fuel tank with fuel. b. Turn starter key ON, and fueling pump starts operating for approx. two minutes and bleed air automatically.

1. FUEL PUMP 2. FUEL FILTER

1

4-45

2

4. MAINTENANCE 4.10.5

GREASING THE SLEWING RING

1. Locate the grease nipple (1) at the front of the slewing ring.

2. Using grease gun filled with general purpose EP grease (Refer to 4-13), lubricate slewing ring with several shots from grease gun.

3. Slew machine 90° right, and repeat step 2. See level on frame.

4. Continue to slew machine at 90° increments and lubricating slewing ring until ring has been completely greased.

4.10.6

1

CHECKING SLEWING RING FITTING BOLTS FOR LOOSENING

Check that bolts (1) securing slewing ring (2) are not loosened. If loosened, remove bolts (1) once, apply Loctite #262 or equivalent, and tighten them again.

3

Torque specification

2

Outer race : 157 ± 16 N•m (116 ± 14 lbf•ft) Inner race : 279 ± 29 N•m (206 ± 22 lbf•ft) Alternately tighten bolts (1) facing each other in order.

1

1. BOLTS 2. SLEWING RING

4

3. BALL 4. LOWER FRAME NOTE: since the tightening of slewing ring requires special tools, contact Dealer for assistance.

4.10.7

FUEL SYSTEM INJECTION PRESSURE AND NOZZLE CONDITION (ATOMIZATION)

Perform this inspection and adjustment every 500 hours of engine operation. Contact Dealer for assistance.

Initial injection pressure : 18.1 MPa (2,625 psi)

4-46

4. MAINTENANCE 4.10.8

CHECKING THE AIR CONDITIONER REFRIGERANT

1. Start the engine. Set the engine speed to the middle speed position.

2

4

2. Set the machine to the conditions shown below when checking the refrigerant. a. Air conditioner switch (1) : “ON” b. Fan switch (2) : HI position (Maximum

)

c. Temp. adjustment switch (3) : Lower temp position (

)

3

d. Door / Window : Close e. Compressor switch (4) : “ON” (The

1

lamp lit up)

3. Follow the procedure below and check the refrigerant volume by looking through the sight glass (inspection window) on the upper part of the receiver dryer. See right table for better reference.

Refrigerant volume

Description

(A) Proper

→

Figure (A) : shows that the refrigerant volume is proper.

→

After the air conditioner is turned ON, little bubbles appear. The refrigerant becomes transparent, then turns a light milky white.

Figure (B) : shows that the refrigerant is over charged. This will make both high and low pressure extreme and exert a bad influence on the pressure switch operation and the air conditioning system.

(B) Overcharged

→

After the air conditioner is turned ON, no bubbles appear.

(C) Insufficient

Figure (C) : shows that the refrigerant is insufficient. Have the refrigerant recharged at your Dealer.

NOTE: • New refrigerant (HFC-R134a), whose characteristics are different from conventional CFC-12, is used in this machine. Do not mix HFC-R134a with CFC-12.

• Keep the air conditioner ready for use all year round.

Operate the air conditioner at least once every week for several minutes to rotate the compressor regardless of the season. This will prevent the refrigerant gas from leaking from the compressor sealing.

→

→

→

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.

4-47

4. MAINTENANCE

4.11

1000 HOUR (12-MONTH) INSPECTION & MAINTENANCE PROCEDURES

4.11.1

ENGINE VALVE CLEARANCE

Check and adjust the engine valve clearance every 1000 hours of engine operation.

Contact Dealer for assistance.

NOTE: Adjust exhaust and intake valves at 0.4 mm (0.016") (With cold engine) 4.11.2

ENGINE COMPRESSION PRESSURE

Check engine compression every 1000 hours of engine operation. Contact Dealer for assistance.

NOTE: compression pressure : 2.9 MPa (426 psi) at 200 min-1 at engine temperature between 82 ~ 95 °C (180 ~ 203 °F) 4.11.3

INSPECTION OF STARTER AND ALTERNATOR.

Check starter and alternator every 1000 hours of engine operation. Contact Dealer for assistance. It is necessary to disassemble these components for proper cleaning and inspection.

4.11.4

ENGINE FUEL INJECTION TIMING

Check engine fuel injection timing every 1000 hours of engine operation. Contact Dealer for assistance.

NOTE: injection timing : Before top dead centre 10 ± 1°

4-48

4. MAINTENANCE

4.12

2000 HOUR INSPECTION & MAINTENANCE PROCEDURES

Perform all other inspection & maintenance procedures as previously described in this section.

4.12.1

CHANGE ENGINE COOLANT

S WARNING BE CAUTIOUS OF HOT FLUIDS AND SURFACES. WEAR GOGGLES, SAFETY SHOES, HARD HAT, WORK CLOTHES AND WORK GLOVES TO PERFORM INSPECTION AND MAINTENANCE ON THIS MACHINE. ALLOW ENGINE TO COOL BEFORE CHANGING FLUIDS. 1. Raise engine bonnet and slowly remove radiator cap (5).

5

2. Locate coolant drain access cover (1) under L.H. rear of machine. Remove the four retaining bolts.

3. Locate radiator drain valve (3), place a 12 liter (3.0 Gal) capacity container under drain tube and turn drain valve (3) counterclockwise to open.

4. After drainage, close drain valve (3) and drain plug (2), and feed water in it.

5. Open drain valve (3) and drain plug (2). And clean it with flowing water for 10 minutes in low idling state.

Be careful that water hose is not disconnected from water feeding port of radiator while cleaning and flowing water.

6. After cleaning, stop engine, and also stop water feeding.

Then after draining water, close drain valve (3) and drain plug (2).

7. After draining, clean it with radiator flush.

Clean it following instruction manual for flush in use.

4-49

1

2

3

4. MAINTENANCE 8. After cleaning, open drain valve (3) and drain plug (2), then close them after completely draining water, and fill it with water and clean out radiator flush material completely.

2

3

NOTE: never spill the coolant on the ground that can cause the environmental pollution.

Expected minimum temperature

Long life coolant

-14.5° C (5.9° F)

30% mixed

-34° C (-29.2° F)

50% mixed

Change contaminated and foamy coolant with new one as soon as possible.

Cooling water other than long life coolant should be changed two times a year, in spring and autumn.

9. Fill radiator with water, open drain valve (3) and drain plug (2), and clean it flowing water with engine in a low idling state until clean water is flowing out.

Adjust water feeding and draining so as to keep radiator in full condition.

10. After clean water has drained out, stop engine and close drain valve (3) and drain plug (2).

Fill with "long life coolant" in appropriate concentration.

Refer to 4-13.

11. Run engine at low idling for 5 minutes and high idling for 5 minutes to bleed air contaminated in coolant (with cap of radiator removed).

12. Drain coolant in reservoir, clean inside of reservoir (4) and fill it up with long life coolant in appropriate concentration to mid point of FULL (A) and LOW (B).

4

13. Stop engine, fill it with water to the top of radiator about 3 minutes later, and tighten cap.

A

14. Return engine bonnet and access door to the closed position respectively.

B

NOTE: total cooling system volume is approximately 10 liters (2.6 Gal).

4-50

4. MAINTENANCE 4.12.2

CHANGE HYDRAULIC OIL

NOTE: the following procedures are to be used for normal changing of the hydraulic oil only.

If necessary to change the hydraulic oil viscosity, change hydraulic oil due to hydraulic component failure or changing main pump, contact Dealer for assistance.

S WARNING BE CAUTIOUS OF HOT FLUIDS AND SURFACES. WEAR GOGGLES, SAFETY SHOES, HARD HAT, WORK CLOTHES AND WORK GLOVES TO PERFORM INSPECTION AND MAINTENANCE ON THIS MACHINE. ALLOW HYDRAULIC OIL TO COOL BEFORE CHANGING. 1. Move the machine to a firm, level surface and place the attachment in the hydraulic oil check position.

NOTE: if machine is cold, warm the hydraulic oil by operating attachment controls before placing machine in the hydraulic oil check position.

1. COVER 2. BOLT 3. SPRING WASHER 4. O-RING 5. SUCTION STRAINER 6. HYDRAULIC TANK 7. SUCTION STOPPER ASSEMBLY 8. SUCTION TUBE 9. HYDRAULIC OIL LEVEL SIGHT GLASS A. PROPER LEVEL B. UPPER LIMIT C. LOW (ADD OIL) 2. Release hydraulic tank pressure (10).

Clean area around cover (1) of dirt and debris.

2 10

4-51

4. MAINTENANCE 3. Slowly remove the six retaining bolts (2) from the suction strainer cover plate (1).

2

4. Remove "O"-ring (4), and suction strainer (5) from hydraulic tank (6).

1

3

4

5

5. Install special suction stopper (7), over suction tube (8) inside hydraulic tank (6). Put environmental warning about spilling and safe disposal.

6

NOTE: never spill the hydraulic oil on the ground, that can cause the environmental pollution.

7

8 6. Remove cover plate under hydraulic tank (6) and locate the hydraulic drain plug on bottom of hydraulic tank (6).

6

7. Place a 60 liter (16 Gal) capacity container under drain plug. Remove plug and allow all oil from hydraulic tank (6) to drain onto container.

8. After all oil has drained, carefully and thoroughly clean inside of hydraulic tank (6).

9. Replace drain plug and tighten securely.

10. Remove suction stopper (7) and clean outside of suction tube (8) with a clean, dry cloth.

11. Carefully inspect suction strainer (5) for damage.

If any damage is found, replace strainer with new part.

12. Install strainer assembly onto suction tube (8).

13. Install new "O"-ring, in cover plate mounting surface groove and install suction strainer cover plate (1) onto hydraulic tank (6). Make certain plate boss is inside suction strainer holder.

14. Torque retaining bolts (2) to proper value. Refer to specifications section.

4-52

2 3

1 4

5

4. MAINTENANCE 15. Fill hydraulic tank to proper level (A) with fresh, clean hydraulic oil through hydraulic return filter.

9

S CAUTION Use same viscosity oil in hydraulic tank as was drained.

Refer to 4-13 for oil specifications.

B A

NOTE: this machine was shipped from the factory with ISO VG32S viscosity hydraulic oil in hydraulic system.

4.12.3

C

CHANGE OIL IN TRAVEL MOTOR REDUCTION UNITS

Change the travel reduction units oil on a new machine after the first 500 hours of engine operation then change every 2000 hours.

S WARNING NEVER CHANGE OILS OR FILTERS ON A MACHINE THAT HAS JUST FINISHED WORKING. ALLOW MACHINE TO COOL FIRST UNTIL OILS AND FLUIDS ARE WARM NOT HOT. 1. Move machine to a firm, level surface. Operate travel until "FILL" plugs (1) on travel motors are at top.

1

2. Stop engine and remove the travel motor reduction unit oil Level plug (2). If oil just seeps from level port, oil level is correct.

2

3. To add oil, remove the oil fill plug (1) and add until oil just begins to flow from level plug (2).

4. To drain oil, remove fill plug (1) and drain plug (3).

Allow oil to drain into a 2 liter (0.5 Gal) capacity container. Replace drain plug (3), remove lever plug (1) and fill through fill port using extreme pressure gear oil #90 grade GL-4.

NOTE: capacity of each travel motor reduction unit is 1.3 liters (0.34 Gallons).

