New Holland EH130 Hydraulic Excavator Operator's Manual 6-82410 - PDF DOWNLOAD

OPERATOR'S MANUAL EH130 CRAWLER EXCAVATORS

CONSTRUCTION 6-82410NA

EH130 HYDRAULIC EXCAVATOR OPERATOR’S MANUAL

Part Number: 6-82410na

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

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

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

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

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

Safety Decals on this machine use the words Danger, Warning, or Caution, which are defined as follows: DANGER: Indicates an immediate hazardous situation that, if not avoided, will result in death or serious injury. The color associated with Danger is RED. WARNING: Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. The color associated with Warning is ORANGE. CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices. The color associated with Caution is YELLOW. If Safety Decals on this machine are ISO two panel Pictorial, decals are defined as follows: The first panel indicates the nature of the hazard.

The second panel indicates the appropriate avoidance of the hazard.

Background color is YELLOW Prohibition symbols such as

and

STOP

if used, are RED.

IMPROPER OPERATION OF THIS MACHINE CAN CAUSE DEATH OR SERIOUS INJURY. BEFORE USING THIS MACHINE, MAKE CERTAIN THAT EVERY OPERATOR: Is instructed in safe and proper use of the machine.

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

Reads and understands ALL Safety Decals on the machine.

Clears the area of other persons.

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

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

WARNING_01_NA

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

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

Wash hands after handling.

Copyright © 2004 CNH America LLC All Rights Reserved

Cst 6-82410naNA Issued February 2004 New Holland Construction, LLC

TABLE OF CONTENTS CHAPTER 1 GENERAL INFORMATION To the Owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

CHAPTER 2 SAFETY, DECALS, AND HAND SIGNALS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Operator Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Hand Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 CHAPTER 3 INSTRUMENTS AND CONTROLS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Instruments And Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Operator’s Compartment Controls and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Operator Cab controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Machine Access Compartments and Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30 CHAPTER 4 OPERATING INSTRUCTIONS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Before Operating the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Machine Operation in Adverse Weather Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Recommendation for Longer Undercarriage Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Bucket Selection Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Use of Optional Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 Machine Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25 CHAPTER 5 LUBRICATION, FILTERS, AND FLUIDS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Fluid and Lubrication capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 CHAPTER 6 MAINTENANCE AND ADJUSTMENTS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Servicing Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Pre-start (every 8 hours) Inspection & Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Every 50 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19 Every 100 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27 Every 120 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27 Every 250 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29 Every 500 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32 Every 1000 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38 Every 2000 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39 Variable And Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47

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CHAPTER 7 ELECTRICAL Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 CHAPTER 8 SPECIFICATIONS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Lifting Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 CHAPTER 9 INDEX

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CHAPTER 1 - GENERAL INFORMATION

CHAPTER 1

GENERAL INFORMATION

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

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

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

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

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CHAPTER 1 - GENERAL INFORMATION Any modification or adaptation which is not approved by the manufacturer may invalidate the machine's initial conformity with safety requirements.

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

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

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

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

Your Dealer is available for any further information. They will also provide any after-sales service you may need, and genuine spare parts, your guarantee of quality and match.

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CHAPTER 1 - GENERAL INFORMATION

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

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

1

6

6

4

3

5

5

2 Figure 1

DC03H142

1. FRONT 2. REAR

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3. RIGHT HAND SIDE 4. LEFT HAND SIDE

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

1-3

CHAPTER 1 - GENERAL INFORMATION

MACHINE COMPONENTS

5

6 7

4

10 11 12 13

3

14 2

15

8

16 9 17

1

18 19

32 31

20 30 29

21 22

28 23

27 26

25

24

Figure 2

DC03H141

MACHINE COMPONENTS

1.

2.

3.

4.

5.

6.

7.

8.

BUCKET BUCKET LINK IDLER LINK BUCKET CYLINDER ARM ARM CYLINDER BOOM BOOM CYLINDER

1-4

9.

10.

11.

12.

13.

14.

15.

16.

OPERATOR CAB SWIVEL JOINT SWING MOTOR BATTERIES HANDRAIL FUEL TANK MAIN CONTROL VALVE HYDRAULIC TANK

17.

18.

19.

20.

21.

22.

23.

24.

ENGINE PUMP ACCESS DOOR HYDRAULIC PUMP COUNTERWEIGHT ENGINE RADIATOR OIL COOLER ENGINE COOLANT RESERVOIR RADIATOR ACCESS DOOR

25.

26.

27.

28.

29.

30.

31.

32.

TRAVEL MOTOR ENGINE AIR CLEANER TRACK GUIDE UPPER ROLLER (2 EACH SIDE) LOWER ROLLER (7 EACH SIDE) TRACK SPRING (1 EACH SIDE) TRACK IDLER (1 EACH SIDE) TRACK SHOE ASSEMBLY

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CHAPTER 1 - GENERAL INFORMATION

IDENTIFICATION NUMBERS MODEL, SERIAL NUMBER, AND YEAR OF MANUFACTURE

ENGINE

When ordering par ts, obtaining infor mation or assistance, always supply your Dealer with the type and serial number of your machine or accessories.

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

Figure 4

DC03H139

ENGINE

Make and Model

Serial Number

COMPONENT SERIAL NUMBERS COMPONENT SERIAL NUMBERS

Hydraulic Pump

Swing Reduction Gear Figure 3

DC03H140

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PRODUCT IDENTIFICATION PLATE

Travel Reduction Gears

Model

Travel Control Valve

Serial Number

Attachment Control Valve

Manufacturing Year

Swing Control Valve

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CHAPTER 1 - GENERAL INFORMATION

NOTES

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

CHAPTER 2

SAFETY, DECALS, AND HAND SIGNALS TABLE OF CONTENTS SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Safety Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Utility Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

OPERATOR PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Mounting and Dismounting Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Starting and Stopping Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Operating Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Maintenance Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Fuel Handling Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Burn Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Hazardous Chemical Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Transporting Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Roll-Over Protective Structure (If equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Seat Belt Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 How to Handle Life Hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Specific Precautions to this Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 HAND SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

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NOTES

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

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

M171C

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

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

· The first panel indicates the nature of the hazard.

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

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

and

STOP

if

Safety decals should be checked every 2000 hours for legibility and condition. Replace a questionable decal BEFORE it becomes eligible.

In harsh conditions, such as heavy land clearing, decals may need to be replaced more often.

SAFETY AREA

1

Figure 1

BC02N197

OPERATOR’S MANUAL STORAGE SPACE

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

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

2 BC02N198

Figure 2

1. WORKING AREA 2. SAFETY AREA

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

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

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

IMPORTANT: The safety messages in this chapter point out conditions which can happen during the normal operation and maintenance of your machine.

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

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

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

· · · ·

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

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

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

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

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

Figure 3

RH99G001

CALL ALL LOCAL UTILITY COMPANIES BEFORE YOU PERFORM ANY MACHINE OPERATION

Know the utility color code (U.S.A. and Canada): Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red Gas, Oil, or Petroleum. . . . . . . . . . . . . . . . Yellow Communication, Telephone, Television. . Orange Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Blue Sewer . . . . . . . . . . . . . . . . . . . . . . .Green/Brown Proposed Excavation . . . . . . . . . . . . . . . . .White Surveying . . . . . . . . . . . . . . . . . . . . . . . . . . .Pink Reclaimed Water and Slurry . . . . . . . . . . . Purple After locating any buried utility lines, carefully dig a hole by hand and/or automatic vacuum equipment to the utility line to verify the location and depth of the line.

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OPERATOR PRECAUTIONS PERSONNEL

MOUNTING AND DISMOUNTING PRECAUTIONS

· Be prepared for emergencies. Always have a first

· Use the recommended hand holds and steps with

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

at leas three points of support when getting on and off the machine. Keep steps and platform clean.

Face the access system when climbing up and down

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

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

· Certain protective equipment should be replaced

· Do not jump off the machine. · Do not dismount while the machine is in motion. · Foreign material or grease on the steps and hand rails can cause an accident. Keep the steps and hand rails clean.

STARTING AND STOPPING PRECAUTIONS

and renewed upon age and wear. Old hard hats may not afford the original users intention. Faded and soiled vest are no longer as highly visible as original intent.

See the manufacture’s recommendation.

· Walk around the machine and warn all personnel

· Do not rush. Walk, do not run. · Know and use the hand signals required for

· Walk around the machines tool, attachment, or

particular jobs and know responsibility for signaling.

who

has

the

GENERAL

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

· Do not operate this machine or perform maintenance work if you have not had appropriate training and read and fully understand the instructions and warnings in this manual.

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

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

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

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

· Remove all loose object stored in the machine.

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

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

Sound the horn, if equipped, before starting. furthermost contact point to view operation danger area from the work site personnel view and angle.

· Check that the parking device is applied, place the transmission in neutral or park as specified by the manufacturer, and disengage the PTO, if so equipped, before starting the machine.

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

· Start and operate the machine only from the operator’s station.

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

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

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

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

· Do not operate the engine in an enclosed area without adequate ventilation.

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

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

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

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2-5

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

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

· If a failure that causes loss of control such as steering, service brakes or engine occurs, stop the machine motion as quickly as possible, remove the starter key or disconnect switch key. Place a do not operate tag on the machine and keep it securely parked until the malfunction is corrected or the machine can be safely towed.

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

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

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

· Carry loads in recommended positions for maximum stability.

· Never lift loads in excess of capacity. · Use the recommended machine ballast and counterweighting.

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

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

· Use the recommended transport devices when roading the machine.

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

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

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

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

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

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

· Contact

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

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

You MUST HAVE THE POWER DISCONNECTED OR KEEP A SAFE WORKING DISTANCE from the lines, cables, or power station. Keep all parts of the machine a safe distance away from the power source. See the decal on the machine. Page 2-22.

You must also know any federal, state/provincial, or local safety codes or regulations that apply to the job site.

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

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

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

· Select a gear that will prevent excessive speed

· If you have extreme conditions, such as a fire, etc.,

· Watch for bystanders and never allow anyone to

when going downhill. Do not coast downhill.

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

Provide and escort for roading where required.

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

2-6

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

· Do not operate the machine if you do not feel well.

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

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

MAINTENANCE PRECAUTIONS

· Do not attempt repairs unless trained. Refer to

· Stay away from hazardous areas such as ditches,

manuals and experienced repair personnel for help.

overhangs, etc. Walk around the work area before you start and look for hazards.

· Before beginning any inspection or maintenance

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

procedures, secure a “DO NOT OPERATE” tag to the operators console to inform the operator that the machine will be inoperable for inspection and maintenance. This tag will prevent accidental starting of the machine. See Figure 4.

Figure 4

SK32004006

· Wear protective glasses and other required safety equipment machine.

when

servicing

or

repairing

the

· Wear gloves to protect hands when handling cable.

· Disconnect the battery before working on the electrical system. Know the consequences of disconnecting any electronic or computer devices.

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

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

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

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

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

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

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2-7

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

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

· When inflating tires, use a self-attaching inflation chuck with remote shutoff and stand clear of the tire. Position yourself beside the tire and not beside the rim.

· When absolutely necessary to tow the machine, do not exceed the recommended towing speed. Be sure the towing machine has sufficient braking capacity to stop the towed load. If the towed machine cannot be braked, a towbar must be used or two towing machines must be used. - one in front pulling and one in the rear to act as a brake.

Avoid towing over long distances.

· Observe proper maintenance procedures. · Whenever servicing or replacing hardened pins, etc., use a brass drift or other suitable material between the hammer and pin.

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

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

FUEL HANDLING PRECAUTIONS

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

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

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

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

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

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

· Never use fuel for cleaning purposes. · Use the correct fuel grade for the operating season.

2-8

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

Antidote: EXTERNAL - Flush with water.

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

DO NOT induce vomiting. Seek medical attention immediately.

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

WARNING: BATTERIES PRODUCE EXPLOSIVE GASES. Keep sparks, flame, cigars and cigarettes away. Ventilate when charging or using in enclosed area. Always wear eye protection when working near batteries. Wash hands after handling. KEEP OUT OF REACH OF CHILDREN. M144B

· When the battery electrolyte is frozen, the battery

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

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

HAZARDOUS CHEMICAL PRECAUTIONS

· If you are exposed to or come in contact with hazardous chemicals you can be seriously injured.

The fluids, lubricants, paints, adhesives, coolants, etc., used with your machine can be hazardous.

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

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

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

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

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

dealer

for

correct

disposal

TRANSPORTING PRECAUTIONS K now t he r ul es, l aw s, a n d s afet y e qu i pm en t necessary for transporting this machine on a road or highway.

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

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

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

SEAT BELT PRECAUTIONS

Figure 6

BC02N200

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

WARNING: Before starting the engine ensure seat belts are securely fastened. The seat belt can help insure your safety if it is used and properly maintained. Never wear a seat belt loosely or with slack in the belt system. Never wear the belt in a twisted condition or pinched between the seat structural members.

M422A

WARNING: Securely fasten your seat belt.

Your machine is equipped with a ROPS cab, ROPS canopy or ROPS frame for your protection. The seat belt can help insure your safety if it is used and maintained. Never wear a seat belt loosely or with slack in the belt system. Never wear the belt in a twisted condition or pinched between the seat structural members.

1

M437

2

HOW TO HANDLE LIFE HAMMER Figure 5

BC02N375

1. RIGHT-HAND BELT STRAP 2. LATCH MECHANISM

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

A life hammer is provided on the right 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 seat belt, etc. See Figure 7.

2. Tighten the seat belt by pulling on the loose end on the right-hand seat belt.

YQ101BREAKGLASS

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Figure 7

2-9

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS SPECIFIC PRECAUTIONS TO THIS MACHINE

· Always know where the travel motors, (travel reduction motors), (final drives), (sprockets), are in relation to the upperstructure.