5. Replace all plugs and tighten securely.

4-53

3

4. MAINTENANCE 4.12.4

CHANGE OIL IN SLEWING REDUCTION UNIT

Change the swing reduction unit oil on a new machine after the first 500 hours of engine operation then change every 2000 hours.

S WARNING NEVER CHANGE OILS OR FILTERS ON A MACHINE THAT HAS JUST FINISHED WORKING. ALLOW MACHINE TO COOL FIRST UNTIL OILS AND FLUIDS ARE WARM NOT HOT. 1. Remove the drain plug on the rear lower side of the slewing reduction unit to drain oil to the container.

1

1. SLEWING MOTOR 2. DIPSTICK

2

3. FILL PLUG 4. DRAIN PORT 2. Clean the drain plug seal it with teflon tape, and install.

3

3. Remove the oil filler plug (3) and fill with extreme pressure gear oil #90 grade GL-4.

4. Using the dipstick (2) , confirm that the extreme pressure gear oil #90 grade GL-4 levels is within the designated range.

5. Clean the fill plug (3) and install.

NOTE: capacity of each slewing reduction unit is 1.5 liters (0.4 Gallons).

4-54

4

4. MAINTENANCE 4.12.5

CHANGE GREASE IN SLEWING RING GREASE BATH

1. Drain water by removing drain plate (1) located in lower frame cavity.

S CAUTION If the slewing ring ever becomes submerged in water, it is mandatory that the sump bath grease be changed.

2. To replace the slewing bath grease it is necessary to remove the upper frame. Contact Dealer to do it.

1

SUMP BATH GREASE QUANTITIES GREASE TYPE is N.L.G.I.LITHIUM BASE W/MoS2: 5 kg (11.0 lb)

4.12.6

HYDRAULIC TANK BREATHER

1. Release hydraulic tank pressure (1).

1

S WARNING THE TEMPERATURE OF HYDRAULIC OIL IS HIGH IMMEDIATELY AFTER STOPPING THE OPERATION. SPECIAL ATTENTION MUST BE PAID WHEN RELEASING THE PRESSURE BECAUSE HOT GASES MAY ERUPT.

1. RUBBER CAP

1

2. NUT 3. BREATHER HOUSING

2

4. FILTER 2. Remove rubber cap (1) and nut (2) .

3. Remove breather housing (3) .

4 3

4-55

4. MAINTENANCE 4. Remove old filter (5), clean mounting surfaces and install new filter.

5.

Install breather housing (3) .

6.

Install retaining nut (2) and tighten securely.

Torque : 8 to 10 N•m (5.9 to 7.4 lbf•ft)

5

7. Install rubber cap (1).

4.12.7

ATTACHMENT AND DUST SEALS

1. Bucket Clearance a. Inspect bucket clearance (1) frequently for wear.

If clearance between bucket and bucket link and/ or between arm and bucket is greater than 1.2 mm (0.05") adjust clearance according to bucket manufacturers instructions.

S CAUTION

1

Set the safety lock lever to the locked position and stop the engine when adjusting the clearance of the bucket.

STANDARD CLEARANCE OF THE BUCKET (A):1.2 mm (0.05") or less

1

b. Lower the bucket onto the ground to stabilize, as shown in the right figure. c. Move the O-ring (1) from its normal position to the bucket boss (2) . d. Slightly rotate in the left direction to slightly push the arm end to the bucket left side (where no clearance adjusting mechanism is equipped). e. Set the safety lock lever to the locked position; then stop the engine. f. Measure the clearance (A) between the arm and bucket boss (2) . If the measurement value is 1.0 mm (0.04") or more, adjust the clearance. g. Five shims (3) 1.0 mm (0.04") on the average are inserted in the three capscrews (4) at the clearance adjusting part. Loosen every capscrews (4) and remove shims (3) corresponding the clearance. h. Tighten the capscrews (4) equally to the specified tightening torque.

Tightening torque : 115 ± 12 N•m (85 ± 9 lbf•ft) i. Return the O-ring (1) to the normal position.

4-56

2 4 3

(A)

1

4. MAINTENANCE 2. Reversing Backhoe Bucket a. Move the machine to a firm, level surface and rest the bucket on the ground, making certain the bucket is stable.

b. Remove flexible ring and pin (1) , and also remove main pin (2) and link pin (3) . c. Clean pins and pin hole, and apply grease on it.

1

d. Carefully remove main pin (2) and link pin (3) attaching arm and bucket link to bucket. e. Rotate bucket 180° or move machine, install arm and bucket link in their respective positions.

NOTE: make certain "O"-rings are on bucket boss for reinstallation. f. Roll "O"-rings into grooves between bucket / arm and bucket / bucket link. g. Align each pin holes, insert main pin (2), and fit flexible ring and pin (1).

NOTE: inspect "O"-rings for damage or excessive wear. If worn or damaged replace with new parts to protect seals, pins and surfaces from dirt and debris which can cause premature failure.

4-57

3 2

3

2

4. MAINTENANCE 3. Dust Seals a. The attachment incorporates several dust seals that should be periodically checked for damage and excessive wear. b. If excessive wear or damage is found, remove seal and replace with new parts.

NOTE: order the following part numbers for replacement seals: • BOOM FOOT (2 Req’d) • ARM to BOOM (2 Req’d) • ARM to IDLER LINK (2 Req’d)

A

• BKT CYLINDER to BKT LINK (4 Req’d) • ARM to BUCKET (2 Req’d) • BOOM CYLINDER HEAD (2 Req’d) • BOOM CYLINDER ROD (2 Req’d)

3

• ARM CYLINDER HEAD AND ROD (4 Req’d) • BKT CYLINDER HEAD AND ROD (4 Req’d) 1. SEAL 2. BUSHING 3. BOSS A. LIP OUT c. Install replacement seals (1). d. Make certain pin surface and tapered end are smooth and free from all burrs or imperfections.

Rough pin surfaces can cause damage to the new seals.

2 1

4.12.8

WINDSHIELD WASHER RESERVOIR

Fill the windshield washer fluid reservoir as required using approved windshield washing fluid.

1. Open engine radiator access door to locate washer fluid reservoir.

2. Pull cap off and fill with proper windshield washing fluid (1).

3. Replace cap (1) and reposition engine radiator access door.

4-58

1

4. MAINTENANCE

4.13

MISCELLANEOUS

4.13.1

FUSES

Follow the procedures below to replace "blown" or faulty fuses.

1. Move seat and seat base completely forward.

2. Remove fuse box cover from fuse box (1).

3. Locate and remove faulty fuse. Replace fuse with same amperage fuse as removed.

1

NOTE: NEVER REPLACE A FAULTY FUSE WITH A HIGHER AMP FUSE. NEVER USE A "JUMPER" IN PLACE OF A FUSE. NEVER SPLICE ACCESSORIES DIRECTLY INTO FUSE TERMINALS. 4. Refer to fuse box cover for fuse amperage and their functions.

20

19

18 20

17

10

16

20

15

30

20

20

14

12

13

10

10 20

10

10

10

11

10

10

10

10

20

4

10 9 No. AMPS

FUNCTION

1

10 A

Controller (CPU)

2

10 A

Wiper, Washer Relay

3

10 A

Cigarette Lighter 24V

4

10 A

DC to DC converter

5

10 A

Horn

6

NONE None

7

NONE None

8

20 A

Fuel pump

9

10 A

DC to DC Converter, Engine Room Lamp, Dome Lamp

10

20 A

Starter Switch

11

10 A

Travel Alarm

12 13

NONE None 10 A

Gauge Cluster

14

20 A

Wiper, Washer

15

10 A

Solenoid Valve (Lever lock)

16

20 A

Working Light

17

30 A

CAB Working Light

18

20 A

Heater, Air Conditioner

19

10 A

Air Conditioner

20

20 A

Spare 24 V

4-59

8

7

6

5

3

2

1

4. MAINTENANCE 4.13.2

PERIODICAL INSPECTION ITEMS

Since there is no definite time table for the replacement of hydraulic lines, tubes and hoses, inspect the following periodically for tightness and signs of damage. Replace all damaged lines, tubes and hoses with new parts. Refer to the parts manual for correct part numbers when ordering.

S WARNING DO NOT BEND, STRIKE OR DAMAGE HIGH PRESSURE LINES. DO NOT INSTALL BENT OR DAMAGED LINES, TUBES OR HOSES. REPLACE ALL DAMAGED LINES, TUBES AND HOSES IMMEDIATELY. TIGHTEN ALL LOOSE FITTINGS AND CONNECTIONS TO THE PROPER TORQUE VALUE. CLEAN UP ALL FUEL AND OIL SPILLS IMMEDIATELY TO HELP PREVENT FIRES. NEVER USE HANDS TO CHECK FOR LEAKS CAREFULLY INSPECT ALL LINES, TUBES AND HOSES FOR: 1. Fittings & connections damaged or leaking.

2. Outer covering of hoses worn, cut or damaged exposing wire reinforcement.

3. Hose swelling or "ballooning".

4. Evidence of hose being kinked or collapsed.

5. Steel protective covering worn or damaged.

6. Loose fittings and connections.

MAKE CERTAIN ALL CLAMPS, GUARDS AND HEAT SHIELDS ARE IN PLACE AND SECURE. THIS WILL HELP PREVENT VIBRATION, EXCESSIVE WEAR OF COMPONENTS AND EXCESSIVE HEAT DURING OPERATION. 1. Heater Hoses Inspect the heater hoses (1) between heater and engine for signs of damage and wear.

1

2. Boom Hoses & Tubes Inspect boom head and rod hoses and tubes (2) for damage, wear and loose connections.

2

4-60

4. MAINTENANCE 3. Arm Hoses & Tubes Inspect arm head and rod hoses and tubes (3) for damage, wear and loose connections.

3

4. Bucket Hoses & Tubes Inspect bucket head and rod hoses and tubes (4) for damage, wear and loose connections.

4

5. Fuel Lines and Hoses Inspect fuel lines and hoses for damage, wear and loose connections. Repair or replace fuel lines and hoses before operating the machine.

6. Hydraulic Suction Tubes & Hoses

5

Inspect all hydraulic tubes and hoses (5) for damage, wear and loose connections.

7. Radiator Hoses & Cap Inspect the radiator hoses (6) for signs of damage or deterioration. Replace hoses if found to be in bad condition. Inspect the radiator cap seal for signs of damage and deterioration and replace with new part if found to be in bad condition.

6

4-61

4. MAINTENANCE 8. Foam Seals Inspect the foam rubber seals (7) around the radiator, oil cooler and on the engine cover. Make certain they are in place and secure to prevent overheating of the engine.

7

9. Fuel Filler Strainer Inspect the fuel filler strainer (8) beneath fuel filler cap for damage, dirt and debris. Make certain the strainer is clean and in place before fueling the machine. If the strainer is damaged, replace with a new part.

8

NOTE: do not remove this strainer to refuel machine.

To do so may allow dirt and debris to enter fuel tank.

10. Fuel Lines and Hoses Inspect fuel lines and hoses (9) for damage, wear and loose connections. Repair or replace fuel lines and hoses before operating the machine.

9

4-62

4. MAINTENANCE 11. Rear View Mirrors Inspect the rear view mirrors. Make certain both sides rear view mirrors are in place, properly adjusted, clean, and in good condition. Secure them tight to prevent them from breaking.

4-63

4. MAINTENANCE 4.13.3

MACHINE STORAGE

Perform the following procedure to prepare the machine for long term storage.

1. Perform all inspection and maintenance procedures as previously described in this section.

2. Thoroughly clean the machine, inspect for damaged or worn parts and components and replace or repair all damaged or worn parts.

S CAUTION Protect CPU and all electrical components from water and steam when cleaning the machine.

3. Completely fill fuel tank with fresh, clean fuel to aid in preventing condensation of moisture inside the fuel tank.

4. Move machine to an indoor location for storage.

5. Operate bucket and arm completely "IN" extending cylinders. Then lower boom until attachment is resting on the floor.

6. Coat cylinder rods with a heavy coat of grease to prevent corrosion during storage (1).

7. Remove batteries and store in a well ventilated, warm area.

1 4.13.4

CARE DURING STORAGE

1. Every 30 days during storage, it will be necessary to start and run the machine to circulate the fluids through the systems. Before starting clean cylinder rods and after running re-grease cylinder rods.

NOTE: run and operate machine for approximately 1 hour to allow all fluids to circulate well and reach normal operating temperatures.

4.13.5

REMOVING MACHINE FROM STORAGE

1. Perform all Inspection and maintenance procedures as described in this section before bringing machine out of storage for normal operation.

2. Remove drain plugs from travel motor and slewing gear reduction units to drain off any moisture which may have accumulated during storage.

3.

Carefully and closely inspect all hydraulic hoses after long periods of storage for signs of deterioration. Replace all hoses showing these signs.

4-64

4. MAINTENANCE

4.14

INSPECTION MAINTENANCE CHECK LIST

MACHINE MODEL:________________ SERIAL No.:________________ MACHINE HOURS:________________

ITEM

OK

MAINT.PERFORMED

ITEM

ENGINE OIL LEVEL ENGINE COOLANT LEVEL CHECK FOR FLUID LEAKS CHECK BELT TENSION CHECK FUEL LEVEL DRAIN WATER SEPARATOR CHECK AIR CLEANER CHECK ENGINE ELECTRICAL DRAIN WATER FROM FUEL CLEAN PRE-FILTER BOWL CHANGE ENGINE OIL CHANGE OIL FILTER CHANGE FUEL FILTER CHANGE WATER SEPARATOR CHANGE COOLANT FILTER CHECK AIR INTAKE SYSTEM CHECK FAN ASSEMBLY CHECK BELT TENSIONER CHECK VIBRATION DAMPER CLEAN RADIATOR CLEAN DEBRIS SCREEN CHANGE ENGINE COOLANT AIR CLEANER ELEMENTS ADJUST VALVE CLEARANCE CHANGE EITHER CYLINDER HYDRAULIC OIL LEVEL CHECK HYDRAULIC FUNCTIONS CHECK FOR OIL LEAKS CHECK HOSES/LINES CLEAN SUCTION SCREEN CHANGE RETURN FILTER PILOT MANIFOLD FILTER CHANGE HYDRAULIC OIL CLEAN HYDRAULIC TANK INSPECT ALL WIRING BATTERY ELECTROLYTE BATTERY SERVICE

OK

MAINT.PERFORMED

HYDRAULIC FUNCTION OPERATION CHECK SWITCHES CHECK TRAVEL ALARM CHECK SLEWING BRAKE CHECK WARNING LIGHTS CHECK BUZZER CHECK GAUGES CHECK HORN CHECK DISPLAY MONITOR SLEWING REDUCTION OIL SLEWING RING GEAR GREASE BATH LEVEL SLEWING RING PINION SLEWING RING SEAL SWIVEL JOINT SEALS DRAIN WATER FROM BATH GREASE SLEWING RING CHANGE GREASE BATH CHECK BOLTS/HARDWARE CHECK FOR OIL LEAKS CHECK LINES FOR DAMAGE CHECK STEPS CHECK FRAME STRUCTURE CHECK TRACKS & LINKS CHECK SPROCKET WEAR CHECK IDLER WEAR CHECK ROLLER WEAR CHECK TRACK TENSION ADJUST TRACK TENSION TRAVEL REDUCTION OIL CHECK BOOM & ARM BUCKET TEETH SIDE CUTTERS GREASE BOOM PINS GREASE ARM PINS GREASE BUCKET PINS CHECK COOLANT ADDITIVE

These item include non-equipped part by the machine specification.

MECHANIC: SIGNATURE:

4-65

DATE:

4. MAINTENANCE

4-66

5. TRANSPORTATION

5-1

5. TRANSPORTATION

5-2

5. TRANSPORTATION

5.1

GROUND TRANSPORTATION

5.1.1

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, trusses and traffic flow on route.

3. Obtain any permits required from proper government agencies for transport of machine.

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.

6,760 mm (22´-2 )

2,600 mm (8´-6 ) 1,200 mm (3´-11 )

3,800 mm (12´-6 )

1,650 mm (5´-5 )

Dimensions and weights are with 1.80 m (5´-11 ) arm, 0.28 m3 (0.37 cu.yd) bucket and 3.72 m (12´-2 ) boom.

450 mm (17.7) Shoe weight: 8,000 kg (17,640 lb) NOTE: this illustration is for demonstration purposes only. Always, make sure to check actual dimensions after machine is loaded on trailer.

5-3

5. TRANSPORTATION 5.1.2

LOADING THE MACHINE

S WARNING

2

1

LO

1. Apply parking brakes on tractor and trailer and chock trailer wheels before attempting to load or unload machine.

2. Lower ramps of trailer.

3. Place travel speed select switch (1) on travel lever in 1st (T) speed position and move throttle control (2) to the "LO" idle position.

4. Slowly travel machine up trailer ramps and over rear axles of trailer.

S WARNING TO PREVENT THE ARM AND BUCKET CYLINDER (S) FROM ANY DAMAGE, YOU ARE ADVISED TO FOLLOW THE FOLLOWING INSTRUCTIONS. DO NOT HAVE THE ARM AND/OR BUCKET CYLINDER FULLY EXTENDED TO A "RAMP OVER CENTER" SITUATION. THIS ALLOWS SUDDEN AND ABRUPT CONTACT OF THE ARM OR BUCKET TO A TRAILER DECK, RAMP (1) OR THE GROUND. THIS CAN RESULT IN INTERNAL MECHANICAL CONTACT, WHICH CAN STRETCH THE CYLINDER ROD(S).

BE SURE TO TURN THE AUTO ACCEL RELEASE SWITCH "OFF". THE OPERATION IN THE CONDITION WHERE THE AUTO ACCEL RELEASE SWITCH "ON" MAY CAUSE THE SUDDEN CHANGE OF ENGINE SPEED. PLEASE PUSH A SIDE WITHOUT THE MARK OF AN AUTO ACCEL SWITCH, AND CHANGE INTO THE CONDITION OF RELEASE. IF THE MACHINE IS OPERATED WITH AN AUTO ACCEL SWITCH NOT CANCELED, ENGINE SPEED MAY CHANGE SUDDENLY.

1

5. Slowly travel machine completely onto trailer until in proper transport position.

6. Slowly slew machine 180° until attachment is toward rear of trailer.

7. Slowly lower boom and dozer blade until attachment rests on trailer bed.

5-4

HI

NEVER ATTEMPT TO LOAD OR UNLOAD MACHINE WITHOUT RAMPS. NEVER USE ATTACHMENT AS AN AID IN LOADING OR UNLOADING THE MACHINE.

5. TRANSPORTATION 8. Place safety lock lever in the up "LOCKED" position (2).

2

9. Turn machine "OFF", remove Key and lock all doors, filler caps and access panels.

S CAUTION Place a cover over the exhaust pipe of the machine and secure to avoid water entering the engine.

5-5

5. TRANSPORTATION 5.1.3

SECURING MACHINE TO TRAILER

1. Use cable or wire rope with sufficient capacity to secure front and rear of the machine to trailer (1).

Chock the tracks, use the lower frame front and rear brackets to secure machine to trailer (2). Also, make sure to secure front and rear of each track.

2. Securely fasten all loose parts, as well as removed parts to trailer or transporting platform.

S CAUTION

1

Place hardwood or steel block between cables and crawler frame to prevent damage to the tracks from cables during lifting.

2

A - FRONT (Between 1st front roller)

B - REAR (Between the last two rollers)

420 mm (1’-5”)

220 mm (8.7”)

A B

5-6

5. TRANSPORTATION

5.2

LIFTING MACHINE

The following procedures are for lifting the machine, as built by Manufacturer. These procedure do not take into account modifications made to the machine that affect machine weight or center of gravity (1).

1. Locate lifting locations at the front and rear of each crawler frame.

2. Attach cables or wire rope with a capacity rating sufficient to lift the machine, at lifting locations.

S CAUTION Place a hardwood or steel block between cables and crawler frame (2) to prevent damage to the tracks from cables during lifting.

3. Bring loose ends of cables together at machine center of gravity and attach to an overhead lifting device with a rated lifting capacity sufficient to lift the machine.

NOTE: it may be necessary to place reinforced spreader bars between lifting cables to prevent damage to the machine during lifting.

4. Slowly lift and move machine to desired location.

S WARNING •

•

ALWAYS USE PROPER LIFTING EQUIPMENT AND DEVICES. USE OF IMPROPER LIFTING EQUIPMENT COULD ALLOW THE LOAD TO SHIFT OR FALL CAUSING SEVERE DAMAGE, SERIOUS INJURY OR DEATH. DO NOT USE COUNTERWEIGHT LIFTING EYES TO LIFT WHOLE MACHINE. LIFTING EYES CAN FALL UNDER THIS LOAD RESULTING IN PERSONAL INJURY. REFER TO OPERATOR’S MANUAL FOR PROPER WAY OF LIFTING MACHINE.

ITEM

SIZE

Q.TY

CABLE (A)

ø 25 X 13.3 m

1

CABLE (B)

ø 25 X 13.4 m

1

3.6 m

2

SPREADER BARS (C)

(4 ° )

°)

0

(1

B

A

1,800mm (5´-11 )

TOOLS

3,100mm (10´-2 )

1

650 mm (25.6 )

550 mm (21.7 )

2

WEIGHT ARM SHOE 1.

2.

: 8,000 kg (17,640 lb) : 1.8 m (5’-11”) : 450 mm (17.7”) CENTER OF GRAVITY PLACE BLOCK

5-7

(45 ° )

°)

(45

3,600mm (11´-10 )

C

5. TRANSPORTATION

ITEM

SIZE

Q.TY

CABLE (A)

ø 25 X 13.3 m

1

CABLE (B)

ø 25 X 13.4 m

1

3.6 m

2

SPREADER BARS (C)

(4 °)

A

°)

(10

B

1,800mm (5´-11 )

TOOLS

3,100mm (10´-2 )

1

550 mm (21.7 )

650 mm (25.6 )

2 WEIGHT

: 8,020 kg (17,680 lb)

ARM

: 2.07 m (6’-9”)

SHOE

: 450 mm (17.7”) 1. CENTER OF GRAVITY 2. PLACE BLOCK

5-8

(45 ° )

°)

(45

3,600mm (11´-10 )

C

5. TRANSPORTATION

5.3

LIFTING MACHINE (WITHOUT ATTACHMENT)

Lift up machine without attachment is the procedure described above.