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

· Never smoke while refuelling. · Do not use tractive force of the machine for loading the bucket attachment nor to push or pull any objects.

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

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

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

· Do not operate bucket and arm cylinders to stroke end repeatedly.

· Do not over exert the machine’s capacities. · Never pull standing objects toward the machine. · Do not use the long reach attachment for general construction work at any time.

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

DECALS WARNING: An illegible or missing decal can have far-reaching consequences. Inspect decals daily.

CE-NA000

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

CE-NA000

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

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

Figure 1

PE20T01014P1

SWING-DANGER

Two decals. One on each side of the rear counterweight.

Figure 2

DC03J050

HOT COOLANT

Located on top of the engine radiator.

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2-11

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

Figure 3

YN20T01009P1

STOP ENGINE - WARNING

Located on top of the engine radiator.

Figure 4

YN20T01001P1

PREVENT BATTERY EXPLOSIONS - WARNING

Located on the hydraulic tank.

YN20T01015P2

Figure 5 BOOSTER CABLE - WARNING

Located on the hydraulic tank.

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Figure 6

YN20T01017P1

AVOID ACID BURNS - WARNING

Located on the hydraulic tank.

Figure 7

DC03J046

PRESSURIZED HOT OIL - WARNING

Located on top of the hydraulic tank.

Figure 8

YN20T01014P1

HYDRAULIC OIL CHECK POSITION - NOTICE

Located on the hydraulic tank.

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

Figure 9

DC03H145

DO NOT CLIMB - WARNING

Located on the engine cover.

Figure 10

PY20T0169P1

HANDLING BATTERY - DANGER

Located on the hydraulic tank.

YN20T01221P1

DO NOT USE COUNTERWEIGHT LIFTING - DANGER

Located on the counterweight.

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Figure 11

YN20T01220P1

ROTATING AND HOT PARTS - CAUTION

Located on the engine hood.

Figure 12

YT20T01040P1

AIR CLEANER - CAUTION

Located on the air cleaner.

Figure 13

YN20T01013P1

BUCKET TO CAB CONTACT - CAUTION

Located on the right-hand, inside of the cab.

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

Figure 14

2432T6110

ADJUSTING TRACK TENSION - WARNING

Located on the right-hand, inside of the cab.

Figure 15

PY20T01062P1

OPERATION BY FOOT PEDAL - CAUTION

Located on the right-hand, inside of the cab.

Figure 16

PY20T01073P1

SAFETY LOCK LEVER - WARNING

Located on the right-hand, inside of the cab.

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Figure 17

YN20T01016P1

GENERAL PRECAUTIONS - WARNING

Locate on the right-hand, inside of the cab.

Figure 18

YN20T01338P1

BOOSTER CABLE - WARNING

Located on the hydraulic tank.

Figure 19

YN20T01006P1

ELECTRICAL POWER LINES - WARNING

Located on the right-hand, inside of the cab.

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

Figure 20

YY20T01039P1

SELECTOR VALVE - CAUTION

Located on the right-hand, inside of the cab.

Figure 21

DC03J143

LIFTING FRONT WINDOW - CAUTION

Located inside the front window.

Figure 22

YT20T01054P1

NIBBLER AND BREAKER OPERATION POSITION - CAUTION

Located on the rear compartment cover.

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Figure 23

DC03J147

KEEP CLEAR WORKING AREA - DANGER

Two decals. One located on each side of the arm.

Figure 24

DC03J129

HANDRAIL - WARNING

Located on the right-hand, inside of the cab.

Figure 25

YN20T01495P1

CALIFORNIA PROPOSION 65 - WARNING

Located on the hydraulic tank.

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

Figure 26

2432T6457

CALIFORNIA PROPOSITION 65 - WARNING

Located on the right-hand, inside of the cab.

Figure 27

YN20T01039P1

CHECKING CONTROL FUNCTION - WARNING

Located on the right- hand, inside of the cab.

Figure 28

DC03J072

ENGINE HOOD OPEN - CAUTION

Located on the engine hood.

2-20

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

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

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.

SK32003046

Raise Load Vertically Face Machine Operator, raise right forearm vertical, with index finger pointing up and move hand in a small circular motion. See Figure 29.

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. See Figure 32.

Figure 29

SK32003044

Lower Load Vertically

SK32003047

Face Machine Operator, extend right arm down, point index finger down and move hand in small circular motion. See Figure 30.

Figure 32

Raise Boom Face Machine Operator, extend right ar m out horizontally from shoulder, make a fist with thumb up.

See Figure 33.

Figure 30

SK32003045

Move Load In Horizontally Face Machine Operator, extend right arm toward operator with hand facing operator and move hand in direction of movement required. See Figure 31.

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Figure 31

Issued 02-04 Bur

SK32003048

Figure 33

Lower Boom Face Machine Operator, extend right ar m out horizontally from shoulder, make a fist with thumb down. See Figure 34.

2-21

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

SK32003049

Figure 34

Figure 37

SK32003052

Swing Left

Arm Out

Face Machine Operator, extend right ar m out horizontally from shoulder, make a fist with index finger pointing in swing direction. See Figure 35.

Face Machine Operator, bend at elbows with arms facing operator, make fists and point thumbs out away from each other. See Figure 38.

SK32003050

Figure 35

Figure 38

SK32003053

Swing Right

Counter Rotate Left

Fac e M ac hi ne O pe rato r, ext en d le ft a r m ou t horizontally from shoulder, make a fist with index finger pointing in swing direction. See Figure 36.

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. See Figure 39.

SK32003051

Figure 36

Arm In SK32003054

Face Machine Operator, bend at elbows with arms facing operator, make fists and point thumbs in toward each other. See Figure 37.

2-22

Figure 39

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. See Figure 40.

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Figure 40

SK32003055

SK32003058

Figure 43

Travel Forward

Open Bucket (Bucket Out or Dump)

Face Machine Operator, bend both elbows in, make fists and rotate fists one over the other in a reverse circular motion. See Figure 41.

Face Machine Operator, hold left hand in, open and stationary, hold right hand in, make fist with index finger pointing toward left hand and move right hand in small forward circular motion. See Figure 44.

Figure 41

SK32003056

SK32003059

Travel Reverse Face Machine Operator, bend both elbows in, make fists and rotate fists one over the other in a forward circular motion. See Figure 42.

SK32003057

Figure 44

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. See Figure 45.

Figure 42

Close Bucket (Bucket In or Dig) SK32003060

Face Machine Operator, hold left hand in, closed and stationary, hold right hand in, make a fist with index finger pointing toward left hand and move right hand in a small forward circular motion. See Figure 43.

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Figure 45

Turn Right Face Machine Operator, raise left forearm up, make fist with left hand and hold stationary, bend right hand arm in, make fist with right hand and rotate right fist in a small forward circular motion. See Figure 46.

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

SK32003061

Figure 46

Figure 49

SK32003064

Move This Much

Emergency Stop

Face Machine Operator, raise both forearms up, hands open and facing each other, move hands in laterally indicating how far to go. See Figure 47.

Face Machine Operator, raise both ar ms out horizontally from shoulders with hands open and facing down, move arms in a horizontal motion back and forth. See Figure 50.

SK32003062

Figure 47 Figure 50

SK32003065

Move Slowly Fa c e M a c h i n e O p e r a t o r, r a i s e l e f t a r m o u t 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).

See Figure 48.

Stop Engine Face Machine Operator, right arm at side, draw left thumb or index finger across throat. See Figure 51.

SK32003066

SK32003063

Figure 51

Figure 48

Stop Fa c e M a c h i n e O p e r a t o r, r a i s e l e f t a r m o u t horizontally from shoulder with hand open and facing down, move arm in a horizontal motion back and forth. See Figure 49.

2-24

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

CHAPTER 3

INSTRUMENTS AND CONTROLS TABLE OF CONTENTS INSTRUMENTS AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cab Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cab Door Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cab Windshield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Opening and Closing Door Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Opening and Closing Sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Operator Manual Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator Seat Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator Weight Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seat Height Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Seat Front to Back Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Stand Front to Back Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Arm Rest Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Head Rest Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

3-3 3-3 3-3 3-4 3-4 3-4 3-4 3-5 3-5 3-5 3-5 3-6 3-6 3-6 3-6 3-6 3-7 3-7 3-7 3-7

OPERATOR’S COMPARTMENT CONTROLS AND ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 OPERATOR CAB CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Safety Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Throttle Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Auto Acceleration Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Hydraulic Auto Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Left Hand Operator Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Right Hand Operator Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Left and Right Travel Levers and Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Gauge cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Travel Speed Select Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 L.C.D. Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Normal Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Warning Displays and alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Service Function Icon Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 Releasing Hydraulic System Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 24 Volt Cigarette Lighter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 Location for Optional Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 Cup Holder and Ashtray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 Climate Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 Climate Control Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 Air Outlet Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 Fundamental Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 Control Panel Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 Double Pump Flow Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 Rear Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 KPSS and Swing Parking Brake Release Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 12 Volt Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 Fuse Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 Issued 02-04

Bur

6-82410NA

3-1

CHAPTER 3 - INSTRUMENTS AND CONTROLS Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28 Engine Emergency Stop Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28 Pattern Control Change ISO (Excavator) to BHL (Backhoe/Loader) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29 MACHINE ACCESS COMPARTMENTS AND DOORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30 Engine Coolant and Engine Air Cleaner Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30 Main Pump Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30 Fuel Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30 Battery Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30 Engine Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31

3-2

Issued 02-04

Bur

6-82410NA

CHAPTER 3 - INSTRUMENTS AND CONTROLS

INSTRUMENTS AND CONTROLS CAB DOOR

CAB DOOR LATCH

1

3

Figure 1

YQ102DOORLOCK

ACABLATCH

Figure 5

The cab door can be latched in a full open position.

Open the door until it locks into the cab latch (3).

When operating the machine the door must be locked in a full open or full closed position.

2

Figure 2

YQ102DOORLATCH

To open the cab door, use the handle (1) from the outside and use the handle (2) from the inside.

YQ102OPENDOORLATCH

WARNING: Be careful not to get your hand or anything caught in the door when closing it.

Figure 6

To close the door from inside use this lever.

Figure 3

Figure 4

YQ102DOORLOCK

The cab may be locked with the starter switch key.

6-82410NA

Issued 02-04 Bur

3-3

CHAPTER 3 - INSTRUMENTS AND CONTROLS CAB WINDSHIELD

REMOVING AND STORING LOWER FRONT WINDOW

The upper front window will slide to the cab overhead for storage. The lower window may then be removed to open the entire cab front for operator comfort.

WARNING: Make sure you follow the instruction below properly. If the windshield and window are not handled correctly they could slip and injure your fingers or hand.

Figure 7

OPENING

1 Figure 9

YQ102REMOVEGLASS

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

2. Securely store the removed lower front window in th e ho ld er at t he r ea r o f c ab, b eh in d th e operator’s seat.

2

YQ102FRONTWINDOWUNLOCK

Figure 8

1. Pull the lock levers (1) on the right and left sides of front window upper section to unlock the window.

2. Hold the handles on the upper central (2) and lower left sides of the front window. Lift the front window up and slide overhead all the way to the back of the cab. Pull down the lock levers on both sides to lock the window in place.

IMPORTANT: Be sure both sides are locked into place before releasing the handles.

WARNING: Special attention must be paid not to injure hands and others when the front window is being closed. Always make sure to properly lock the front window in place to avoid injury.

Figure 10

YQ102LOWGLASSONHOLDER

3. Secure by inserting the right, left and bottom portions of glass into the holders provided.

CLOSING 1. Release the lock levers at the upper rear of the cab.

2. Hold the handles on the upper central and lower left sides of the window and slowly bring the glass down.

3-4

Issued 02-04

Bur

6-82410NA

CHAPTER 3 - INSTRUMENTS AND CONTROLS Opening and Closing Door Glass

OPERATOR MANUAL STORAGE The Operator’s Manual storage pouch is located on the back of the operators seat. Keep the Operator’s Manual in this location at all times for quick, easy reference.

Figure 11

YQ102DOORWINDOW

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

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

YQ102SEATPOCKET

Figure 13

OPENING AND CLOSING SUNROOF

Figure 12

YQ102CABDOME

Pull the right and left side locks inward to open the sunroof. Close the sunroof and pull the locks inward.

The sunroof can be left slightly open to ventilate air by placing lock “A” section on “B” section.

CAB DOME LIGHT 1. Turn the Cab Dome Light ON by pushing the switch to the right.

2. Turn the Cab Dome Light OFF by pushing the switch to the left.

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

6-82410NA

Issued 02-04 Bur

3-5

CHAPTER 3 - INSTRUMENTS AND CONTROLS OPERATOR SEAT ADJUSTMENTS The operator seat incorporates several adjustment mechanisms to insure operator comfort, ease of operation and operator safety.

SEAT RECLINING ADJUSTMENT

OPERATOR WEIGHT ADJUSTMENT

Figure 16

YQ102RSSEATADJUST

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

YQ102SEATSUSPADJST

Figure 14

Rotate the Adjustment knob until weight read out is close to the operator’s weight at the end of the dial.

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

SEAT FRONT TO BACK ADJUSTMENT

SEAT HEIGHT ADJUSTMENT

Figure 17

YQ102SEATFWDADJST1 YQ102LSSEATADJUST

Figure 15

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

1. Pull up on top bail for seat adjustment and move seat forward or backward to desired position.

2. Release bail to lock seat in position.

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

3-6

Issued 02-04

Bur

6-82410NA

CHAPTER 3 - INSTRUMENTS AND CONTROLS CONTROL STAND FRONT TO BACK ADJUSTMENT

Figure 18

YQ102SEATFWDADJST2

SEAT BELT

YQ102BUCKLEUP

Figure 21

1. Pull up on bottom bail for control stand adjustment and move entire frame forward or backward to desired position.

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

2. Release bail to lock the control stand in position.

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

ARM REST ADJUSTMENT

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

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

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

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

Figure 19

YQ102ARMREST

Lower the arm rest and with finger, turn adjustment wheel until arm rest is in desired position.

HEAD REST ADJUSTMENT

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

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

Figure 20

YQ102HEADREST

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

2. Raise or lower head rest to desired height.

6-82410NA

Issued 02-04 Bur

3-7

CHAPTER 3 - INSTRUMENTS AND CONTROLS

OPERATOR’S COMPARTMENT CONTROLS AND ACCESSORIES 2 20

3

4

1 5

19

6

18 17

7 8

16 15

9 10

14

13

12

11 Figure 22

BC04B001

COMPONENTS 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

3-8

LEFT TRAVEL PEDAL AND LEVER TRAVEL SPEED SWITCH RIGHT TRAVEL PEDAL AND LEVER GAUGE CLUSTER 24 VOLT CIGARETTE LIGHTER RIGHT HAND OPERATOR CONTROL LEVER AUTO ACCEL SWITCH THROTTLE POTENTIOMETER HYDRAULIC AUTO WARM-UP IGNITION SWITCH

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

SWING BRAKE RELEASE SWITCH (UNDER COVER) KPSS RELEASE SWITCH (UNDER COVER) FLASHER BREAKER / NIBBLER SELECT SWITCH 12V POWER SUPPLY CLIMATE CONTROL PANEL RADIO HYDRAULIC FUNCTION LOCK OUT LEVER LEFT HAND OPERATOR CONTROL LEVER HORN BUTTON

Issued 02-04

Bur

6-82410NA

CHAPTER 3 - INSTRUMENTS AND CONTROLS

OPERATOR CAB CONTROLS SAFETY LEVER

IGNITION SWITCH

Figure 23

This lever is used to activate or de-activate the left and right operator control functions for hydraulics.

Pull the lever up, as shown above to lock out functions. Always shut down the engine and place the lever up before leaving the cab.

IMPORTANT: If equipped, the dozer function lever is still active with the Safety Lever up.

BC04B041

Figure 26

The Ignition Switch is located on the right hand operator console and has 5 operating positions.

HEAT - This position is used for starting the engine in cold climates. In temperature below 32° F (0° C) turn the key to this position and E/G PREHEAT will display. When FINISH PREHEAT is displayed and the buzzer sounds the operator may start the engine.

Figure 24

Place the lever in the down position to activate the left and right operator control hydraulic functions.

HORN

OFF - When Key is turned to this position, the en gi n e s top s a nd el ec tr ic a l powe r t o th e machine’s electrical system is stopped after approximately 4 seconds.

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

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

START - When the Key is turned to this position, electrical power is supplied to the starter solenoid causing the starter to start the engine. Release the key after the engine starts and it should remain in the ON position.

Figure 25

The horn switch is a momentary push button located on the operator’s left control lever.

IMPORTANT: Always sound the horn before starting the engine to alert personnel of your intention.

6-82410NA

Issued 02-04 Bur

3-9

CHAPTER 3 - INSTRUMENTS AND CONTROLS THROTTLE POTENTIOMETER

DC03J153

AUTO ACCELERATION FUNCTION

Figure 27

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.

NOTES: a. In operation, when the pilot pressure from the hand and pedal control levers does not act for 1 second, and if the position of the throttle potentiometer is higher then 1050 rpm, the auto acceleration actuates automatically and engine speed returns to 1050 rpm. b. When the throttle potentiometer is positioned lower than the auto acceleration speed, the engine speed is maintained to the throttle potentiometer position.

3-10

Figure 28

BC04B042

Press the switch to activate this function for operating fuel efficiency.

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

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

Issued 02-04

Bur

6-82410NA

CHAPTER 3 - INSTRUMENTS AND CONTROLS HYDRAULIC AUTO WARM UP

The following actions will stop the Warm Up procedure:

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

· If the auto warm up switch is pressed to the off position, the warm up system is disconnected.

NOTE: In climates below 0°f (-18°c) it may be necessary to use a coolant heater, fuel heater, engine heater jacket and/or additional battery power to aid in starting the engine.

Auto warm up should be utilized anytime the machine is to be operated in climate temperatures below 50°f (10°c) to stabilize machine control response. cold oil can cause erratic machine operation.

Figure 29

BC04B043

Before turning the ignition switch to the ON position, turn ON the warm up switch located on the right hand control console then start the engine.

NOTE: The auto warm up system will not activate if the ambient temperature is above 50°f (10°c).

Warming up the engine: The “WARMING UP” is displayed on the multi display after operating the engine for 3 minutes at auto accel speed (1050 rpm). When the accel dial set value is the value for deceleration or lower, the engine speed returns to the speed set by the throttle potentiometer.

Warming the hydraulic oil sequence:

· Pump max. flow rate at engine speed 1050 rpm for 3 minutes.

· Pump max. flow rate with control valve closed at engine speed 1600 rpm for 5 minutes.

· Pump max. flow rate with control valve fully open at engine speed 1600 rpm for 5 minutes.

· Pump max. flow rate at engine auto accel speed (1050 rpm) for 10 minutes.

WARMING UP is displayed on the multi-display during warming up operation.

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

6-82410NA

Issued 02-04 Bur

3-11

CHAPTER 3 - INSTRUMENTS AND CONTROLS Left Hand Operator Control Lever

RIGHT HAND OPERATOR CONTROL LEVER

Figure 31

Figure 30

The Left Hand Operator Control Lever is located at the top front of the LH operator console. Its purpose is to allow the operator to control operations of the swing and arm. Operating speed of function is variable from stop to full stroke depending on how far lever is operated. The left hand operator control lever has 4 basic operational functions.

· · · · ·

FORWARD - Variable speed ARM out.

BACKWARD - Variable speed ARM in.

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

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

· · · · ·

FORWARD - Variable Speed BOOM down.

BACKWARD - Variable speed BOOM up.

LEFT - Variable speed BUCKET in (Digging).

RIGHT - Variable speed BUCKET out (Dump) CENTER - Neutral position.

Figure 32

BC04B054

WARNING: This machine is equipped with 2 Operating Patterns. Check the control functions in a safe area before operating this machine. Failure to check the control pattern before operating can cause unexpected machine movement, death or serious injury.

3-12

Issued 02-04

Bur

6-82410NA

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

1

1

Figure 33

BC04B049

1. LEFT TRAVEL LEVER AND PEDAL

The travel levers and pedals are located in front of the operator seat. They are used to move the left or right track of the machine forward or reverse. These controls have 2 basic operational functions.

A. FORWARD: Variable speed forward track movement.

B. REVERSE: Variable speed reverse track movement.

C. CENTER: Neutral position.

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

WARNING: It is the responsibility of the operator to always know the location of the travel motors in relation to the upperstructure.

ALL instructions and procedures in this manual are with travel motors to the rear of the operator and upperstructure.

Figure 34

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Issued 02-04 Bur

3-13

CHAPTER 3 - INSTRUMENTS AND CONTROLS GAUGE CLUSTER

4 2

HH H

S

FC

1

3

Figure 35

DC03J154

1. Fuel Gauge This gauge indicates the amount of fuel in the tank.

The LOW FUEL LEVEL icon will illuminate when the tank needs topping off. Refill the tank immediately, once the icon illuminates.

2. Water Temperature Gauge This gauge indicates the temperature of the engine coolant, and activates 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 the operator must move th e e n gi n e t hr ot t l e c on t r o l to I D LE u n ti l t h e temperature move back into the white portion of the gauge.

3. KPSS Work Mode Switch The KPSS Work Mode Switch is located on the lower side of the monitor and has 3 operating functions. By pressing the switch the operator may change modes and the appropriate mode lamp (2) will illuminate.

After starting the engine, the mode switch defaults to the S mode.

The operator may select the most effective work mode for the job site. The mode will begin in S on start up and then switch to H and FC and back to S in succession.

S Mode: Provides standard power and best fuel consumption.

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

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

4. KPSS Work Mode Indicators The work mode selected will illuminate.

3-14

Issued 02-04

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

9

5

6

7

8 Figure 36

5. Screen Change Switch Use this switch to scroll through the available functions. After the engine is started OK will appear on the screen.

Figure 37

8. Windshield Wiper Switch Press the switch once and the wiper will work intermittently.

Press the switch and the engine RPM will display.

Press the switch again and the wiper will work continuously.

Press the switch again and the Engine Oil Change cumulative time will appear.

Press again to turn the wiper off.

6. Buzzer Stop Switch When the engine coolant temperature is too high or various sensors in the controller system fail an alarm buzzer will sound. Press the switch to stop the button.

9. Washer Switch Press this switch and washer fluid is sprayed while it is depressed.

IMPORTANT: Make certain the washer reservoir has washer fluid before operating washer.

NOTE: For some alarms it will be necessary to turn the engine off.

7. Working Light Select Switch Press this switch to turn the working lights on. Press again to turn them off.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS TRAVEL SPEED SELECT SWITCH

BC04B059

L.C.D. DISPLAY

Figure 38

Select high speed (2nd) or low speed (1st) with this switch located on the right-hand travel lever. On start up the machine will be in low (1st). Push the switch for high (2nd), push again to return to low (1st).

Figure 40

YQ102MULTIDISPLAY

WARNING: Do not use High (2nd) when performing delicate operations such as pipe laying, or loading the machine onto a trailer.

Do not change travel speed while loading onto trailer.

Figure 39

The LCD Display is illustrated above and will display the icons listed in this section. Study these icons and their definitions so that possible ser vice and maintenance situations will be quickly recognized.

NORMAL DISPLAYS System Status Display

LOW (1st) Used on rough or soft road, slope, narrow place, or when powerful tractive force is required.

HIGH (2nd) Used when moving on flat, hard ground.

This message will display after the key switch is turned ON and all machine system and components are checked by the CPU and fo und to b e normal.

Day Time Display Five seconds after the system status is shown on the LCD, the time will be displayed on the monitor. See “Monitor T i m e A d j u s tm e n t” i n t h i s section for details on how to set this feature Engine R.P.M. Display Actual engine speed. When auto accel is deactivated, RPM shown corresponds to the throttle potentiometer position.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS WARNING DISPLAYS AND ALARMS Some warning displays will activate an alarm.

I.T.C.S. Controller / CPU Display This warning will display when a p r o b l e m ex i s t s i n t h e I .T.C. S. ( In t e l l i ge n t To t al Control System).

Figure 41

Engine Lubrication Cumulative Time 256 hours have elapsed since the change of the engine oil.

This message shows the total cumulative time since the last engine oil change.

Fuel Filter Cumulative Time 256 hours have elapsed since the change of the fuel filter.

This message shows the total cumulative time since the last fuel filter change.

Hydraulic Filter Cumulative Time 256 hours have elapsed since the change of hydraulic oil filter.

This icon shows the total cumulative time since the last time the hydraulic oil filter was changed.

Hydraulic Oil Cumulative Time 256 hours have elapsed since the change of the hydraulic oil.

This message shows the total cumulative time since the last oil change.

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

Should this icon remain on display, stop operation, shut down the engine, remove rear p a n e l c ove r, a n d f l i p t h e KPSS (not used) and Swing Parking Brake switches to their release position.

Contact a New holland Construction technician for repair.

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

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

Contact New Holland Construction technician for repair.

KPSS Release Display and Alarm Turn the “KPSS Work Mode Release Switch” on the rear side of operator’s seat to the “RELEASE” position, and this warning is displayed.

While this war ning is d i s p l ay e d , t h e n o r m a l electro-hydraulic controls are de- acti vated . This switc h should be used only in the event of emergency. Contact New Holland Construction technician for repairs.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS Engine Pre-Heating Display

Engine Air Cleaner Display

This message is displayed when the key switch is turned to the heat position and the engine preheat circuit is activated.

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

T h i s wa r n i n g w i l l d i s p l ay should the Engine Air Filters become restricted.

If this message is displayed, stop the engine immediately and clean or replace engine air cleaner element(s) as required.

Battery Charging System Display

Engine Pre-Heat Complete Display and Alarm

This warning will display if the electrical charging system is not functioning properly.

This message is displayed w h e n t h e P R E H E AT i s completed. The monitor alarm will sound continuously.

If alarm the can’t be cancelled by the buzzer stop switch, turn the ignition key to the O F F p o s i t i o n . , wa i t fo r 4 seconds, then star t the engine. Continuous preheat after this icon is displayed could cause damage to the engine. DO NOT OPERATE THE PREHEAT POSITION OF THE KEY SWITCH FOR MORE THAN 20 SECONDS AT THE TIME. Engine Oil Pressure Display and Alarm This message will display and the alarm will sound if the Engine Oil Pressure is below a safe operation.

Stop the engine immediately and check engine oil level. If the e ngi ne ha s LOW OIL PRESSURE, it will automatically go to LO idle.

Engine Coolant Temperature Display and Alarm This warning will display and the alarm will sound should the Engine Coolant Temperature rise above safe operating temperature.

If this system is displayed have the electrical charging system repaired immediately.

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

Fuel Level Display T h i s wa r n i n g w i l l d i s p l ay should the Fuel Level in the tank reach a minimum requirement.

When this message displays refill the fuel tank immediately.

Auto Warming Up display This message is displayed to indicate the warming up operation of the engine and hydraulic oil when this system is activated.

The following actions will cancel the warm up function:

· Turn off the auto warm up switch. · Turn the key switch OFF. · Activate the left or right operator control lever.