S WARNING DO NOT USE COUNTERWEIGHT LIFTING EYES TO LIFT WHOLE MACHINE. TOOLS SIZE

Q.TY

CABLE (A)

ø 25 X 13.4 m

1

CABLE (B)

ø 25 X 13.3 m

1

3.6 m

2

SPREADER BARS (C)

(1

0 °)

1,800mm (5´-11 )

ITEM

°)

(4

B

A

3,100mm (10´-2 )

1

650 mm (25.6 )

550 mm (21.7 )

2 WEIGHT

: 6,940 kg (15,300 lb)

SHOE

: 450 mm (17.7”) 1. CENTER OF GRAVITY 2. PLACE BLOCK

5-9

(45 ° )

°)

(45

3,600mm (11´-10 )

C

5. TRANSPORTATION

5.4

SHIPPING DIMENSIONS

5.4.1

MACHINE WITH ATTACHMENTS Refer to the following figure for reference in regards to the machine basic dimensions, as manufactured, with standard attachments: a. Standard boom : 3.72 m (12’-2") b. Standard arm : 1.8 m (5’-11") c. Bucket : 0.28 m3 (0.37 cu•yd) d. Shoe : 450 m (17.7")

1070mm (3·-6") 565mm (1·-10") 250mm (9.8")

mm 650 ") 1 R ·-5 (5

*750mm (2·-6")

2240mm (7·-4") 2860mm (9·-5") 1430mm (4·-8") 2090mm (6·-10") 6760mm (22·-2") 7200mm (23·-7")

3730mm (12·-3")

* Marked dimension do not include height of shoe lug.

5-10

260mm (10.2")

*380 mm (15·)

2600mm (8·-6")

460mm (18.1") 550mm (21.7")

2380mm (7·-10")

2170mm (7·-1")

450mm (17.7") 2320mm (7·-7")

5. TRANSPORTATION BOOM WITH ARM CYLINDER Boom mm (ft-in)

3,720 (12’-2")

L×H×W mm (ft-in)

3,860 × 1,420 × 400 (12’-8" × 4’-8" × 1’-4")

Weight w/Arm Cylinder kg (lb)

520 (1,150)

H

5.4.2

L 5.4.3

ARM WITH BUCKET CYLINDER 1.8 m (5’-11")

2.07 m (6’-9")

L×H×W mm (ft-in)

2,370 × 540 × 360 (7’-9" × 1’-9" × 1’-2")

2,640 × 540 × 360 (8’-8" × 1’-9" × 1’-2")

Weight w/Bucket Cylinder kg (lb)

320 (705)

340 (750)

H

Arm

L ARM WITH BUCKET CYLINDER AND BUCKET Combination

Arm 1.8 m (5’-11") Bucket 0.28 m3 (0.37 cu•yd)

Arm 2.07 m (6’-9") Bucket 0.22 m3 (0.29 cu•yd)

L×H×W mm (ft-in)

3,340 × 710 × 750 (10’-4" × 2’-4" × 2’-6")

3,610 × 710 × 650 (11’-10" × 2’-4" × 2’-2")

Weight kg (lb)

520 (1,150)

530 (1,170)

H

5.4.4

L

5-11

5. TRANSPORTATION DOZER BLADE L×H×W mm (ft-in)

1,520 × 470 × 2,320 (5’-0" × 1’-7" × 7’-7")

Weight kg (lb)

350 (770)

H

5.4.5

L 5.4.6

BUCKET

Standard bucket is 0.28 m3 (0.37 cu•yd)

B

A : Length is 980 mm (3’-3") B : Height is 890 mm (2’-11") C : Width without side cutters is 680 mm (2’-3") D : Width with side cutter is 750 mm (2’-6") E : Bucket weight is 200 kg (440 lb)

A

5-12

C D

6. SPECIFICATIONS

6-1

6. SPECIFICATIONS

6-2

6. SPECIFICATIONS

6.1

GENERAL SPECIFICATIONS

The specifications found in this section are given on the standard hydraulic excavator as produced by Manufacturer.

No modifications or options are taken into consideration in regard to these specifications.

6.1.1

MACHINE DIMENSIONS

These dimensions consider the following: 1. Standard boom : 3.72 meter (12’-2") 2. Standard arm : 1.8 meter (5’-11") 3. Bucket : 0.28 m3 (0.37 cu•yd) 4. Standard shoe : 450 mm (17.7") 5. Boom swing angle : Right (82º)/Left (50º) 6. Dozer blade stroke : Above 545 mm (21.5")/Below 260 mm (10.2")

1070mm (3·-6") 565mm (1·-10") 250mm (9.8")

mm 650 ") 1 R ·-5 (5

*750mm (2·-6")

2240mm (7·-4") 2860mm (9·-5") 1430mm (4·-8") 2090mm (6·-10") 6760mm (22·-2") 7200mm (23·-7")

3730mm (12·-3")

* Marked dimension do not include height of shoe lug.

6-3

260mm (10.2")

*380 mm (15·)

2600mm (8·-6")

460mm (18.1") 550mm (21.7")

2380mm (7·-10")

2170mm (7·-1")

450mm (17.7") 2320mm (7·-7")

6. SPECIFICATIONS

2,320mm (7’-7")

2,150mm (7’-1")

DOZER BLADE SPECIFICATIONS

2,490mm (8’-2")

6.1.2

(B)

460mm (18.1")

(A)

(C)

m 70 m R1,5 ’-2") (5

STRAIGHT DOZER (A type)

STRAIGHT DOZER (B type)

STRAIGHT DOZER (C type)

R 1,570 mm (5'-2")

←

←

Width

2,490 mm (8'-2")

2,320 mm (7'-7")

2,150 mm (7'-1")

Height

460 mm (18.1")

←

←

Weight

350 kg (770 lb)

360 kg (790 lb)

340 kg (750 lb)

ITEM Length (From the center of the arm fixing pin to the tip of the blade)

Set Pressure of Main Relief Valve

19.6 MPa {200 kgf/cm2}

Set Pressure of Overload Relief Valve

27.5 MPa {280 kgf/cm2}

Dozer Blade 6.1.3

Above

550 mm (21.7")

Below

260 mm (10.2")

WORKING WEIGHTS TRIPLE GROUSER SHOES

Track shoe width

mm (in)

450 (17.7")

Overall width

m (ft-in)

2.32 (7’-7")

Ground pressure

kPa (psi)

35.7 (5.18)

Working weight

kg (lb)

8,050 (17,750)

Bucket weight : 200 kg (440 lb)

6-4

6. SPECIFICATIONS 6.1.4

STANDARD WORKING RANGES

Standard working ranges :

A B

1. Boom : 3.72 m (12’-2") 2. Arm : 1.8 m (5’-11")

H

Maximum digging reach

7,170

23'-6"

B

Maximum digging reach at ground level

7,010

23'-0"

C

Maximum digging depth

4,380

14'-4"

D

Maximum digging height

6,790

22'-3"

E

Maximum dumping clearance

4,780

15'-8"

F

Minimum dumping clearance

2,110

6'-11"

G

Max vertical wall digging depth

3,170

10'-5"

H

Minimum swing radius

2,520

8’-3”

I

Max height at min slewing radius

5,460

17’-11”

J

8 feet level digging depth

3,950

13’-0”

K

Horizontal digging stroke at ground level

Stroke

3,080

10'-1"

Minimum

2,370

7’-9”

L

F

A

I

SAE

E

mm

K G

FUNCTION

C J

ITEM

D

3. Bucket SAE heaped : 0.28 m3 (0.37 cu•yd) Struck : 0.22 m3 (0.29 cu•yd) Width with side cutters : 750 mm (2’-6") Width w/o side cutters : 680 mm (2’-3") Weight : 200 kg (440 lb)

S CAUTION Do not excavate with the machine in transport position.

Such operation can cause attachment damage and cab interference.

6-5

L

6. SPECIFICATIONS 6.1.5

BOOM

Standard Boom is 3.72 m (12’-2") A - Length is 3.72 m (12’-2") Center line to center line of pins.

C

B - Height is 1,085 mm (42.7") From centerline of boom end to centerline of arm cylinder boss.

1

C - Width is 360 mm (14.2") From edge to edge of boom foot.

Weight - Approximately 390 kg (860 lb)

B

2

1. ARM CYLINDER BOSS

A

2. GROUND LEVEL 6.1.6

ARM

Standard arm is 1.8 m (5’-11")

B

A - Length is 1.8 m (5’-11") Center line to center line of pins.

B - Width is 180 mm (7.1") From edge to edge of arm end.

Weight - Approximately 190 kg (420 lb)

A

6.1.7

SHOES

1. Iron shoes are 450 mm triple grouser (1).

2. Quantity of shoes: (39 per track)

1

6-6

6. SPECIFICATIONS 6.1.8

PERFORMANCE SPECIFICATIONS

The following performance specifications are based on the standard machine with standard attachment.

1. Travel speed, swing speed & gradeability DESCRIPTION

SPECIFICATION 5.5 km per hr (3.4 mph) in U mode

TRAVEL SPEED

3.1 km per hr (1.9 mph) in T mode

SWING SPEED

12.5 min-1 in M-Mode / "HI" idle

GRADEABILITY

70 % (35º)

2. Engine a. Major engine specifications Engine maker

ISUZU

Model

4JG1NABGA

Type

4-cycle, water cooled, direct injection

Number of cylinders-Bore × Stroke

4 - 95.4 mm × 107 mm {3.76" × 4.21"}

Displacement

3.059 liter {187 cu•in.}

Compression ratio

18.6 : 1

Output rating

40.5 kW / 2,100 min-1 (55 PS / 2,100 rpm)

Maximum torque

187 N•m / 1,800 min-1 (138 lbf•ft / 1,800 rpm)

Maximum rpm at no load - high idle

2,310 ± 25 min-1

Maximum rpm at no load - low idle

1,000 ± 25 min-1

Ignition order

1 - 3 - 4 - 2 clockwise rotation

Injection timing

10 ± 1º Before Top Dead Point

Intake valve clearance cold

0.4 mm (0.016")

Exhaust valve clearance cold

0.4 mm (0.016")

Electrical system

D.C. 24 V

Starting motor

24 V - 3.2 kW

Alternator

24 V - 30 A

Batteries

2 - 12 V- 64 Ah

Engine dry weight*

250 kg (550 lb) Begin to open at 82ºC (180ºF) Full open at 95ºC (203ºC)

Thermostat Cooling fan drive method

ø450 (ø17.7") suction type belt drive, pulley ratio : 1.12

Air cleaner

Dry type with safety elements

*Less flywheel and electrics.

3. Hydraulic components COMPONENT Hydraulic Pumps 2 × 66 L / min (14.5 Gal / min)

TYPE Tandem, variable displacement, axial piston with pilot gear pump.

Slewing Motor

Axial piston

Travel Motor

Axial piston

Control Valves

8 spool multiple control

Cylinders (all)

Double acting

Return Filter

Safety valve containing filter type

Oil Cooler

Air cooled

6-7

6. SPECIFICATIONS 4. Operating pressures MPa (psi) Pilot System

3.43 (500)

Implement (Attachment)

32.9 (4,770)

Slewing

24.5 (3,550)

Travel

29.4 (4,260)

Swing

32.9 (4,770)

Dozer

27.5 (3,990)

5. Digging forces Arm Length

1.8 m (5'-11")

Bucket digging force

52.9 kN

Arm crowding force

37.0 kN

6-8

6. SPECIFICATIONS 6.1.9

MACHINE AND COMPONENT WEIGHTS

The following weight specifications are based on the standard machine with standard attachment.