NOTE: Returning the left or right operator control levers to neutral will re-activate the function.

Reduce the engine RPM to idle and allow the engine to cool evenly. If the temperature does not come down to a safe operating level stop operation and service as necessary.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS Auto Warming Up Finish Display This message is displayed when the warming up of the engine and hydraulic oil is finished or when the warming up system is forced to stop.

The monitor alarm will sound continuously for 5 seconds.

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

The recommended oil change interval is every 500 hours of operation. After changing the oil it will be necessar y to re-set the cumulative time.

Hydraulic Pressure Drain Display and Alarm This message will display when the hydraulic system pressure release has been ac t i vat ed . Th e al a r m w i ll sound intermittently during the draining process.

Hydraulic Pressure Drain Fail Display This message will display when the hydraulic system pressure drain process fails.

The alarm will sound continuously.

Turn the ignition key OFF to cancel the a l a r m a n d r e p e a t t h e hy d r a u l i c p r e s s u r e d r ai n p r oc e du r e b e fo r e servicing the machine.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

Service Function Icon Sequence The following chart is provided to familiarize personnel with the priority of the Monitor Display Icons. Pay close attention to these icons as they can help in avoiding unnecessary repairs and expense.

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

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

Figure 42

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CHAPTER 3 - INSTRUMENTS AND CONTROLS RELEASING HYDRAULIC SYSTEM PRESSURE

The engine speed will switch to low idle and the monitor will display DRAINING HYD PRESSURE and the monitor alarm will sound intermittently.

4. Operate the control levers several times to release the system pressure.

IMPORTANT: If the Draining Hydraulic Pressure procedure fails FAIL DRAIN HYD PRESS is displayed and the alarm will sound continuously.

5. Turn the ignition switch to OFF. The alarm will stop and after 4 seconds the display will clear.

6. Begin at step 3 again until pressure is released successfully.

Figure 43

BC04B070

A new convenient feature is now incorporated in the electro-hydraulic system to help the operator release the pressure in the hydraulic system directly from the operator’s cab for machine service or to switch auxiliary attachments.

Figure 45

WARNING: Never change oils or filters on a machine that has just completed working.

Allow the machine to cool until oils and fluids are warm, not hot.

Release hydraulic tank pressure before working with any hydraulic or engine fluids.

7. Press the hydraulic tank pressure relief valve and proceed to ser vice or change auxiliar y attachments.

Proceed as follows to release hydraulic system pressure:

Figure 44

BS04B072

1. Select hard, flat ground and place the machine in the position shown.

2. Start the engine with the throttle set at LOW idle.

3. Press and hold the screen change switch and the buzzer stop switch simultaneously for at least 5 seconds.

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3-21

CHAPTER 3 - INSTRUMENTS AND CONTROLS 24 Volt Cigarette Lighter

DC03J170

CUP HOLDER AND ASHTRAY

Figure 46

The cigarette lighter is located on the right side control panel, next to ignition switch. 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.

Figure 48

DC03J172

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

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

LOCATION FOR OPTIONAL SWITCHES

DC03J171

Figure 47

This additional switch panel is provided on the right side console for any machine customization if desired.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS CLIMATE CONTROL PANEL 1. Climate Control Air Conditioner The Climate Control-AC provides a comfortable indoor environment and adjustable control of cab temperature. It removes moisture from humid air and reduces window glass fogging.

AIR OUTLET SELECTOR See Figure 49 Select a preferable air diffuser direction that is most comfortable moving grill by hand.

A, B, C, D ----------- Air Outlets

DC03J198

Figure 49

CONTROL PANEL See Figure 49 and Figure 50

Figure 50

DC03J197

ATTENTION: The lcd display indicates temperature, air outlet mode, compressor ON- OFF - AUTO, recirculate, fresh air, and fan speed.

ATTENTION: The background of the control panel is illuminated whenever the a/c system is activated.

FUNDAMENTAL USE Refer to Figure 50 Before turning the Air Conditioner ON, close the door and windows to achieve the best performance. a. Press the AUTO control switch 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 AUTO indicator in the LCD display will come on.

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The outlet temperature, outlet opening and fan speed are adjusted automatically so that indoor temperature of the cab comes closer to the set temperature. b. Select proper mode manually through recirculate and fresh air capacity selector switch and compressor switch ON - OFF. c. Select preferable fan speed manually through fan speed selector switch when fan speed, selected through auto control is not preferable.

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

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CHAPTER 3 - INSTRUMENTS AND CONTROLS CONTROL PANEL FUNCTIONS

C. Temperature Setting Switch and Display See Figure 53

A. Main Power Switch and Display See Figure 51

Figure 53

YQ102ACPANEL4 YQ102ACPANEL2

Figure 51

a. LCD display is illuminated when the Climate Control-AC is operating. When the Climate Control-AC is stopped, LCD will turned off. b. Press main power switch, and all functions for the Climate Control-AC switch ON or OFF. Each time when this switch is pressed, the f u n c t i o n sw i t c h e s O N a n d O F F. W h e n switched ON, the Control Climate-AC starts operating at the point set before switching OFF (When it is set to AUTO, in auto mode; if NORMAL is selected, then in normal mode).

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.

B. Auto Control Switch and Display See Figure 52

YQ102ACPANEL3

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

Figure 52

a. Press the main power switch to activate the Climate Control-AC and the LCD display will illuminate. b. Press control switch AUTO, and fan speed and air outlet are automatically controlled, and AUTO indicator lamp on LCD display is illuminated. c. When the main power switch is OFF, the system will retain the previous setting in memory. Therefore, when the main power sw i t c h i s p r e s s e d a g a i n , t h e C l i m a t e Control-AC will come on in the auto control mode.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS D. Air Outlet Mode Selector Switch and Display See Figure 54

a. Air outlet position is indicated by the arrow on LCD display. b. Press Air outlet Mode Switch in the condition where auto display light is on, and the display mode is fixed, AUTO indicator lamp on LCD display goes out, and AUTO control of the air outlet opening is released. Press it again, and the level is change to: VENT

BI-LEVEL

FOOT

FACE

(See Figure 55)

Figure 54

YQ102ACPANEL5

Figure 55

DC03J199

E. Defroster Switch and Display

F. Recirculate and Fresh Air Selector Switch and Display

See Figure 56

See Figure 57

Figure 56

DC03J200

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

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DC03J201

Figure 57

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

3-25

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

2. Double Pump Flow Selector Switch

See Figure 58

See Figure 61

Figure 58

DC03J204

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

H. Fan Speed Selector Switch and Display See Figure 59

Figure 61

YQ102TWOPUMPFLOW

Use this switch, provided on the left hand control console, to select a single or double pump flow to the auxiliary system.

· Press it Forward to activate the double pump flow for the auxiliary system.

· Press it Backward to cancel the double pump flow and activate the single pump flow for the auxiliary system.

Figure 59

DC03H205

CAUTION: Do not set this switch to double pump flow, unless the attachment (eg: breaker) requires more than one pump flow, if in doubt, contact New Holland Construction Service Representative.

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

Display

Fan Speed

LCD 4 bars are lit up.

MAX.

LCD 3 bars are lit up.

HIGH

LCD 2 bars are lit up

MEDIUM

LCD 1 bar is lit up.

YQ102AIRCAPDISPLAY

LOW

Figure 60

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

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CHAPTER 3 - INSTRUMENTS AND CONTROLS REAR PANEL

12 VOLT POWER SUPPLY

KPSS AND SWING PARKING BRAKE RELEASE SWITCHES

The 12 Volt power supply is located at the right rear control console.

When ever the CPU MECHATRO CONT. FAIL is displayed on the LCD screen, use the KPSS and Swing Parking Brake release switches to override the computer control system. The switches are located behind the operator’s seat under a rubber grommet.

Proceed as follows:

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.

1. Stop the engine.

2. Remove the rubber grommet cover.

3. Locate the switches to release the KPSS and Swing Parking Brake and flip them to their release position.

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

MAXIMUM CONTINUOUS OUTPUT - 180 Watt FUSE BOX

4. Install the rubber grommet.

5. Start the engine.

NOTE: Contact your New Holland Construction Dealer Service Department for immediate repairs.

Make sure to return these switches to their normal position after repairing the mechatronic system.

NOTE: If engine rpm control is completely lost at the throttle potentiometer, the engine acceleration will have to be controlled manually for temporary operation. Unplug the stepping motor connections before manually controlling the engine acceleration.

Make sure to connect the stepping motor connections after repairs are completed.

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BC04B046

Figure 62

The fuse box is located behind the right side of the operator’s seat. It contains all necessary fuses for the electrical circuits of the machine. Should it become necessary to inspect or change a fuse, remove the fuse box cover by gently pulling each end away from the box. Should a fuse require replacement, use a replacement fuse of the same type and amperage.

Tur n key switch OFF and wait approximately 4 seconds for all electrical power to stop before removing or replacing a bad or blown fuse. The fuse cover incorporates a fuse puller to remove fuses.

Refer to the Maintenance Section of this manual for a detailed diagram and description of fuse box.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS 3. Hour Meter

YQ102HOURMETER

Figure 63

The Hour Meter indicates the total time that the engine has run. It meters the time continuously as long as the engine is running.

ENGINE EMERGENCY STOP CONTROL

BC04B048

Figure 64

The Engine Emergency Stop Control Cable is located at the lower right hand side of the operator’s seat. It is used only in an emergency situation to stop the engine quickly. It has 2 operating positions.

IN - Releases the fuel stop lever on the governor to allow normal starting of the engine.

OUT - Activates the fuel stop lever on the engine governor to immediately stop the engine.

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

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CHAPTER 3 - INSTRUMENTS AND CONTROLS Pattern Control Change ISO (Excavator) to BHL (Backhoe/Loader) WARNING: The attachment must be on the ground with the engine off before changing the operational pattern.

To change the machine’s control pattern from ISO (Excavator) to BHL (Backhoe/Loader) pattern, proceed as follows:

ISOPATTERNDECAL

Figure 67

BHLPATTERNDECAL

Figure 68

DC03K040

Figure 69

Figure 65

BS04B072

1. Place the attachment on the ground, throttle control in low idle, and turn the ignition key off.

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

3. Open the hydraulic tank access cover and support it with the strut.

6. Make sure to place the BHL pattern plate in its respective holder, located below the cab door handle. Make sure BHL pattern is showing.

Figure 66

4. Loosen the wing-nut on the rotary multi control valve and change the position to the desired pattern.

7. Slowly operate Left and Right Operator Control Levers to make sure it matches BHL pattern and to familiarize yourself with the new control pattern.

· I - ISO Pattern · D - BHL Pattern 5. Tighten the wing-bolt.

WARNING: Check machine’s control pattern for conformance to pattern on decal-card in cab. If the pattern does not match the decal-card on the cab door holder, flip the decal-card on to match the machine’s control pattern before operating machine.

Failure to do so could result in injury.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

MACHINE ACCESS COMPARTMENTS AND DOORS ENGINE COOLANT AND ENGINE AIR CLEANER ACCESS

FUEL CAP

.

Figure 72

YQ102FUELTANKCAP

Located behind the cab on the left upperstructure.

BD04B001

Figure 70

The engine coolant bottle and engine air filters are located behind this left side door. The door may be locked with the ignition key.

Make sure engine is off and keep battery cover and engine hood closed when fueling.

BATTERY COMPARTMENT

ATTENTION: Always make sure to use the door stays to lock them open while performing inspection and/or maintenance.

MAIN PUMP ACCESS

Figure 73

Located on the right front of the upper frame. This cover allows access to the batteries and battery relay. This access cover is also locked and unlocked using the ignition key. Use stay to lock the cover open.

BD04B003

Located on the right side of the machine.

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Figure 71

ATTENTION: Always make sure to use the door stays to lock them open while performing inspection and/or maintenance.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS ENGINE COVER

Figure 74

BD04B002

The engine cover is located at the very back top of the upperstructure.Always make sure to use the door stays to lock them open while performing inspection and/or maintenance.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

NOTES

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CHAPTER 4 - OPERATING INSTRUCTIONS

CHAPTER 4

OPERATING INSTRUCTIONS TABLE OF CONTENTS BEFORE OPERATING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Operating the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Starting & Stopping Machine Engine with Temperature above 32°F (0°C) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Starting Machine Engine with Booster Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Connecting Booster Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Auto Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Engine Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Hydraulic Oil Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Manual ENGine Warm Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Control Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Operating Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Operating Pattern Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Basic Operation of Hydraulic Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Safety Lock Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Unlocked Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Locked Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 KPSS Work Mode Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Machine Travel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Operating Both Travel Levers Together . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Turning Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Travel Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Boom Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 Lowering The Attachment When Engine Failure Occurs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 Using Auto Acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Auto Accel Operation and Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 MACHINE OPERATION IN ADVERSE WEATHER CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Operation in Extreme Cold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Operation in Extreme Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Operation in High Altitudes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Operation in Sandy and Dusty Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Operation at Seashore or Salty Climate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Operation in Humid Climate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 RECOMMENDATION FOR LONGER UNDERCARRIAGE LIFE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 BUCKET SELECTION GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 USE OF OPTIONAL ATTACHMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Auxiliary Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Single Flow Configuration (Breaker) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Oil Level Check and Contamination Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-20 4-21 4-21 4-22

TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 Loading the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 SHIPPING Quick reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 MACHINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

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CHAPTER 4 - OPERATING INSTRUCTIONS

NOTES

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CHAPTER 4 - OPERATING INSTRUCTIONS

BEFORE OPERATING THE MACHINE WARNING: Do not attempt to operate this machine unless you have first read and perfectly understood the safety messages and instructions appearing in this manual.