1. Component weight

Unit : kg (lb)

COMPLETE MACHINE (STANDARD)

8,000 (17,640)

UPPER FRAME ASSEMBLY

3,815 (8,410)

Counterweight

820 (1,810)

Cab

191 (420)

Boom Cylinder*

92 (203)

Engine*

250 (550)

Radiator*

39 (86)

Pump Assembly

44 (97)

Control valve

63 (140)

Fuel Tank*

59 (130)

Hydraulic Tank*

65 (143)

Swing Motor & Reduction Unit

67 (150)

Swing Cylinder*

59 (130)

Swing Bracket

244 (538)

LOWER FRAME ASSEMBLY

2,910 (6,420)

Slewing ring

115 (250) 81 (180) × 2

Travel Motor & Reductin Unit Idler Assembly

44 (97) × 2

Lower Roller Assembly

15 (33) × 10

Upper Roller Assembly

4 (9) × 2

Track Tension Assembly

29 (64) × 2

Sprocket

27 (59) × 2

Swivel Joint

21 (46)

Dozer Blade

350 (770)

Dozer Blade Cylinders*

60 (130) 421 (928) × 2

Grouser shoe [w/450mm (17.7") width] ATTACHMENT (STANDARD)

1,050 (2,315)

Bucket Assembly [0.28 m3 (0.37 cu•yd)]

200 (440)

Arm Assembly [1.8 m (5’-11")]

330 (728)

Arm [1.8 m (5’-11")]

190 (420)

Bucket cylinder*

48 (106)

Idler link

9 (20) × 2

Bucket link

17 (37)

Pin (2pcs for mtg bucket cylinder & bucket)

18 (40)

Boom Assembly

514 (1,130)

Boom

390 (860)

Arm cylinder*

72 (160)

Pin (mounting the arm & arm cylinder)

16 (35)

FLUIDS

208 (460)

Hydraulic Oill

102 (225)

Engine Oil

9 (20)

Fuel

83 (183)

Water

10 (22)

*Dry weight

S WARNING USE ONLY LIFTING DEVICES AND EQUIPMENT WITH RATED CAPACITIES SUFFICIENT TO LIFT THE SPECIFIC COMPONENT(S) BEING REMOVED OR INSTALLED.

6-9

6. SPECIFICATIONS 6.1.10

LIFTING CAPACITIES

RATED OBJECT HANDLING CAPACITIES TABLE - SHOE WIDTH 450 mm (RUBBER SHOE) WORKING CONDITIONS: - with no tool (bucket, clamshell..). If object handling is performed with tool installed, the weight of the tool shall be deducted from the values of this table.

- with extended bucket cylinder.

- on a compact or horizontal, level ground.

- in complete swing of the upper structure 1. LIFT POINT (AXIS)

1

2. HEIGHT (m) 3. AXIS - ARM (SEE THE FOLLOWING TABLE) 4. BOOM (SEE THE FOLLOWING TABLE)

2 3 7

4

6

5. COUNTERWEIGHT 820 kg 6. WORKING CIRCUIT PRESSURE 29,420 kPa 7. HOLDING CIRCUIT 29,420 kPa

5

5 LD

PRESSURE

Z2

4

8. AXIS OF ROTATION

3

9. OUTREACH (m)

2 1 0

Z1

1 2

6

3

7

4

8 0

1

2

3

4

5

6

Z3

5 8

7

9 THESE LOADS ARE VALID FOR THE HEIGHT OF THE CONSIDERED ZONE (Z.) FOR THE INTENDED OUTREACH BOOM LENGTH 3.72 m ARM LENGTH (m)

OUTREACH IN mLOADS IN kg OUTREACH (m)

1.5

3.0

Z2 1.80

LD = 2.16

LD = 2.40

4.5

6.0

MAX REACH

1460

870

-

780

760 (6.25 m)

Z1

2590

2250

1190

Z3

4520

2310

1220

Z2 2.07

(BOOM FOOT HEIGHT)

-

1480

880

-

760

670 (6.71 m)

Z1

2220

2220

1170

Z3

3990

2270

1190

LD : BOOM POINT TO HOOK POINT DISTANCE

6-10

-

6. SPECIFICATIONS 6.1.11

LIFTING CAPACITIES

RATED OBJECT HANDLING CAPACITIES TABLE - SHOE WIDTH 450 mm (TRIPLE GROUSER SHOE) WORKING CONDITIONS: - with no tool (bucket, clamshell..). If object handling is performed with tool installed, the weight of the tool shall be deducted from the values of this table.

- with extended bucket cylinder.

- on a compact or horizontal, level ground.

- in complete swing of the upper structure 1. LIFT POINT (AXIS)

1

2. HEIGHT (m) 3. AXIS - ARM (SEE THE FOLLOWING TABLE) 4. BOOM (SEE THE FOLLOWING TABLE)

2 3 7

4

5. COUNTERWEIGHT 820 kg

6

6. WORKING CIRCUIT PRESSURE 29,420 kPa 7. HOLDING CIRCUIT 29,420 kPa

5

5 LD

PRESSURE

Z2

4 3

8. AXIS OF ROTATION 9. OUTREACH (m)

2 1 0

Z1

1 2

6

3

7

4

8 0

1

2

3

4

5

6

Z3

5 8

7

9 THESE LOADS ARE VALID FOR THE HEIGHT OF THE CONSIDERED ZONE (Z.) FOR THE INTENDED OUTREACH BOOM LENGTH 3.72 m ARM LENGTH (m)

OUTREACH IN mLOADS IN kg OUTREACH (m)

1.5

3.0

Z2 1.80

LD = 2.16

LD = 2.40

4.5

6.0

MAX REACH

1460

880

-

790

770 (6.25 m)

Z1

2590

2270

1200

Z3

4510

2330

1230

Z2 2.07

(BOOM FOOT HEIGHT)

-

1480

880

-

760

670 (6.71 m)

Z1

2220

2240

1180

Z3

3980

2280

1200

LD : BOOM POINT TO HOOK POINT DISTANCE

6-11

-

6. SPECIFICATIONS 6.1.12

LIFTING CAPACITIES

RATED OBJECT HANDLING CAPACITIES TABLE - SHOE WIDTH 600 mm (TRIPLE GROUSER SHOE) WORKING CONDITIONS: - with no tool (bucket, clamshell..). If object handling is performed with tool installed, the weight of the tool shall be deducted from the values of this table.

- with extended bucket cylinder.

- on a compact or horizontal, level ground.

- in complete swing of the upper structure 1. LIFT POINT (AXIS)

1

2. HEIGHT (m) 3. AXIS - ARM (SEE THE FOLLOWING TABLE) 4. BOOM (SEE THE FOLLOWING TABLE)

2 3 7

4

5. COUNTERWEIGHT 820 kg

6

6. WORKING CIRCUIT PRESSURE 29,420 kPa 7. HOLDING CIRCUIT 29,420 kPa

5

5 LD

PRESSURE

Z2

4 3

8. AXIS OF ROTATION 9. OUTREACH (m)

2 1 0

Z1

1 2

6

3

7

4

8 0

1

2

3

4

5

6

Z3

5 8

7

9 THESE LOADS ARE VALID FOR THE HEIGHT OF THE CONSIDERED ZONE (Z.) FOR THE INTENDED OUTREACH BOOM LENGTH 3.72 m ARM LENGTH (m)

OUTREACH IN mLOADS IN kg OUTREACH (m)

1.5

3.0

Z2 1.80

LD = 2.16

LD = 2.40

4.5

6.0

MAX REACH

1460

910

-

820

800 (6.25 m)

Z1

2590

2350

1250

Z3

4510

2410

1270

Z2 2.07

(BOOM FOOT HEIGHT)

-

1480

920

-

800

700 (6.71 m)

Z1

2220

2320

1230

Z3

3980

2360

1240

LD : BOOM POINT TO HOOK POINT DISTANCE

6-12

-

6. SPECIFICATIONS

6.2

OPTIONAL ATTACHMENTS -SPECIFICATIONS

6.2.1

WORKING RANGES

The following working ranges specifications are based on the standard machine with optional attachments.

1. Attachment with :

A B

a. Boom : 3.72 m (12’-2") b. Arm : 2.07 m (6’-9")

H

Maximum digging reach

7,590

24'-11"

B

Maximum digging reach at ground level

7,440

24'-5"

C

Maximum digging depth

4,660

15'-3"

D

Maximum digging height

7,330

24'-1"

E

Maximum dumping clearance

5,270

17'-3"

F

Minimum dumping clearance

1,980

6'-6"

G

Max. vertical wall digging depth

3,890

12'-9"

H

Minimum swing radius

3,120

10’-3”

I

Max height at min slewing radius

5,500

18’-1”

J

8 feet level digging depth

4,340

14’-3”

K

Horizontal digging stroke at ground level

Stroke

3,160

10'-4"

Minimum

2,710

8’-11”

L

F

A

I

SAE

E

mm

K G

FUNCTION

C J

ITEM

D

c. Bucket SAE heaped : 0.22 m3 (0.29 cu•yd) Struck : 0.18 m3 (0.24 cu•yd) Width with side cutters : 650 mm (2’-2") Width w/o side cutter : 580 mm (1’-11") Weight : 190 kg (420 lb)

S CAUTION Do not excavate with the machine in transport position.

Such operation can cause attachment damage and cab interference.

6-13

L

6. SPECIFICATIONS 6.2.2

BUCKET AND ARM COMBINATIONS BUCKET m3 (cu.yd)

SAE (JIS) (HEAPED)

JIS, SAE (STRUCK)

0.14 (0.18)

0.12 (0.16)

0.18 (0.24)

0.14 (0.18)

0.22 (0.29)

0.18 (0.24)

0.28 (0.37)

0.22 (0.29)

0.35 (0.46)

0.26 (0.34)

ARM 1.8 m (5'-11")

2.07 m (6'-9")

Normal working Standard Light duty only Do not use this combination

6-14

6. SPECIFICATIONS

6.3

TORQUE SPECIFICATIONS

The following torque specifications are provided for use when actual torque value of a fastener is not known.

6.3.1

CAPSCREWS AND NUTS

1. Metric coarse thread standard tightening torque values. Make certain to tighten all capscrews & nuts to proper torque values.