CE-NA000

Before operating this machine, be sure to do the following: 1. Check the level of all fluids (engine oil, hydraulic fluid, and coolant) and make sure that the fluids and lubricants are suitable for prevailing conditions.

2. Carry out the daily maintenance operations.

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

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

5. Check the track assemblies.

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

7. Clean or replace any decals which are illegible. See Decals in Chapter 2.

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

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

10. Remove any obstructions which hinder visibility. Clean the windshield, the windows and the rear view mirrors.

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

12. Make sure no one is on or under the machine. The operator must be alone on the machine.

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

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

15. Work out a convenient means of escape from the machine (emergency exit via the windshield, the rear window glass) in the event of the cab door being jammed or the machine turning over.

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

Emergency shut down Only in cases of emergency, when the key switch fails to shut down the engine, should this method be used.

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

1

Figure 1

BC04B048

1. Pull out the engine emergency stop control (1) located at the lower right hand side of the operator’s seat until the engine stops.

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CHAPTER 4 - OPERATING INSTRUCTIONS OPERATING THE MACHINE WARNING: Check all controls and safety devices in a safe, open area before starting work.

CE-NA000

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

2. Regularly consult the hourmeter to ensure that all ser vicing operations are carried out punctually. See Chapter 5.

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

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

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

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

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

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

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

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

19. Do not stop the engine without running at low idle long enough to prevent turbocharger damage.

See Stopping the engine.

20. See Parking the machine when you have to park the machine.

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

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

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

8. Modify your driving to suit the type of work and working conditions. See Operating instructions in the Job Site Operation section.

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

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

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

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

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

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

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CHAPTER 4 - OPERATING INSTRUCTIONS SELECTING TRAVEL SPEED

Figure 2

BC04B059

The Travel Speed Select Switch is located on the right hand control lever.

On start up the machine will be in LOW (1st).

1. For fast travel speed, depress and release the travel speed select switch once. This puts the travel motors in HIGH (2nd) speed and the lamp for FAST on the gauge cluster display will illuminate.

2. To return to LOW (1st) travel speed, stop travel and depress and release travel speed select switch once. The icon for LOW will display on the gauge cluster.

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4-5

CHAPTER 4 - OPERATING INSTRUCTIONS STARTING & STOPPING MACHINE ENGINE WITH TEMPERATURE ABOVE 32°F (0°C) 1. Move throttle control to LO position.

STOPPING ENGINE - NORMAL CONDITIONS

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

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

4. Turn key to the START position and release as soon as engine starts. Key will automatically return to the “ON” position. Release key after 20 seconds of cranking if engine does not start. Wait at least 2 minutes before attempting to star t engine again to allow starter motor to cool.

Figure 3

BS04B072

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

2. Move throttle to LO position. Allow engine to idle fo r a t l e a s t 5 m i n u t e s t o a l l o w e n g i n e components to cool evenly and prevent damage to the turbocharger.

3. Turn Key Switch to OFF. STARTING & STOPPING MACHINE ENGINE WITH TEMPERATURE BELOW 32°F (0°C) 1. Move throttle control to LO position.

NOTE: WARMING UP will display on the multi display after about 3 minutes.

7. After approximately 25 minutes the WARMING UP display will disappear and the buzzer will sound for 5 seconds to indicate completion.

8. Turn the Auto Warm-Up switch to OFF. NOTE: If the Pilot Control system is activated while the machine is in Auto Warm-Up mode the system will shut down. Warm-Up will start automatically after the Pilot Controls have been in neutral for 10 seconds.

YQ103ENGPREHEAT

Figure 4

2. Turn the key switch to HEAT and preheat for 20 seconds to make star t-up easier. The E/G Preheat Icon will display.

3. Press the Auto Warm-Up Selector Switch located on the right hand switch panel.

4. Turn key switch to ON position.

NOTE: Engine acceleration will be automatic while the hydraulic pump is performing various flow rates.

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

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

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CHAPTER 4 - OPERATING INSTRUCTIONS STARTING MACHINE ENGINE WITH BOOSTER CABLE CONNECTING BOOSTER CABLE 1. Move vehicle or machine to be used for boosting as close to the batter y box of the disabled machine as possible.

CAUTION: 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.

7. Start the engine of the boosting machine in normal manner according to climate conditions.

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

9. Start the engine of the disabled machine in a normal manner according to climate conditions.

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

CAUTION: Use only vehicles or machines with 24v dc electrical system to boost starting this machine.

2. Make certain the key switch of the disabled m a c h i n e i s i n t h e O F F p o s i t i o n b e fo r e proceeding with booster cable connection.

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 on the battery of the disabled machine. See .

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

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

DISCONNECTJUMPINGCABLES

Figure 6

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

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

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

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

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

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

Figure 5

CONNECTINGJUMPINGCABLE

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

WARNING: The negative cable, when connected to the upper frame of disabled machine, may arc causing sparks. sparks coming in contact with batteries could trigger an explosion. never connect negative cable to negative (-) terminal of disabled battery.

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CHAPTER 4 - OPERATING INSTRUCTIONS MACHINE WARM UP AUTO WARM UP

NOTE: If the left or right operator control lever is activated while the warm up system is active, the warm up cycle is aborted. The warm up system will restart after 10 seconds of neutral condition in the pilot control system.

NOTE: If the auto warm up switch is pressed to the off position, the warm up system is disconnected.

Warming Up Complete After an elapsed time of about 26 minutes of warming of hydraulic oil, or when the hydraulic oil temperature switch turns OFF, the warming up indication “WARMING UP” on the multi-display disappears and concurrently buzzer sounds for 5 seconds. Turn the auto warm up switch OFF. CAUTION: While operating the machine with cold hydraulic oil, the operator may experience slow or unexpected movement of functions.

YQ102WARMUP

Figure 7

Before turning the ignition switch to the ON position, turn on the warm up switch located on the left panel and then start the engine.

NOTE: The auto warm up system will not activate if the ambient temperature is above 50°F (10°C).

ENGINE WARM UP The WARMING UP is displayed on the multi display after operating the engine for 3 minutes at auto accel speed (1050 rpm). When the accel dial set value is the value for deceleration or lower, the engine speed returns to the speed set by the accel dial (throttle potentiometer).

HYDRAULIC OIL WARM UP The warm up of hydraulic oil is performed as follows:

· Operation of pump max. flow rate at the engine speed 1050 rpm for 3 minutes.

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

CAUTION: Auto warm up should be utilized anytime machine is started in climate temperatures below 50°f (10°c) to stabilize machine control response.

Cold oil can cause erratic machine operation, MANUAL ENGINE WARM UP PROCEDURE 1. Allow the engine to run for 5 minutes under no load conditions with Throttle Control At LO idle position.

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

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

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

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

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

· WARMING UP is displayed on the multi-display during warming up operation.

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CHAPTER 4 - OPERATING INSTRUCTIONS MANUAL WARMING OF HYDRAULIC OIL This procedure should be started only after the engine has been warmed up.

1. Move Throttle Control to HI idle position.

Figure 8

DC03K043

2. Perform bucket dig operation and hold over relief for 10 to 15 seconds, then operate bucket dump and hold over relief for 10 to 15 seconds.

Figure 9

DC03K044

3. Move Throttle control to Mid position and operate the Boom and Arm controls for 5 to 10 minutes each.

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

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

IMPORTANT: Auto Warm Up should be utilized anytime the machine is started in temperatures below 50°F (10°C) to stabilize machine control response. Cold oil can cause erratic machine operation.

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CHAPTER 4 - OPERATING INSTRUCTIONS CONTROL DECAL OPERATING PATTERN The operating and travel controls of this machine are factory set at ISO Excavator operating patterns for optimum performance of the machine and its system.

OPERATING PATTERN DECAL Figure below is a representation of the CONTROLS decal located inside the right side window of the operator cab. Study this decal and understand the directions each control can be operated and the functions as sociated with eac h movement of particular control. Detailed instructions for each control and its functions are explained on the following pages of this Chapter. Should this decal become damage or missing, install a new decal.

WARNING: Check and make sure that operation’s pattern control matches the decal provided inside the right side window.

WARNING: This machine is equipped with the operational pattern control changer. When changing Control Patterns make sure to place the correct Operation Pattern Control Decal inside the door, below the door handle.

Figure 10

DC03K045X

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CHAPTER 4 - OPERATING INSTRUCTIONS BASIC OPERATION OF HYDRAULIC CONTROLS The following instructions are aimed at providing an operator with the basic function of each hydraulic control. Use of this instructions, and practice with a machine, will allow a given operator to become more efficient in the operation of this equipment.

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

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

YQ102SAFETYLEVERUP

Figure 13

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

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

KPSS WORK MODE SWITCH

Figure 11

DC03K046

It is the operator’s responsibility to always know the location of the travel motors in relation to the upperstructure.

SAFETY LOCK LEVER

YQ102MODESWITCH

Figure 14

Press the work mode selector switch, and S, H, or FC modes can be selected.

NOTE: By default, the EH 130 LC Excavators start in S mode.

KPSS WORK MODE FUNCTIONS Figure 12

YQ102SAFETYLEVERDOWN

1. Unlocked Position Before any Hydraulic Operation is possible the Safety Lock lever must be placed in the UNLOCKED (down) position. Placing the Safety Lever in the UNLOCKED (down) position also positions the LH Operator’s Console in its operating and lock position.

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The KPSS work mode switch allows the operator to select the most effective power for the job.

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

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

FC - Mode: Allows fine control of hydraulic functions for attachments.

4-11

CHAPTER 4 - OPERATING INSTRUCTIONS 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 counter rotate the machine or to travel straight.

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

TURNING MACHINE

The machine brakes will be applied when the travel levers or pedals are in the neutral position.

OPERATING BOTH TRAVEL LEVERS TOGETHER With the travel motors positioned behind the cab:

Figure 17

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

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

Figure 15

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

Figure 18

YQ103TRAVELLEFT

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

Figure 16

2. Pull both travel levers or press the pedals toward operator seat and machine will travel REVERSE. 3. Return both travel levers to NEUTRAL (center) position and machine will stop travelling. Parking brakes are automatically applied when travel levers are in neutral position.

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.

4-12

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

IMPORTANT: The drive motor brakes are spring applied and hydraulically released (SAHR). When the engine is stopped the brakes are applied.

Contact your Dealer if the engine should require service with the machine in a compromising position.

WARNING: Releasing swing or travel motors manually should only be performed by trained, experienced, authorized technicans. Failure to follow these instructions could result in Death or Serious Injury.

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CHAPTER 4 - OPERATING INSTRUCTIONS COUNTER ROTATING THE MACHINE

YQ103COUNTERROTATERS

Figure 19

YQ103COUNTERROTATELS

1. Pull the left travel lever BACK and Push the right tr avel l eve r FORWAR D t o c o u n te r r o ta t e machine to LEFT.

Figure 20

1. Pull the right travel lever BACK and Push the left travel lever FORWARD to counter rotate machine to the RIGHT.

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

IMPORTANT:

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

· When approaching or descending a slope, operate and travel slowly. · For braking, slowly return travel levers or pedals to the neutral (center) position. Brakes are engaged automatically.

· The travel operation for 2 hours or more may cause the failure of the travel motors due to the rise of the operating temperature. Do not travel continuously for more than 2 hours. Stop for 10 minutes at low idle before resuming travel.

· In extremely cold conditions, below -4°F (-20°C), the travel lever or pedal action may be heavier than normal.

This is due to the viscosity of the hydraulic oil in frigid climates.

TRAVEL SAFETY

· · · · · · · ·

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

Travel on firm, level surfaces as much as possible.

When traveling on rough terrain, travel in SLOW speed with engine at a low idle.

Travel with the travel motors in the back of the machine for long distance travel.

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

Keep a safe distance from stationary objects and electrical power lines.

Be aware of load capacities of bridges and road shoulders.

Use decking or plating to protect road surfaces as much as possible. Be careful when turning or counter rotating machine on asphalt pavement.

· Do not allow large or heavy objects to strike travel motors. · Do not travel over large objects such as boulders, rock, etc. · On soft ground or mud the machine can sink. Stay constantly aware of undercarriage position.

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CHAPTER 4 - OPERATING INSTRUCTIONS MACHINE ATTACHMENT AND SWING

ARM OPERATION

The following operational instructions are for the use of backhoe bucket attachment only.

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

Operation of the Arm is performed by pushing or pulling the Left Control Lever forward and backward. Arm speed is determined by how far the lever is activated.

BOOM OPERATION The operation of the Boom is performed by pushing and pulling the Right Control Lever forward and backward. Boom speed is determined by how far the lever is activated.

Figure 23

1. Push the left control lever FORWARD to move the arm out.

Figure 21

1. Pull the right control lever BACK to raise the boom.

Figure 24

2. Pull the left control lever BACK to bring the arm in.

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

LOWERING THE ATTACHMENT WHEN ENGINE FAILURE OCCURS Figure 22

2. Push the right control lever FORWARD to lower the boom.

Contact your Dealer if the engine fails with the attachment in an unsafe position.

3. Return the right control lever to the neutral (center) position to stop the operation of the boom.

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CHAPTER 4 - OPERATING INSTRUCTIONS BUCKET OPERATION

SWING OPERATION

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

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

NOTE: Use swing flashers during swing operations.

Figure 25

YM103BUCKETIN

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

YM103SWINGLEFT

Figure 27

1. Moving the left control lever to the LEFT swings the machine to the left.

Figure 26

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

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

YM103SWINGRIGHT

Figure 28

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

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

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

IMPORTANT: The swing motor brake is spring applied and hydraulically released (SAHR). When the engine is stopped the brakes are applied.

Contact your Dealer if the engine should require service with the machine in a compromising position.

WARNING: Releasing swing or travel motors manually should only be performed by trained, experienced, authorized technicans. Failure to follow these instructions could result in Death or Serious Injury.

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4-15

CHAPTER 4 - OPERATING INSTRUCTIONS USING AUTO ACCELERATION

DC03J153

Figure 29

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

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

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

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CHAPTER 4 - OPERATING INSTRUCTIONS

MACHINE OPERATION IN ADVERSE WEATHER CONDITIONS · Keep a close watch on the Cluster gauge for

OPERATION IN EXTREME COLD

· Follow procedures at the beginning of this Chapter as starting engine may be difficult due to extremely cold temperature.

· Use an engine oil, hydraulic oil, and diesel fuel designed for use in cold climates.

Maintenance Section for reference.

See

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

· 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 9°F (5°C) lower than the machine experience during operation, storage or transport.

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

OPERATION IN EXTREME HEAT

· Use an engine oil, hydraulic oil and fuel designed for use in hot climates. See Maintenance Section for reference.

· Clean radiator, oil cooler and debris screen often

warning icons during operation.

Avoid unnecessary low speed running of the engine during operation.

OPERATION IN HIGH ALTITUDES

· Due to low atmospheric pressure at high altitudes, a decrease in engine power will be experienced.

Be aware of this fact when placing machine under heavy load in high altitudes climates.

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

OPERATION IN SANDY AND DUSTY AREAS

· Check the engine air cleaner elements frequently in sandy or dusty conditions.

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

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

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

OPERATION AT SEASHORE OR SALTY CLIMATE

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

electrical

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

to prevent damage or overheating of the machine.

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

· Keep all belts properly tensioned. · Make certain that the engine coolant mixture is sufficient to keep the machine safe.

OPERATION IN HUMID CLIMATE

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

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

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

WARNING: Do not drain the cooling system when the engine is hot. allow time to cool all engine parts.

· Also keep batteries fully charged. Check the battery electrolyte (acid) level frequently and fill as necessary with distilled water.

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CHAPTER 4 - OPERATING INSTRUCTIONS OPERATING THE MACHINE IN WATER 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.

DC03K051

Figure 30

If the machine is operated while the swing bearing is submerged in water, then the swing bearing, swing pinion, and the swivel joint may wear out prematurely. immediately replacement of grease in grease bath and flushing of the swing bearing is required. See maintenance section.

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CHAPTER 4 - OPERATING INSTRUCTIONS

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

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

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

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

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

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

Always operate machine parallel to the inclination of the slope. Operating machine across the inclination of the slope will not only shorten the machine’s u n d e r c a r r i a g e l i fe , b u t t h e m a c h i n e c o u l d unexpectedly slide down hill, and/or roll over.

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

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

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

BUCKET SELECTION GUIDE Bucket selec tion is ex tremel y imp or tant to a machine’s productivity, durability, and stability.

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

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

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

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

NOTE: See the “bucket selection chart” in the specification’s section to select the appropriate bucket size according to the application for the eh160lc.

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

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

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

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

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

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CHAPTER 4 - OPERATING INSTRUCTIONS

USE OF OPTIONAL ATTACHMENT If a machine is equipped with optional attachments such as a bucket quick coupler, and/or thumbs (either hydraulic or mechanical), applicable bucket sizes and s u s p e n d e d l o a d s mu s t b e r e d u c e d i n d i r e c t proportion to the weight or combined weight of these attachments. Failure to consider the added weight of such attachments will cause stability complaints.

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

SK32008019

Figure 31

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

Use of quick couplers for bucket interchangeability will reduce effective arm digging force and particularly bucket breakout force due to an increase of tooth tip radius.

Example: Some couplers can increase tooth tip radius up to 12 inches. If this is used with 48” tooth tip r a d i u s , e f fe c t i ve bu c k e t b r e a k o u t fo r c e c a n b e reduced 25%, a 5% reduction in effective ar m fo r c e, a r e d u c t i o n i n l i f t capacities of up to 600 lbs. It is also important to mention that some quick couplers offer a gr eat ad van tag e, par ticularly when lifting loads. Some quick couplers allow the operator to quickly remove the bucket for lifting purposes; therefore, increasing lifting capacity, h e i g h t a n d v i s i b i l i t y. A l way s fo l l ow c o u p l e r manufacturing instructions for safe operation.

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

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

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

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

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CHAPTER 4 - OPERATING INSTRUCTIONS AUXILIARY HYDRAULIC CIRCUITS This machine has two types of auxiliary hydraulic circuits. One circuit is for single flow equipment, such as hydraulic breakers. The second type of circuit is designed for two flow use, such as nibblers.

SINGLE FLOW CONFIGURATION (BREAKER) W h e n m o u n t i n g a B r e a ke r o n t h e H y d r a u l i c Excavator, it is necessary to match stability, hydraulic pressure, and the oil flow for each Breaker. To select Hydraulic Breakers, contact your Dealer or vendor source. Unmatched components may cause damage to the machine and void warranty.

1. Proceed to connect the accessory on the supply valves at the end of the arm.

Figure 34

4. Use an allen wrench to loosen and remove the retaining bolt.

Figure 32

2. Use a 24 mm wrench to open the supply valves on the arm. After removing the attachment set the valves back to STOP.

5. Use a spanner wrench to turn the selector valve to B for breaker.

6. Replace and tighten the allen bolt.

NOTE: There are two auxiliary selector valve positions. B for breaker (single flow) and N for Nibbler (Bi flow).

Figure 33

BD04B003

3. Access the Auxiliary Hydraulic Selector Valve, which is located on the main control valve, behind the right rear access door.

BC04B051

Figure 35

7. Set the cab flow selector switch to the single flow position.

WARNING: Wear goggles, safety shoes, hard hat, work clothes, and work gloves to perform any inspection or maintenance on this machine.

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CHAPTER 4 - OPERATING INSTRUCTIONS BI FLOW CONFIGURATION (NIBBLER) 1. Proceed to connect the accessory on the supply valves at the end of the arm.

Figure 36

8. Release the pedal lock to operate the floor mounted control pedal.

9. Depress the toe section of the pedal to operate the breaker.

10. Return the pedal to the neutral position and the breaker stops.

WARNING: Operation of breaker or nibbler longer than one (1) minute intervals could cause premature wear or damage to the attachment and the machine.

If material is not breaking, reposition breaker or nibbler and repeat operation in one (1) minute intervals.

Figure 38

2. Use a 24 mm wrench to open the supply valves on the arm. After removing the attachment set the valves back to STOP.

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

Figure 37

HYDRAULIC OIL LEVEL CHECK AND CONTAMINATION PREVENTION When the hydraulic breaker is not installed on the machine, attach the blank plugs to the tube end on the Arm-Bucket end and the hose end on the on the hydraulic breaker side to prevent dust and water from entering into piping.

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

4-22

Figure 39

BD04B003

3. Access the Auxiliary Hydraulic Selector Valve, which is located on the main control valve, behind the right rear access door.

WARNING: Wear goggles, safety shoes, hard hat, work clothes, and work gloves to perform any inspection or maintenance on this machine.

Figure 40

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CHAPTER 4 - OPERATING INSTRUCTIONS

Figure 43

8. Release the pedal lock to operate the floor mounted control pedal.

9. Depress the toe section of the pedal to close the nibbler.

10. Depress the heel section of the pedal to open the nibbler.

Figure 41

BC04B053

4. Use an allen wrench to loosen and remove the retaining bolt.

5. Use a spanner wrench to turn the selector valve to N for Bi flow (nibbler).

NOTE: Markings on the Selector Valve determine the Nibbler or Breaker functions: B: Breaker N: Nibbler

6. Replace and tighten the allen bolt.

NOTE: There are two auxiliary selector valve positions. B for breaker (single flow) and N for Nibbler (Bi flow).

Figure 42

BC04B051

7. Set the cab flow selector switch to the Bi flow position.

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CHAPTER 4 - OPERATING INSTRUCTIONS

TRANSPORTATION Machine Preparation

· · · · ·

You must know the total weight, length, width and height of the machine being transported.

Know route to be traveled. Investigate bridges, overpasses, height of road signs on route.

Obtain any permits required from proper government agencies for machine transportation.

Use only a trailer with a rated capacity sufficient to transport the machine.

Make certain the trailer has ramps or a ramp is available for loading and unloading the machine.

LOADING THE MACHINE WARNING: Never attempt to load or unload machine without ramps.

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 on travel lever in LO (1st) speed position and move throttle control to the LOWEST idle position.

Figure 46

YQ102SAFETYLEVERUO

8. Place the safety lock lever in the up LOCKED position.

9. Turn the machine OFF, remove key and lock all doors, filler caps and access panels.

CAUTION: Place a cover over the exhaust pipe of the machine and secure to avoid water entering the engine, and possible turbo damage.

SHIPPING QUICK REFERENCE

DC03K082

Figure 44

Heaviest Machine Configuration . . . . . . . 33 282 lbs.

Length in Transport Position . . . . . . . . . . . . 24 ft 6 in Overall Width . . . . . . . . . . . . . . . . . . . . . . . . . 8 ft 6 in Overall Height . . . . . . . . . . . . . . . . . . . . . . . . 9 ft 3 in

4. Raise the attachment and slowly travel machine up trailer ramps and over rear axles of trailer.

5. Slowly travel machine completely onto trailer until in proper transport position.

6. Slowly swing machine 180 degrees until the attachment is toward rear of trailer.

DC03K084

Figure 45

7. Slowly lower the boom until the attachment rests on the trailer bed.

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CHAPTER 4 - OPERATING INSTRUCTIONS

MACHINE STORAGE Preparation for storage The following procedure applies when the machine is to be stored for a month or more. Store the machine on flat, level ground, inside a building. If a building is not available, park the machine in a dry area on planks and cover the machine with a waterproof covering. Before storing the machine, carry out the following operations: IMPORTANT: In an outdoor situation it is vital to make sure no water reaches the rollers.

1. Clean the machine.

2. Retract the dipper cylinder rod as for as possible and lower the boom until the attachment is resting on the ground.

3. Grease the machine thoroughly. The exposed surfaces of the cylinder rods should be greased or covered with a protective film. See your Dealer.

NOTE: When the machine resumes service, the film will disappear automatically.

4. Drain the fuel tank and fill with a mixture of 90% diesel fuel and 10% anti-corrosive oil. Run the engine at idle speed for five minutes to allow the anti-corrosive oil to reach the lines, filters, pump and injectors.

5. While the engine is still warm, drain the oil sump, fill with anti-corrosive oil and replace the engine oil filter.

6. When the engine is cold, clean the outer parts of the engine with diesel fuel.

7. Clean or replace the air filter element.

8. Drain the cooling system, leave the drain valves open and do not tighten the radiator cap.

9. Remove the batteries, clean the battery housings and make sure not to leave any traces of acid. Store the batteries in a cool, dry place, where temperature is always above freezing.

10. Paint any areas where the paintwork is not good.

11. Plug the air filter inlet and the exhaust pipe.

12. Remove the starter switch key and place a “Do not operate” label on the right-hand control arm and then raise the function cancellation lever (safety bar in inward position).

13. Lock the hoods and the cab door.

Periodical checks Every month, check: 1. The electrolyte level in the batteries and the battery charge. Recharge the batteries if necessary.

2. The grease on the cylinder rods.

3. The fuel level in the fuel tank and the corrosive oil level in the engine. Add more if necessary.

4. The condition of all lines, connectors and clamps (rust). Grease if necessary.

17. The condition of the paintwork. Apply a coat of anti-rust treatment where necessary.

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CHAPTER 4 - OPERATING INSTRUCTIONS

Starting up after storage 1. Close the drain valves and fill the cooling system.

2. Drain the fuel tank and fill with clean diesel fuel.

3. Drain the engine sump, fill with clean engine oil and check the oil level.

4. Change the fuel filter.

5. Install the batteries.

6. Grease the machine thoroughly.

7. Check the condition of the fan drive belt and replace it if necessary.

8. Check the hydraulic fluid level and add more fluid if necessary.

9. Check the travel reduction gears oil level and add more oil if necessary.

10. Clean the cylinder rods.

11. Unplug the air filter inlet and the exhaust pipe.

12. Remove the “Do not operate” tag and start the engine, following the starting up procedure.Keep a careful watch on all systems display panel lamps and indicators.

!

WARNING: Check the machine for leaks or for any parts that are broken, defective or missing.

!

WARNING: Before starting the engine, make sure that all controls are in neutral position. This prevents the machine from moving unexpectedly or an electrical appliance from starting up.

!