Torque value Unit : N•m (lbt•ft) Classification Nominal size

4.8T

7T

10.9T

No lubrication Oil lubrication No lubrication Oil lubrication No lubrication Oil lubrication

M6

P=1

0.45 ± 0.05 (3.2 ± 0.4)

0.38 ± 0.04 (2.7 ± 0.3)

0.98 ± 0.1 (7.1 ± 0.7)

0.83 ± 0.08 (6.0 ± 0.6)

17.7 ± 0.18 (12.8 ± 1.3)

1.5 ± 0.15 (10.8 ± 1.1)

M8

P=1.25

1.09 ± 0.11 (7.9 ± 0.8)

0.92 ± 0.09 (6.6 ± 0.7)

2.4 ± 0.2 (17.3 ± 1.4)

2.0 ± 0.2 (14.5 ± 1.5)

4.3 ± 0.4 (31.0 ± 2.9)

3.6 ± 0.4 (26.0 ± 2.9)

M10

P=1.5

2.2 ± 0.2 (15.9 ± 1.4)

1.83 ± 0.18 (13.2 ± 1.3)

4.7 ± 0.5 (34.0 ± 3.6)

4.0 ± 0.4 (28.9 ± 2.9)

8.5 ± 0.9 (61.3 ± 6.5)

7.2 ± 0.7 (52.0 ± 5.1)

M12

P=1.75

3.7 ± 0.4 (26.7 ± 2.9)

3.2 ± 0.3 (23.1 ± 2.2)

8.1 ± 0.8 (58.5 ± 5.8)

6.8 ± 0.7 (49.1 ± 5.1)

14.6 ± 1.5 (105 ± 10.8)

12.3 ± 1.2 (88.8 ± 8.7)

M14

P=2

5.9 ± 0.6 (42.6 ± 4.3)

5.0 ± 0.5 (36.1 ± 3.6)

12.8 ± 1.3 (92.5 ± 9.4)

10.8 ± 1.1 (78.0 ± 7.9)

23 ± 2 (166 ± 14)

19.5 ± 1.9 (140 ± 14)

M16

P=2

9.0 ± 0.9 (64.9 ± 6.5)

7.6 ± 0.7 (54.8 ± 5.1)

19.5 ± 2.0 (140 ± 14.4)

16.4 ± 1.6 (118 ± 11.5)

35 ± 4 (252 ± 28.9)

29 ± 3 (209 ± 21.6)

M18

P=2.5

12.4 ± 1.2 (89.6 ± 8.7)

10.5 ± 1.0 (75.8 ± 7.2)

27 ± 3 (195 ± 22)

23 ± 2 (166 ± 14)

49 ± 5 (354 ± 36)

41 ± 4 (296 ± 29)

M20

P=2.5

17.5 ± 1.7 (126 ± 12.3)

14.7 ± 1.4 (106 ± 10.1)

38 ± 4 (274 ± 29)

32 ± 3 (231 ± 22)

68 ± 7 (491 ± 51)

57 ± 6 (412 ± 43)

M22

P=2.5

23 ± 2 (166 ± 14)

19.6 ± 2.0 (142 ± 14)

51 ± 5 (368 ± 36)

43 ± 4 (310 ± 29)

92 ± 9 (663 ± 65)

77 ± 7 (555 ± 58)

M24

P=3

30 ± 3 (217 ± 22)

24 ± 3 (173 ± 22)

65 ± 7 (469 ± 51)

53 ± 5 (383 ± 36)

118 ± 12 (852 ± 87)

96 ± 10 (693 ± 72)

M27

P=3

44 ± 4 (318 ± 29)

36 ± 3 (260 ± 22)

96 ± 10 (693 ± 72)

78 ± 8 (563 ± 58)

173 ± 17 (1250 ± 120)

140 ± 14 (1010 ± 100)

M30

P=3.5

60 ± 6 (433 ± 43)

50 ± 5 (361 ± 36)

131 ± 13 (946 ± 94)

110 ± 11 (794 ± 79)

235 ± 24 (1700 ± 170)

198 ± 20 (1430 ± 140)

M33

P=3.5

81 ± 8 (585 ± 58)

68 ± 7 (491 ± 51)

176 ± 18 (1270 ± 130)

148 ± 15 (1070 ± 110)

317 ± 32 (2290 ± 200)

266 ± 27 (1920 ± 200)

M36

P=4

105 ± 10 (758 ± 72)

88 ± 9 (636 ± 65)

227 ± 23 (1640 ± 170)

190 ± 19 (1370 ± 140)

409 ± 41 (2960 ± 300)

343 ± 34 (2480 ± 250)

6-15

6. SPECIFICATIONS 2. Metric fine thread standard tightening torque values. Make certain to tighten all capscrews & nuts to proper torque values.

Torque value Unit : N•m (lbt•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

1.15 ± 0.11 (8.3 ± 0.8)

0.97 ± 0.1 (7.0 ± 0.7)

2.5 ± 0.2 (18.0 ± 1.4)

2.1 ± 0.2 (15.2 ± 1.4)

4.5 ± 0.4 (32.5 ± 2.9)

3.8 ± 0.4 (27.4 ± 2.9)

M10

P=1.25

2.3 ± 0.2 (16.6 ± 1.4)

1.91 ± 0.19 (13.8 ± 1.4)

4.9 ± 0.5 (35.4 ± 3.6)

4.2 ± 0.4 (30.3 ± 2.9)

8.9 ± 0.9 (64.4 ± 6.5)

7.5 ± 0.7 (54.2 ± 5.1)

M12

P=1.25

4.0 ± 0.4 (28.9 ± 2.9)

3.4 ± 0.3 (24.5 ± 2.2)

8.7 ± 0.9 (62.8 ± 6.5)

7.3 ± 0.7 (52.7 ± 5.1)

15.7 ± 1.6 (113 ± 13)

13.2 ± 1.3 (95.3 ± 9.4)

M16

P=1.5

9.4 ± 0.9 (68.0 ± 6.5)

7.9 ± 0.8 (57.2 ± 5.8)

20 ± 2 (145 ± 15)

17.2 ± 1.7 (125 ± 13)

37 ± 4 (268 ± 29)

31 ± 3 (224 ± 22)

M20

P=1.5

19 ± 9 (137 ± 4)

15.8 ± 1.6 (114 ± 14)

41 ± 4 (296 ± 29)

34 ± 3 (246 ± 22)

74 ± 7 (535 ± 51)

62 ± 6 (448 ± 43)

M24

P=2

32 ± 3 (231 ± 22)

27 ± 3 (195 ± 22)

70 ± 7 (506 ± 51)

58 ± 6 (420 ± 44)

126 ± 12 (910 ± 87)

105 ± 10 (758 ± 72)

M30

P=2

65 ± 6 (470 ± 44)

54 ± 5 (390 ± 36)

142 ± 14 (1030 ± 100)

118 ± 12 (853 ± 87)

255 ± 256 (1840 ± 190)

212 ± 21 (1530 ± 150)

M33

P=2

87 ± 9 (629 ± 65)

72 ± 7 (521 ± 52)

189 ± 19 (1370 ± 137)

158 ± 16 (1140 ± 114)

341 ± 34 (2470 ± 246)

285 ± 28 (2060 ± 203)

M36

P=3

109 ± 11 (787 ± 79)

91 ± 9 (658 ± 65)

238 ± 23 (1720 ± 170)

198 ± 20 (1430 ± 140)

428 ± 43 (3090 ± 310)

357 ± 36 (2580 ± 260)

6.3.2

ORS JOINT ("O"-RING SEALING TYPE)

1

2

3

4 1. CONNECTOR 2. O-RING 3. NIPPLE 4. NUT

HOSE MOUTH RING AND COUPLING

NOMINAL SIZE

OPPOSING FLATS mm

TORQUE VALUE N•m (lbf•ft)

1-14 UNS

30 • 32

137 ± 14 (101 ± 10)

36

176 ± 18 (18 ± 1.8)

41

206 ± 21 (152 ± 15)

41 • 46

206 ± 21 (152 ± 15)

1-3 / 16 12 UN 1-7 / 16 12 UN

6-16

WORKING PRESSURE MPa (psi)

34.3 (4,980)

6. SPECIFICATIONS 6.3.3

NUTS AND SLEEVES B

2

1

O.D. ( )

O.D. ( )

1. SLEEVE 2. NUT WORKING PRESSURE MPa (psi)

34.4 (4,980)

6.3.4

TUBE SIZE O.D. × THICKNESS mm (in)

OPPOSING FLATS mm Dimension B

TORQUE VALUE N•m (lbf•ft)

10 × 1.5 (0.394 × 0.059)

19

49 ± 9.8 (36 ± 7.2)

15 × 2.0 (0.591 × 0.079)

27

118 ± 12 (87 ± 8.9)

18 × 2.5 (0.709 × 0.098)

32

147 ± 15 (108 ± 11)

22 × 3.0 (0.866 × 0.118)

36

216 ± 22 (159 ± 16)

28 × 4.0 (1.10 × 0.157)

41

275 ± 27 (203 ± 20)

35 × 5.0 (1.38 × 0.20)

55

441 ± 44 (325 ± 32)

FLARE TYPE FITTING JOINTS

Overtightening of flare type (union nut type) metal joints may cause damage to nuts, seat surfaces and prevent optimum sealing resulting in oil leaks.

1. Pipe threads Unit : N•m (lbf•ft) NOMINAL SIZE

TORQUE VALUE

1 / 4"

29 ± 4.9 (21.4 ± 3.6)

3 / 8"

49 ± 4.9 (36.1 ± 3.6)

1 / 2"

78 ± 4.9 (57.5 ± 3.6)

3 / 4"

118 ± 9.8 (87.0 ± 7.2)

6.3.5

1"

137 ± 15 (101 ± 11)

1-1 / 4"

167 ± 15 (123 ± 11)

1-1 / 2"

206 ± 20 (152 ± 15)

2"

245 ± 20 (181 ± 15)

N2 (NYLON) TUBE FITTING JOINTS

1

2

3

1. Clean tube (3) and make certain tube end is trimmed smooth.

2. Insert tube (3) into fitting until tube end is securely seated in fitting body (1).

3. Tighten the nut (2) by hand.

4. Use a spanner wrench, securely tighten nut (2) by turning 1-1/4 turns.

6-17

6. SPECIFICATIONS 6.3.6

TORQUE VALUES FOR MOST COMMON BOLTS

Follow the table below and tighten or retighten every capscrew and nut. Check for any loose or missing capscrews or nuts before daily operation and during periodical inspections. Retighten or supply new parts for missing ones as required.

Size

Q’ty

M5

5

• Sending unit mounting (fuel tank)

• 2.0 ± 0.2 (1.4 ± 0.1)

M6

6

• A/C Condenser mounting

• 4.4 ± 0.5 (3.2 ± 0.4)

4

• Swivel joint dust cover mounting

• 9.02 ± 0.9 (6.6 ± 0.6)

2

• Air cleaner mounting

• 28.0 ± 2.9 (21 ± 2.1)

4

• Muffler mounting (Nut-Upper)

• 10.8 ± 1.1 (8.0 ± 0.7)

4

• Muffler mounting (Nut-Lower)

• 8.8 ± 0.9 (6.5 ± 0.6)

2

• Exhaust tube mounting

• 19.6 ± 2.0 (14 ± 1.4)

4

• A/C compressor mounting

• 10.8 ± 1.0 (8.0 ± 0.7)

5

• Cab mounting

• 46.0 ± 8.0 (34 ± 5.8)

8

• Engine mounting (Hydraulic pump side)

• 43.0 ± 4.0 (32 ± 2.9)

Apply Loctite #271

4

• Engine mounting (Fan side)

• 40.0 ± 4.0 (30 ± 2.9)

Apply Loctite #271

M8

M10

M12

M14

M16

M18 M20 5/8-18 UNF

Location

Tightening torque N•m (lbf•ft)

2

• Intake tube mounting

• 19.6 ± 2.0 (14 ± 1.4)

Apply Loctite #271

3

• Stepping motor mounting

• 19.6 ± 2.0 (14 ± 1.4)

Apply Loctite #242

2

• Exhaust tube clamp mounting

• 83.0 ± 8.0 (61 ± 5.8)

8

• Take-up bracket mounting

• 64.7 ± 6.5 (48 ± 4.3)

8

• Floor plate rubber mounting

• 46.0 ± 5.0 (34 ± 3.6)

4

• Step mounting

• 22.0 ± 2.0 (16 ± 1.4)

4

• Travelling lever mounting

• 46.0 ± 5.0 (34 ± 3.6)

12

• Hydraulic oil tank cover mounting

• 46.1 ± 4.9 (34 ± 3.6)