WARNING: Avoid running the engine in a confined place. Make sure there is adequate ventilation at all times.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

CHAPTER 5

LUBRICATION, FILTERS, AND FLUIDS TABLE OF CONTENTS FLUID AND LUBRICATION CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Travel Motors (Each) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Track Idlers (Each) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating Lever Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Upper Attachment Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Track Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Swing Ring Gear Bath . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3 5-3 5-3 5-3 5-3 5-3 5-3 5-3 5-3 5-3 5-3 5-3 5-3

Issued 12-03

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YM91ZU0004F1NA

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

NOTES

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

FLUID AND LUBRICATION CAPACITIES ENGINE Type of Oil . . . . . . . Ambra Mastergold HSP 15W-40 Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . 4 gal (15 L)

Swing Bearing Type of Oil . . . . . . . . . . . . . . . . . . . EP Grease EP/2 Capacity . . . . . As required (1 place - swing 90° x 4

HYDRAULIC Type of Oil . . . . . . . . . . . . . . Ambra Hydrosystem 46 Tank Capacity . . . . . . . . . . . . . . . . . 37.8 gal (143 L) System Capacity . . . . . . . . . . . . . . . 42.0 gal (159 L)

TRACK TENSION ADJUSTMENT Type of Oil . . . . . . . . . . . . . . . . . . . EP Grease EP/2 Capacity . . . . . . . . . . . . . . . . . As required (2 places)

SWING MOTOR Type of Oil . . . . . . . . . Ambra Hypoide 90 Gear Lube Capacity. . . . . . . . . . . . . . . . . . . . . . . 0.4 gal (1.78 L) TRAVEL MOTORS (EACH) Type of Oil . . . . . . . . . Ambra Hypoide 90 Gear Lube Capacity. . . . . . . . . . . . . . . . . . . . . . . . 0.7 gal (2.7 L) TRACK IDLERS (EACH) Type of Oil . . . . . . . Ambra Mastergold HSP 15W-40 Capacity . . . . . . . . . . . . . . . . . . . . . 6.76 oz (200 cc) OPERATING LEVER JOINT Type of Oil . . . . . . . . . . . . . . . . . . . . EP Grease EP/2 Capacity. . . . . . . . . . . . . . . . As required in each joint UPPER ATTACHMENT PINS Type of Oil . . . . . . . . . . . . . . . . . . . . EP Grease EP/2 Capacity . . . . . . . . . . . . . . . .As required in each pin

SWING RING GEAR BATH Type of Oil . . . . . . . Lithium base grease with MOS2 Capacity . . . . . . . . . . . . . . . . . . . . . . 14.1 lbs (6.4 kg) RADIATOR Coolant . . . . . . . . . Ethylene-glycol Coolant Solution Capacity: Radiator . . . . . . . . . . . . . . . . . . . . . . . .2.2 gal (8.5 L) Total System . . . . . . . . . . . . . . . . . . . . 4.8 gal (18 L)

ENGINE COOLANT MIXTURE Expected Minimum Temp.

Long Life Coolant

5.9°F (-14.5°C)

30% mixed

-29.2°F (-34°C)

50% mixed

FUEL TANK Type of Fuel . . . . . . . . . . . . Diesel Fuel grade No. 2 Capacity. . . . . . . . . . . . . . . . . . . . . . . . 44 gal (168 L)

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NOTES

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

CHAPTER 6

MAINTENANCE AND ADJUSTMENTS TABLE OF CONTENTS SERVICING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Daily Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

PRE-START (EVERY 8 HOURS) INSPECTION & MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Engine Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Engine Fluid Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Belt Tension (Fan And Air) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Fuel Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Hydraulic Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Track Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Hydraulic Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 Hydraulic Oil Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 Machine Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 Engine Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15 Steps And Handrails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 Frame Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 Track Shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 Track Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 Sprockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 Idlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 EVERY 50 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19 Engine Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19 Drain Water From Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 Air Intake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 Drain The Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 Radiator, Oil Cooler And Debris Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21 Hydraulic Return Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21 Check Swing Motor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22 Check Travel Motor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23 Inspect Belt Tensioner (Fan And Air) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23 Complete Battery Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24 Swing Gear Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25 Change Hydraulic Return Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26 EVERY 100 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27 Bucket Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27 EVERY 120 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check Swing Motor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Travel Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Lever Joint Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-27 6-27 6-28 6-28

EVERY 250 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Attachment Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Conditioning Fresh Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspect Counterweight Attaching Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Belt Tensioner (Fan And Air) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-29 6-29 6-30 6-30 6-31

EVERY 500 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32 Engine oil and filter change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32 Issued 02-04

Bur

6-82410NA

6-1

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS Engine fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-33 Bleeding Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-33 Air intake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-33 Change Hydraulic Return Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-34 Greasing The Swing Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-35 Fuel Injection Pressure And Nozzle Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-35 Checking Air Conditioner Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-35 Air Conditioning Recirculate Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-36 Checking Swing Gear Attaching Bolts for Proper Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-36 Change travel motor oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-37 Change Swing Motor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-37 EVERY 1000 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38 Change Engine Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-38 EVERY 2000 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39 Change Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-39 Clean Suction Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-40 Releasing Hydraulic System Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-41 Change Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-42 Change Travel Motor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-43 Change Swing Motor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-44 Hydraulic Tank Breather Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-44 Change Swing Ring Grease Bath . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-45 Guidelines to Replace Ground Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-45 Guidelines for Attachment Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-45 Special Considerations for Hand Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-46 VARIABLE AND PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47 Checking And Cleaning Fuel Tank And Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-47 Engine Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-47 Engine Compression Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-47 Inspection Of Starter And Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-47 Engine Fuel Injection Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-47 Welding Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-47 Hydraulic Lines, Tubes, And Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-48 Hydraulic Suction Tubes And Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-48 Rear View Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-48 Special Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-49

6-2

Issued 02-04

Bur

6-82410NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

SERVICING INSTRUCTIONS Respect the maintenance intervals by checking the hourmeter every day. Before starting maintenance, park the machine on flat, firm ground, away from any obstacles, with the arm retracted and the bucket on the ground. Unless otherwise specified, all maintenance operations must be carried out with: · the engine stopped

· · · ·

the attachment on the ground the key removed from the starter switch place a Do Not Operate tag on the key switch it is preferable to wait for all circuits to cool down before starting work

· release all hydraulic pressure · be certain that any accumulator pressure is released for the appropriate circuit (if equipped) Clean the grease fittings before lubrication. Clean around plugs and filler holes before adding fluid. No dust or dirt must enter the components or the circuits.

Wear suitable clothing and remember to use the necessary safety equipment.

WARNING: There is a risk of serious injury if maintenance or repairs are not carried out correctly. If you do not understand maintenance procedures, consult your Dealer.

WARNING: If the attachment is raised or if the machine moves without an operator, serious injury can result. Before performing any maintenance, proceed as follows: 1. Park the machine on flat, level ground.

2. Lower the attachment until it is resting on the ground.

3. Lower the dozer blade (if equipped) until it rests on the ground.

4. Shut down the engine and remove the starter key switch.

5. Block the tracks to prevent any machine movement.

Any modification to this machine without prior authorization could cause serious injury. Do not make any modifications without authorization.

Consult your Dealer.

IMPORTANT: If you use your machine in particularly harsh conditions (dusty or corrosive atmosphere, etc.), the servicing intervals should be reduced accordingly.

IMPORTANT: Take particular care to replace all filters regularly. Clean filters mean longer engine running life.

IMPORTANT: Oil and fluid should not be thrown on the ground. They must be stored and removed by a company which is responsible for their recycling or their disposal.

SERVICE SPECIFICATIONS Intervals between overhauls are much more frequent for the following applications: construction of tunnels using a hydraulic breaker, scale stripping, foundry cleaning, operation under water etc. For special applications consult your Dealer.

DAILY INSPECTIONS Every day, before starting work, it is necessary to inspect the machine and ser vice cer tain of its components.

GENERAL REMARKS Check for water or oil leaks.

Check that all screws and nuts are correctly tightened.

Wipe off any dust (engine, operator's compartment, etc.).

Check for damage.

ENGINE C he ck t h e o i l l evel an d c ha n g e t h e o i l i f necessary.

Check the coolant level.

Check for clogging or damage to the radiator.

Check the radiator fan belt tension.

WARNING: Be sure all the service operations in this section are carried out punctually at the intervals given, in order to ensure optimum performance levels and maximum safety when using the machine.

Check the air filter is clean and not restricted.

Check for water or oil leaks on the components.

Check the condition of all lines.

When carrying out service work on the machine, place a Do Not Operate tag on the instrument panel.

Never climb down from the operator's compartment leaving the engine running.

6-82410NA

Issued 02-04 Bur

6-3

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS FUEL

COOLANT SOLUTION

Use fuel which is to ASTM (American Society for Testing and Materials) D975 standard.

Put only ethylene-glycol coolant solution in the cooling system. Use good quality ethylene-glycol that has a high boiling point, with no additives to prevent l ea k ag e. Do n o t us e no n- a p pr oved a n ti - r u s t additives. Anti-rust additives and ethylene-glycol can mix and work against each other, thereby reducing anti-corrosion protection, forming deposits in the cooling system and causing damage to the cooling system and radiator.

Use grade No. 2 fuel. The use of other types of fuel can result in a loss of power of the engine and may cause high fuel consumption.

In cold weather, it is tentatively approved to use a mixture of fuels No. 1 and No. 2. Consult your fuel supplier.

If the temperature falls below the fuel cloud point (point at which wax begins to form) the wax crystals will cause power loss or will prevent the engine from starting.

In cold weather, fill the fuel tank at the end of the day's work, in order to prevent the formation of condensation.

FUEL STORAGE Long storage can lead to the accumulation of impurities and condensation in the fuel. Engine trouble can often be traced to the presence of water in the fuel.

The storage tank must be placed outside and the temperature of the fuel should be kept as low as possible. Drain off water and impurities regularly.

Contact your Dealer who will supply you with the suitable coolant solution.

ANTI-FREEZE/ANTI-CORROSION Use anti-freeze in all seasons to protect the cooling system from corrosion and all risk of freezing.

For areas where the ambient temperature is over -36°C, use a blend of 50% ethylene-glycol based anti-freeze.

For areas where the temperature is below -36°C, it is advisable to use a blend of 40% water and 60% anti-freeze.

ENVIRONMENT Before carrying out any maintenance operation on this machine and before disposing of used fluids or lubricants, always think of the environment. Never throw oil or fluid on the ground and never place it in leaking receptacles.

Contact your local ecological recycling authority or your Dealer to obtain information on the correct method of disposing of these lubricants.

6-4

Issued 02-04

Bur

6-82410NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS UPPERSTRUCTURE

HOURMETER

Check the fuel tank level.

Check the hydraulic reservoir level.

Check that the hydraulic oil is clean.

Check for water or oil leaks on the components.

Check the condition of all lines.

Check for electrical short-circuits.

Check the battery connections are properly tightened.

The hourmeter enables service operations to be scheduled. Its hourly indications are the same as those of a clock when the engine is running.

Ser vicing inter vals are carefully calculated to guarantee safe and efficient machine operation.

Be sure to carry out all the servicing operations properly as defined in this manual.

Adjust the rear view mirrors.

UNDERCARRIAGE Check the shoe hardware.

Check the condition of the tracks.

Check that the upper and lower rollers and the idler wheels are not leaking oil.

ATTACHMENT Check for oil leaks on the cylinders.

Check the condition of all lines.

Check the condition of the bucket teeth.

Figure 1

BC04B047

HOURMETER

AFTER STARTING THE ENGINE Did the engine start correctly? Are the exhaust fumes normal? Any strange noises?

Check for abnor mal noise on the hydraulic components.

Check for water or oil leaks on the components.

Check the audible alarm devices, working lights and windshield wipers.

Check that all circuits (travel, swing and tool) are functioning correctly.

IMPORTANT: If a defect is found, repair it immediately before using the machine or see your Dealer.

6-82410NA

Issued 02-04 Bur

6-5

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS MAINTENANCE CHART

Every 8 Hours

Every 50 Hours

Every 100 Hours

6-8 6-8 6-9 6-9 6-9 6-10 6-11 6-12 6-13 6-13 6-14 6-14 6-15 6-16 6-16 6-17 6-17 6-17 6-18 6-18 6-19 6-20 6-20 6-20 6-21 6-21 6-24 6-23 6-23 6-24 6-25 6-26 6-27

Engine oil level Engine coolant level Engine fluid leaks Belt tension Fuel level Air cleaner Hydraulic oil level Track tension Hydraulic control functions Hydraulic oil leaks Machine electrical Engine electrical Fuses Check steps and handrails Check frame structure Track Shoes Track links Sprockets Idlers Rollers Engine oil and filter change Drain water from fuel tank Air intake system Drain the water separator Clean radiator, oil cooler and debris screen Change Hydraulic return filters Check swing motor oil Check travel motor oil Inspect belt tension (fan and air) Battery electrolyte and service Swing gear bolt torque Change hydraulic return filters Grease bucket fittings

1 1 MP 1 1 1 1 1 2 MP MP MP 1 2 MP MP MP 2 2 MP 1 1 1 1 1 1 1 1 1 1 1 MP

REPLACE

LUBRICATE

DRAIN

CHANGE

CLEAN

CHECK

SERVICE POINTS

NUMBER OF POINTS

SERVICE INTERVAL

PAGE NUMBER

FREQUENCY IN HOURS

8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 50 50 50 50 50 50 50 50 50 50 50 100 Figure 2

NOTE: Bold numbers indicate New machine first time service.

NOTE: MP = multiple location points

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS MAINTENANCE CHART

Every 120 Hours

Every 250 Hours

Every 500 Hours

Every 1000 Hours

Every 2000 Hours

6-27 6-28 6-28 6-29 6-30 6-30 6-31 6-32 6-33 6-33 6-34 6-35 6-35 6-35 6-35 6-37 6-38 6-39 6-40 6-44 6-42 6-43 6-46 6-44 6-43

Check swing motor oil Check travel motor oil Control lever joint lubrication Attachment lubrication Air conditioning fresh air filter Inspect counterweight attaching bolts Inspect belt tension (fan and air) Engine oil and filter change Engine fuel filter Air intake system Change hydraulic return filters Grease the swing gear Fuel injection pressure and nozzle condition Air conditioning recirculate filter Check air conditioning refrigerant Change travel motor oil Change swing motor oil Change air cleaner element Change engine coolant Clean suction screen Change hydraulic tank breather Change hydraulic oil Clean hydraulic tank Change grease in swing gear bath Change swing motor oil Change travel motor oil

1 2 2 MP 1 1 1 1 MP 1 1 MP 1 1

REPLACE

LUBRICATE

DRAIN

CHANGE

CLEAN

CHECK

SERVICE POINTS

NUMBER OF POINTS

SERVICE INTERVAL

PAGE NUMBER

FREQUENCY IN HOURS

120 120 120 250 250

500 500

500 500 500

1 1 1 1 1 1 1 1 2

1000 2000 2000 2000 2000 2000 2000 2000 2000 Figure 3

NOTE: Hours shown in bold are Break-in, new machine service requirements.