Apply Loctite #262

4

• Idler and idler adjuster connection

• 115 ± 12.0 (85 ± 8.7)

10

• Travel motor cover mounting

• 115 ± 12.0 (85 ± 8.7)

Apply Loctite #262

12

• Tank guide mounting

• 181 ± 20.0 (134 ± 14) Apply Loctite #262

156

• Shoe bolt mounting

• 294 ± 29.0 (217 ± 22)

24

• Sprocket mounting

• 181 ± 20.0 (134 ± 14) Apply Loctite #262

40

• Lower roller mounting

• 181 ± 20.0 (134 ± 14) Apply Loctite #262

20

• Slewing bearing outer race mounting

• 157 ± 16.0 (116 ± 14) Apply Loctite #262

30

• Slewing bearing inner race mounting

• 279 ± 29.0 (206 ± 22) Apply Loctite #262

2

• Hyd. pump mounting

• 191 ± 19.1 (141 ± 14) Apply Loctite #262

46

• Floor plate rubber mounting

• 191 ± 19.1 (141 ± 14)

4

• Fuel tank mounting

• 216 ± 19.6 (159 ± 14) Apply Loctite #262

8

• Swing motor mounting

• 279 ± 29.0 (206 ± 22) Apply Loctite #262

4

• Hyd. tank mounting

• 216 ± 19.6 (159 ± 14) Apply Loctite #262

24

• Travel motor mounting

• 279 ± 29.0 (206 ± 22) Apply Loctite #262

4

• Engine mounting

• 225 ± 20.0 (166 ± 14) Apply Loctite #272

3

• Counterweight mounting

• 490 ± 49 (361 ± 36)

6

• Side cutter mounting

• 549 ± 34.3 (404 ± 25)

2

• Idler adjuster grease fitting mounting

• 59 ± 10 (43 ± 7)

6-18

Apply Loctite #262

6. SPECIFICATIONS

6.4

MISCELLANEOUS INFORMATION

6.4.1

TEMPERATURE TABLE

°C

°F

°C

°F

°C

°F

°C

°F

°C

°F

°C

°F

-10

14

55

131

120

248

185

365

250

482

315

599

-5

23

60

140

125

257

190

374

255

491

320

608

0

32

65

149

130

266

195

383

260

500

325

617

5

41

70

158

135

275

200

392

265

509

330

626

10

50

75

167

140

284

205

401

270

518

335

635

15

59

80

176

145

293

210

410

275

527

340

644

20

68

85

185

150

302

215

419

280

536

345

653

25

77

90

194

155

311

220

428

285

245

350

662

30

86

95

203

160

320

225

437

290

554

355

671

35

95

100

212

165

329

230

446

295

563

360

680

40

104

105

221

170

338

235

455

300

572

365

689

45

113

110

230

175

347

240

464

305

581

370

698

50

122

115

239

180

356

245

473

310

590

375

707

Example of how to convert 45°C to °F: °F = 1.8 × °C + 32 → °F = 1.8 × 45 + 32 = 81 + 32 = 113°F Example of how to convert 122°F to °C °C = 0.56 (°F - 32) → °C = 0.56 (122 - 32) = 0.56 × 90 = 50°C 6.4.2

SPECIAL PIPE WRENCHES A

B C

G D F

E

Unit : mm (in) TUBE DIA.

A

B

C

D

E

F

G

15 (0.591)

27 (1.06)

70 (2.76)

22 (0.87)

12.7 (0.50)

8 (0.32)

40 (1.57)

16 (0.63)

18 (0.709)

32 (1.26)

70 (2.76)

22 (0.87)

12.7 (0.50)

11 (0.43)

42 (1.65)

19 (0.75)

22 (0.866)

36 (1.42)

70 (2.76)

22 (0.87)

12.7 (0.50)

11.5 (0.44)

48 (1.89)

23 (0.91)

28 (1.10)

41 (1.614)

109 (4.29)

22 (0.87)

12.7 (0.50)

14.5 (0.57)

60 (2.36)

29 (1.14)

35 (1.38)

55 (2.17)

90 (3.54)

45 (1.77)

20 (0.79)

20.5 (0.81)

81 (3.19)

41 (1.61)

6-19

6. SPECIFICATIONS 6.4.3

WEIGHT OF MATERIALS TABLE

lb/yd3

kg/m3

Material (loose weight)

700

420 Wood chips

750

440 Peat, dry

950

560 Cinders

1170

690 Peat, wet

1600

950 Topsoil

1780

1050 Coal

2100

1250 Caliches

2100

1250 Earth, loam

2250

1330 Shale

2400

1420 Sand, dry

2500

1480 Clay, dry

2550

1510 Earth, dry

2600

1540 Limestone, broken or crushed

2700

1600 Earth, wet

2800

1660 Clay, wet

2800

1660 Rock, granite, blasted & broken

2850

1690 Sand, moist

2900

1720 Sand and gravel, dry

3100

1840 Sand, wet

3400

2020 Sand and gravel, wet

6.4.4

CAPS AND PLUGS FOR TUBES AND HOSE FITTINGS

1. Tube & Hose Plugs C

B A

TUBE DIAMETER 10 mm 15 mm 18 mm 22 mm 28 mm 35 mm

6-20

6. SPECIFICATIONS 2. Male PF Plugs "D" "C" "B"

"A"

60

Unit : mm PLUG SIZE

"A" O.D. (ø)

"B" LENGTH

"C" LENGTH

"D" FLATS

PF 1/4

13.5

16.5

24.5

14

PF 3/8

16.6

17.5

25.5

17

PF 1/2

20.6

20.0

31.0

22

PF 3/4

26.2

21.5

34.0

27

PF 1

33.3

23.5

36.0

36

3. Female PF caps

1

1. THREAD SCREW SIZE PF 1/4 PF 3/8 PF 1/2 PF 3/4 PF 1 PF 1 1/4

6-21

6. SPECIFICATIONS

6-22

7. TROUBLESHOOTING

7-1

7. TROUBLESHOOTING

7-2

7. TROUBLESHOOTING

7.1

GENERAL TROUBLESHOOTING

This troubleshooting information covers the components and systems as described in this operator’s manual.

Should in depth troubleshooting, repair or replacement of components or adjustment of valves be required, contact Dealer for assistance.

SYS

PROBLEM

PROBABLE CAUSE

POSSIBLE REMEDY

a. Low hydraulic oil level

Fill oil to specified level

b. Air leaking into the suction pipe

Tighten suction pipe hose clamp or replace hose

1. All operating speeds are slow or power is c. Hydraulic pump damaged lost d. Pilot gear pump damaged

e. Main relief valve is not adjusted correctly

Repair or replace Repair or replace Adjust or replace

f. Pilot relief valve is not adjusted correctly

Adjust or replace

a. Cylinder seal is damaged

Repair or replace

OPERATING

b. Control valve or overload valve functions incorrect- Repair or replace/Bleed air 2. A specific cylinder ly or there are signs of air in the cylinder from cylinder functions improperly or loses power c. Pilot valve is damaged Repair or replace 3. The cylinder position will not hold with operating lever in neutral

4. Machine does not swing

5. Swing speed is slow

6. Abnormal sound occurs when swing

d. Pilot valve piping is loose

Retighten

a. Cylinder seal is scored

Repair or replace

b. Control valve or overload valve is damaged

Repair or replace

c. Overload valve is not operating

Repair or replace

d. Pilot valve is damaged

Repair or replace

a. Brake valve is not working

Repair or replace

b. Hydraulic motor (swing) is not working or swing gear is damaged

Repair or replace

c. Swing bearing is damaged

Repair or replace

d. Pilot valve is not working

Repair or replace

e. Swing reduction unit is damaged

Repair or replace

a. Brake valve is not working

Repair or replace

b. Control valve is not working

Repair or replace

c. Hydraulic motor (swing) is not working

Repair or replace

d. Hydraulic pump is not working

Repair or replace

a. Insufficient lubrication of swing gear and bearings Grease b. Low oil level in the swing reduction unit

7. With swing stopped, a. Brake valve malfunctions the machine drifts and b. Set pressure of brake valve is incorrect is hard to control c. Brake lining is worn

7-3

Refill with proper oil Repair or replace Adjust or replace Repair or replace

7. TROUBLESHOOTING SYS

PROBLEM

TRAVEL

1. Machine does not travel smoothly

PROBABLE CAUSE

POSSIBLE REMEDY

a. Too much track tension

Adjust track tension

b. Dirty track links and shoes

Clean tracks

c. Brake valve is not working

Repair or replace

d. Travel reduction unit is damaged

Repair or replace

a. Hydraulic pump is damaged

Repair or replace

b. Poor engine performance

Repair or replace

c. Main relief valve pressure is set incorrectly 2. Traveling power is ind. Low hydraulic oil level sufficient e. Hydraulic motor (travel) is not working

Adjust or replace Fill to proper level Repair or replace

f. Brake valve is not working

Repair or replace

g. Seal in swivel joint is scored or oil is leaking

Repair or replace

a. Unequal tensions on tracks

Adjust tension

HYDRAULIC

b. Set pressures of main relief valves unbalanced Adjust 3. Machine does not travel in a straight line c. Performances of hydraulic travel motor has deteriRepair or replace orated a. Oil cooler core clogged

Clean

b. Engine fan belt slipping

Adjust or replace

c. Low hydraulic oil level 1. Temperature rise in the hydraulicoil tank. d. Wrong type hydraulic oil used

GAUGE CLUSTER DISPLAY

e. Hydraulic pump is not working 1. Engine oil pressure is a. Engine oil level low too low.(Buzzer b. Oil leaking sounds and icon disc. Wrong oil viscosity plays)

2. Abnormal rise in the coolant temperature(Buzzer sounds and icon displays)

3. Air cleaner clogged

Refill to specified level Replace with correct, new oil Repair or replace Fill to specified level Repair & fill to proper level Replace with proper oil

a. Low coolant

Fill to proper level

b. Coolant leaking

Repair & fill to proper level

c. Loose radiator cap

Tighten

d. Radiator core clogged

Clean cooling system

e. V-belt loose or damaged

Tighten to proper tension

f. Rust or scale in coolant

Flush system / fill to level

g. Faulty thermostat

Replace

a. Clogged air cleaner

Replace elements

b. Hoses from air cleaner to turbo clogged

Clean, repair or replace

7-4

7. TROUBLESHOOTING SYS

PROBLEM

PROBABLE CAUSE

a. Battery disconnected 1. Starter does not turn b. Battery discharged or turns slowly which c. Battery terminals disconnected, loose, or corroded does not start the end. Ground cable disconnected gine e. Engine oil viscosity too thick (Cold weather)

2. Starter turns but engine does not start

ENGINE 5. Engine overheats

6. Engine exhaust is black 7. Poor fuel consumption

8. Excessive oil consumption

9. Engine oil pressure does not rise

Connect Charge Clean and connect Connect Change to proper oil

a. Insufficient fuel

Refuel

b. Improper starting procedure

Refer to 3-9

c. Air in fuel line

Bleed (See 4-44)

d. Clogged fuel filter

Replace element

e. Clogged air cleaner

Replace elements

f. Air heater circuit malfunctioning

Check circuit

a. Low idling rpm

Manufacturer serviceman

3. Engine tends to stop b. Fuel filter clogged at low speed c. Air cleaner clogged

4. No power

POSSIBLE REMEDY

Replace element Replace elements

d. Improper valve clearance

Manufacturer serviceman

a. Fuel filter clogged

Replace element

b. Air cleaner clogged

Replace elements

c. Improper valve clearance

Manufacturer serviceman

d. Loose clamps on the air inlet hose (with turbo charger)

Tighten clamps

e. Cracked air inlet hose (with turbo charger)

Replace hose

a. Insufficient coolant

Refill coolant

b. Clogged radiator

Clean cooling components

c. V-belt to loose or damaged

Adjust or replace belt

d. Faulty thermostat

Replace

a. Air cleaner clogged

Replace elements

b. Improper valve clearance

Manufacturer serviceman

a. Fuel leak

Manufacturer serviceman

b. Air cleaner clogged

Replace elements

c. Loose clamps on suction hose (with turbo charger) Tighten clamps d. Cracked suction hose (with turbo charger)

Replace w/new hose

a. Improper oil

Replace with correct oil

b. Oil leak

Manufacturer serviceman

c. Improper oil replacement intervals

Change at correct interval

d. Improper warming-up operation

Refer to 3-9

a. Low oil volume

Fill to specified level

b. Oil leak

Manufacturer serviceman

c. Improper oil viscosity

Replace with proper oil

a. Battery terminals disconnected loose, or corroded Clean & tighten terminals 10. Battery dies often

b. Low battery electrolyte

Fill cells w/distilled water

c. V-belt loose or damaged

Adjust or replace belt

d. Defective battery

Replace battery

7-5

7. TROUBLESHOOTING

7-6

8. SPECIAL PROCEDURES

8-1

8. SPECIAL PROCEDURES

8-2

8. SPECIAL PROCEDURES

8.1

GENERAL

The machine incorporates automatically applied spring brake systems in the travel motors and swing motors. These systems will automatically engage the brakes when engine is stopped making it impossible to move the machine.

This section contains the required procedures for releasing the travel motor brakes, the swing motor brake and lowering the attachment to the ground should sudden engine failure be experienced.

S WARNING •

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

•

THE PROCEDURES FOUND IN THIS SECTION THE PROCEDURES FOUND IN THIS SECTION SHOULD BE PERFORMED BY A WELL TRAINED EXPERIENCED SERVICE TECHNICIAN WHO IS FAMILIAR WITH THE MACHINE.

8.2

RELEASING TRAVEL MOTOR BRAKES

8.2.1

TOOLS AND EQUIPMENT REQUIRED

1. Four chock blocks.

2. One allen wrench for drain plug.

3. Hammer and punch one each.

4. Drilling device for 2 mm diameter.

5. Two 2.6 Liter (0.7 Gal) capacity drain pans.

6. Rubber or soft faced mallet.

8.2.2

PROCEDURES

NOTE: make sure to align the plugs on the travel motor covers perpendicular to the ground, before shutting off the engine.

1. Place chock blocks at front and rear of each track to prevent machine from moving when brakes are released.

S WARNING MAKE CERTAIN CHOCK BLOCKS ARE SECURE AT FRONT AND REAR OF EACH TRACK (1) BEFORE ATTEMPTING TO RELEASE BRAKES. NEVER STAND IN THE PATH OF THE TRACKS WHEN RELEASING BRAKES.

1

8-3

8. SPECIAL PROCEDURES 2. Lower attachments to ground. See 8-7.

3. Turn key switch "OFF" and remove key.

4. Remove fill plug (1) from each travel motor using the 8 mm allen wrench.

5. Place a clean 5 liter (1.3 Gallon) capacity drain pan under each travel motor drain plug (2) and remove drain plug (2) using the 8 mm allen wrench.

"OFF"

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.

1. FILL PLUG 2. DRAIN PLUG 3. CHECK PLUG

1

4. RING 5. COVER 6. HUB

3

7. O-RING 8. EYE-BOLT (PF 3/8) A. MATING PART

2

7. Find the mating part of ring (4) and punch at a point of the outside of the hub, approximately 20 mm inward from the tip of ring (4) for drilling purpose.

6

6 2

4

20

5

A

8-4

4

8. SPECIAL PROCEDURES 8. Drill through 2 mm hole from the outside of hub (6) toward ring (4) using electric drill.

S CAUTION •

Be careful not to damage lip of cover plate. Any damage to the lip could result in a gear oil leak.

•

When removing the following components it will be necessary to have a clean area free of dirt and grit to lay these components.

9. Put a steel bar into the hole and push ring (4).

10. Hold the tip of ring (4) sticking out of the cover (5) and draw the ring out of the ring groove of the hub (6).

4

11. Fix PF3/8 eye bolts (8) to the two threaded holes of cover (5) (to which socket plugs and fixed).

5 12. Place the hook and a wire sling in the PF3/8 eye bolts (8), lift it by hoist and remove the cover (5).

8 5

7

13. Remove the covers from both travel reduction units to expose the planetary gears.

S CAUTION Be aware of and protect hands from pinch areas when removing and installing planetary gears or any other component which may cause personal injury.

8-5

8. SPECIAL PROCEDURES 14. Using snap ring pliers, remove the snap ring (1) from the "Shaft" (2).

1

15. Carefully remove "Input gear" (3) from the shaft (2) by hand and lay it aside.

16. Remove shaft (2) from coupling.

17. Remove ball from shaft (2).

18. Remove coupling from shaft (2).

19. Install cover plates onto housings and fix ring into the ring groove of hub.

20. Install fill and drain plugs (2) into cover plates and replace gear oil into travel reduction units through fill port to proper level.

2

21. After steps 4 through 20 have been performed on both travel reduction units, the machine may be towed to an area where repairs can be made.

22. After repairs are made reinstall the "Input Gear" (3) in reverse order.

NOTE: • Refer to Section IV, See 4-11 and 4-13 for proper oils specification and capacity.

•

Install new O-ring seals on cover plates after all repairs are completed.

8-6

3

8. SPECIAL PROCEDURES

8.3

LOWERING ATTACHMENT WHEN SUDDEN ENGINE FAILURE OCCURS

8.3.1

HOW TO LOWER ATTACHMENT

The port relief valve is used to return the oil remaining in the cylinder to the hydraulic tank to protect the piping when the pressure inside of piping rises higher than the set pressure owing to the external load exerted on the cylinder, and also may be used as a measures to lower attachment when the engine stops owing to trouble, etc.

After loosening lock nut of port relief valve as adjuster screw is loosened the set pressure gradually falls. When the set pressure decreases lower than the hold pressure of cylinder currently holding attachment, the above hold pressure opens the poppet, the plunger moves rightward and the continuity from P to R is made. And the oil remaining in the cylinder returns to the tank.

With this, attachment can be brought down to the ground while engine stops.

NOTE: before loosening adjuster screw, mark those positions, and after bringing down attachment to the ground, tighten adjuster screw to the marked positions.

3

5

1 P

P

2

6

4

1 14 13 12 11 10

15 16 17

9

Pa2

7

B2

A2

8

1.

2.

3.

4.

5.

6.

TO TANK PLUNGER PISTON POPPET LOCKNUT ADJUST SCREW

7.

8.

9.

10.

11.

12.

BOOM SPOOL BOOM CYLINDER TRAVEL RIGHT TRAVEL STRAIGHT BOOM TRAVEL LEFT

8-7

13. BUCKET 14. SLEWING 15. CUT VALVE 1 & ARM CONFLUENCE VALVE 16. ARM 17. CUT VALVE 2

8. SPECIAL PROCEDURES 8.3.2

HOW TO LOWER ATTACHMENT

When engine stops because of troubles, the stop valve incorporated in the holding valve (1) mounted on the boom cylinder head side is available to lower attachment.

As shown in the figure, after loosening lock nut (2) of stop valve as setscrew (3) is loosened, the poppet (4) is opened and then the oil remaining in the boom cylinder head side returns to the tank through T port enabling attachment to be lowered.

1

NOTE: after lowering attachment, tighten the above setscrew to the specified torque without fail.

S CAUTION Be careful when lowering attachment. Do not stand under boom.

3

2.5 ~ 3.5 kgf•m

2

4

8.4

HYDRAULIC TANK PRESSURE

How to release air pressure remaining in the hydraulic tank.

After engine stops, the air pressure remaining in the hydraulic tank.

Can be released by pushing valve on the air breather rubber cap (1) several times (5 ~ 7 times). Air breather mounted on the upper part of hydraulic tank.

1

8-8

8. SPECIAL PROCEDURES

8.5

RELEASING SLEWING BRAKE

S WARNING MAKE CERTAIN THAT THE ATTACHMENT IS ON THE GROUND TO HELP PREVENT SUDDEN ROTATION OF THE UPPER STRUCTURE BEFORE ATTEMPTING TO RELEASE THE SLEWING BRAKE. REFER TO 8-7 FOR ATTACHMENT LOWERING PROCEDURES. 8.5.1

TOOLS & EQUIPMENT REQUIRED

1. Hand tools required for removal of hydraulic tubes, hoses and fittings.

2. Plugs and caps for tubes, hoses and fittings.

3. 12 mm allen wrench.

4. 5 mm allen wrench.

5. Overhead lifting device capable of lifting and holding 45 kg (100 lb).

6. Plenty of clean, dry shop rags.

7. Torque wrenches.

8.5.2

PROCEDURES

1. Lower attachment to ground. Refer to see 8-7 for proper procedures in lowering the attachment.

2. Remove all hoses and tubes from the swing motor top plate and swing valve to gain access to the top plate attaching bolts.

3. Install the proper plugs and caps onto hoses, tubes and fittings to avoid the possibility of contamination entering the hydraulic system.

S CAUTION Use only plugs and caps designed to properly seal the specific hose, tube or fitting they are to be installed on.

4. Thoroughly clean the top of the slewing motor and slewing valve removing all dirt and debris.

NOTE: place a large quantity of clean, dry shop rags around the slewing motor to help catch any overflow of hydraulic oil from the removal of the top plate.

8-9

8. SPECIAL PROCEDURES 5. Loosen the four top plate attaching bolts with the 10 mm allen wrench (1).

1

6. Remove four top plate attaching bolts from corners opposite of each other (2).

7. Attach overhead lifting device to the lifting eye and remove most of the slack from the cable or chain.

2

M12-1.75 X 20MM

8. Carefully remove the remaining two bolts from the top attaching plate.

NOTE: the top plate will raise from spring pressure as the last two bolts are removed. Some movement of the upper frame may be experienced as the spring tension is released.

9. Using the overhead lifting device, carefully lift the slewing motor top plate and slewing valve assembly off of and away from the slewing motor.

S CAUTION Do not allow any dirt or debris to enter the slewing motor or settle on the top plate.

10. Carefully remove all brake springs (3) and place in a container filled with fresh, clean hydraulic oil.

Then, seal the container to prevent contamination.

3

8-10

8. SPECIAL PROCEDURES 11. Align the holes of the distributor plate in the slewing motor until they are located toward the front and back of the slewing motor housing (4).

4

12. Carefully place the top plate over the slewing motor and align the dowel pins (5) of the top plate with the holes in the distributor plate.

13. Carefully and slowly lower the top plate into position on the slewing motor and install, by hand, the four top plate attaching bolts.

14. Carefully and slowly lower the top plate into position on the slewing motor and install, by hand, the four top plate attaching bolts.

S CAUTION Make certain the top plate dowel pins (5) and the distributor plate holes mesh together.

8-11

5

8. SPECIAL PROCEDURES

8-12