NOTE: MP = multiple location points

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6-7

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

PRE-START (EVERY 8 HOURS) INSPECTION & MAINTENANCE

ENGINE COOLANT LEVEL

The following procedures are to be performed every 8 hours or daily, before starting the machine.

WARNING: Be cautious of hot fluids and sufaces. wear goggles, safety shoes, hard hat, work cloths, and work gloves to perform inspection and maintenance on this machine.

ENGINE OIL LEVEL

Figure 5

YQ104EXPANSIONTANK

1. Open left rear compartment cover and inspect coolant level in engine coolant reservoir.

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

3. If necessary to add coolant, remove reservoir cap and fill to proper level with fresh coolant mixture, 4. If no coolant is shown in reservoir, check coolant level in radiator. Fill radiator with proper coolant mixture and replace cap. See Figure 94. Then refill reservoir to proper level.

YMYL104ENGOILLEVEL

Figure 4

1. Stop engine and raise the engine cover.

2. Locate and pull engine dipstick, clean it with a clean, dry, lint free cloth. Reinsert into engine.

Pull out again to visually inspect the engine oil level on dipstick.

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

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

Figure 6

SK32004017

WARNING: Never remove radiator cap when engine is hot. allow engine to cool down before removing radiator cap.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS ENGINE FLUID LEAKS

FUEL LEVEL

1. Inspect complete engine for signs of fluid leaks.

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

YMYL104FUELGAUGE

Figure 9

1. Turn ON the ignition key and the fuel level gauge in the cluster gauge will indicate the fuel tank level.

Figure 7

YQ104CHECK4LEAKS

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

To refuel the machine, use the ignition key to remove the fuel tank cap. Do not remove the fuel screen for fueling. Refill fuel tank to full mark to reduce air volume (condensation). Failure to do so could create problems such as rusting and fuel freezing, as well as other associated problems.

BELT TENSION (FAN AND AIR)

BC04B109

Figure 8

Inspect the belt tension on a new machine after the first 50 hours of operation. Then at every 250 hours of engine operation.

Use your finger to exert pressure of 22.0 lb (10 kg) force on the center of the belts.

Tension slack should be: .3 to .4 in (8 to 12 mm).

1. Measure belt tension on longest span of belt.

2. Loosen the attaching nuts, adjusting nut and adjust the belts.

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6-9

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS AIR CLEANER IMPORTANT: The air restriction indicator will not signal if the element is torn or if the air cleaner compartment is not sealed properly. If REST’D AIR CLEANER icon is displayed, as indicated in Figure 96, inspect, clean, and/or replace the air cleaner elements.

Figure 13

BS04B013

4. Remove the wing nut and air cleaner inner element from the housing.

5. To clean the outer element, blow compressed air [less than 2.8 bar (40 psi) up and down along the folds of the filter element interior to remove clogged dust or other contaminants.

CAUTION: Wear protective glasses or goggles when using compressed air.

YQ104AIRRESTRICTION

Figure 10

1. Open engine air cleaner access door.

6. After cleaning, use light to check the inside of the eleme nt for tear ing, pinhol es, or packi ng damage. Replace with new element if necessary.

7. Assemble elements in the reverse order or disassembly.

8. Make sure to properly place the O-ring seal on the wing nut sleeve for the outer filter element.

Failure to do so could cause engine failure.

BS04B011

Figure 11

2. Remove the air cleaner cover.

BS04B012

Figure 12

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

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS HYDRAULIC OIL LEVEL Check the hydraulic oil level daily.

Figure 14

BC04B094

1. Place the machine in the oil check position on a firm level surface.

YQ104ADDHYDOIL

Figure 17

c. Add hydraulic oil, filling hydraulic tank to the proper level.

Figure 15

BS04B014

2. Check the sight glass through the opening of the hydraulic tank side cover.

WARNING: For safe operation on inclines, the hydraulic oil level must be maintained between proper level and upper limit mark. Do not operate machines on inclined surfaces with a slope greater than 35 degrees.

d. Before replacing filter cover, replace O-ring. e. Lubricate the new O-ring and place it properly in seat. Place cover over opening and install mounting bolts with lock washers. f. Torque mounting bolts to proper value. Refer t o To r q u e S p e c i f i c a t i o n Ta b l e i n t h e Specifications Section.

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

3. To add hydraulic oil, proceed as follows: a. Release hydraulic tank pressure.

CAUTION: Always use clean hydraulic oil. Use caution to avoid contamination during filling.

NOTE: Machine is shipped from factory with SHELL TELLUS 46 hydraulic oil, unless other equivalent requested. Reference oil specification decal on hydraulic tank.

YQ101RELEASEPRESS

Figure 16

CAUTION: Gasses from hydraulic tank may be hot.

Wear safety equipment. b. Slowly remove the six mounting bolts from the hydraulic suction filter cover plate.

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6-11

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS TRACK TENSION 1. Operate swing, arm, bucket, and boom controls until machine is set up as shown.

10.6-11.8 270-300 mm

Figure 19

DC03K222

Figure 18

YQ104LIFTTRACK4ADJUSTMENT

TRACK SAG SHOULD BE 10.6-11.8 IN (270-300 MM)

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, inject extreme pressure No. 2 grease into idler adjustment grease fitting with a grease gun until proper tension is reach.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS HYDRAULIC FUNCTIONS

HYDRAULIC OIL LEAKS

Always check all hydraulic controls for proper functionality before operating the machine or after service has been completed.

Check complete hydraulic system for leaks. Use a small piece of cardboard when checking areas with high pressure.

You must know and identify which control operating pattern is engaged.

WARNING: Never use hand to check for leaks. High pressure fluid leaks will penetrate the skin and cause severe injury.

Figure 23

Figure 20

YQ104MOVECONTROLS

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

Figure 21

YQ104CHECK4LEAKS

Figure 24

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

WARNING: This machine is equipped with two control lever operating patterns. You must know which pattern is engaged.

Figure 22

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

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

Figure 25

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6-13

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS MACHINE ELECTRICAL

ENGINE ELECTRICAL

1. Check all switches for proper operation.

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

Visually and manually inspect all engine electrical wiring, connectors and components for signs of damage and malfunction.

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

4. Check all gauges and L.C.D. display on the gauge cluster display for proper operation.

Figure 27

YQ104BROKENWIRES

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.

Figure 28 YQ104CHECKDISPLAY

6-14

Figure 26

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS FUSES Follow these procedures to replace blown or faulty fuses.

1. Move seat and seat base completely forward.

No.

AMPS

1A/1B

20A

Mechatro Controller (CPU)

2

10A

Wiper, Washer Relay

3

10A

Cigarette Lighter 24V

4

10A

DC-DC Converter

5

10A

Horn

6

FUNCTION

NONE None

7

10A

Mechatro Controller (Back up)

8

20A

Fuel Supply Pump

9

10A

E n g i n e C o m p. L a m p, D C - D C Converter

10

20A

Starter Switch

11

20A

Fuel Pump

12

20A

Travel Alarm

13

10A

Gauge Cluster (Monitor)

14

20A

Wiper, Washer

15

10A

Solenoid Valve (Lever Lock)

16

20A

Working Light (Front)

Figure 30

17

10A

Resistor

4. Refer to the fuse box cover for amperage and function.

18

20A

Air Conditioner

19

10A

Controller (A/C)

20

20A

Spare 24V

Figure 29

BC04B046

2. Open the fuse compartment and remove fuse box cover from fuse box.

3. Locate and remove faulty fuses. Replace any fuse needed with the same type and amperage.

WARNING: Never replace a faulty fuse with a higher amperage fuse. never use a JUMPER in place of a fuse. never splice accessories directly into fuse terminals.

Figure 31

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6-15

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS STEPS AND HANDRAILS

FRAME STRUCTURE

Inspect daily all mounting steps and handrails on the machine to make sure they are clean and in safe working condition.

Carefully inspect the entire frame structure for signs of damage, broken welds, etc.

DC03K220

NOTE: Remove any excessive grease from the attachment pin connecting areas to inspect for welds.

Figure 32

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

WARNING: Use steps and handrails when mounting and dismounting the machine.

Keep steps, handrails, and step rails clean and in safe working condition.

Figure 33

DC03K221

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

· In cases where the welding repair is required, consult an authorized Service Dealer for proper procedures concerning weld repair. Use only certified welding personnel familiar with structural welding methods to perform repairs requiring welding. Never allow current to flow through a joint such as between a pin and bushing and/or between upper and lower structures.

IMPORTANT: Disconnect batteries before welding on this machine. connect welder ground cable within 3 ft 3 in (1 M) from area to be welded.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS TRACK SHOES

SPROCKETS

Visually inspect track shoes for signs of excessive wear or damage.

Inspect sprockets for excessive wear and damage.

Check track shoes for loose bolts and damage.

YQ104SPROCKETS

Figure 34

DC03K215

g. Have all repair or replacement work done by an authorized Service Dealer. h. Check tightness of shoe mounting bolts and nuts. If loose, remove bolt, clean thread, apply engine oil and torque to 296 - 325 lb ft (41 - 45 kgf-m)

Figure 36

j. Should the sprockets require service, contact an authorized Service Dealer. Check and make sure all sprocket bolts are properly torqued.

NOTE: If any sprocket bolt is loose, proceed as follow: c1 - Remove bolt and clean threads.

TRACK LINKS

c2 - Apply Loctite #262 to the bolt.

Inspect link for signs of excessive wear or damage.

c3 - Torque to xxxxx

Figure 35

YQ104CHECKLINKWEAR

i. Have all repair or replacement work done by an authorized New Holland Construction Service Dealer.

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6-17

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS IDLERS Inspect Idlers for excessive wear and damage.

YQ104IDLER

Figure 37

Should the Idlers require ser vice, contact an author ized New Holland Constr uction Ser vice Dealer.

NOTE: Every 8 hours of operation, make sure to check idlers and rollers for leakage and repair as needed. Contact your Dealer’s Service Department for any assistance.

ROLLERS Inspect Rollers for excessive wear and damage.

Figure 38

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

EVERY 50 HOURS ENGINE OIL AND FILTER 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 hour interval.

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.

3

Figure 39

3

NOTE: Change the oil while the engine is still warm.

The oil will flow more easily.

CT02D021

ENGINE OIL AND FILTER CHANGE

1. Park the machine on flat, horizontal ground. Shut down the engine and remove the starter switch key.

Figure 42

5. Clean the area around the oil filters (3) and remove them, using a filter wrench.

2. Remove the oil filler cap (1).

1

6. Coat the seal of the new filter with a fine film of oil.

Figure 40

CT02D019

7. Install the new filters. Turn the filters until the seals come into contact with the filter head then tighten an extra half turn by hand.

3. Place a receptacle of a suitable capacity under the engine sump drain plug, remove the plug and allow the oil to flow out.

IMPORTANT: Do not use a filter wrench to tighten the filters. Excessive tightening can damage the filters and the seals.

4. Put a new seal on the drain plug and install the plug.

8. Fill the engine with new engine oil. Install the filling plug.

9. Run the engine for a few minutes and check that there are no leaks. Check the level again and top up if necessary.

NOTE: For accuracy, allow enough time for the oil to drain down to the sump before checking the level.

Figure 41

CT02D020

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

Every 50 Hours DRAIN WATER FROM FUEL TANK

DRAIN THE WATER SEPARATOR The water separator isolates water that may mix in with the fuel. The separator is equipped with a float that will rise when water accumulates. When the float rises to the level line the water must be drained.

Figure 43

BC04B098

1. Place the machine on firm, level ground with the attachment on the ground.

2. Shut the engine off and remove the key.

3. Locate and open the fuel tank drain valve on the bottom of the fuel tank.

4. Allow all water and sediment to drain from the fuel tank into a suitable container.

Figure 47

BC04B088

1. Loosen the drain plug to drain the water.

2. Close the drain plug once the float reaches the bottom.

3. Make certain that there are no leaks.

5. Close the drain valve.

WARNING: Never service a machine that has just finished working. Allow the machine and components to cool first.

IMPORTANT: Drain the separator when the float reaches the line, regardless of machine service intervals.

Figure 44

WARNING: You must clean and dispose of any spilled fuel in accordance with environmental regulations.

Figure 45

WARNING: Fuel oil is highly flammable.

Spilled fuel can cause fires.

Figure 46

AIR INTAKE SYSTEM Check all hoses and clamp that maintain the integrity of the air cleaner housing and the air cleaner.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

Every 50 Hours RADIATOR, OIL COOLER AND DEBRIS SCREEN

HYDRAULIC RETURN FILTERS

Clean the radiator after every 50 hours of operation.

This service interval should be done as often as necessary when working in severe environmental conditions.

Change the hydraulic tank return filter on a new machine after the first 50 hours of operation and then every 500 hours .

1. Place the machine on firm, level ground and place the attachment on the ground.

WARNING: Never change oils or filters on a machine that has just finished working. Allow machine and components to cool first. Oils and fluids should be WARM not HOT. Release hydraulic tank pressure before working with any hydraulic components.

2. Shut the engine off and remove the ignition key.

3. Open the engine air cleaner access door.

4. Open the engine access door.

Figure 49

1. Place the machine on firm, level ground with the attachment on the ground.

2. Shut the engine off and remove the key.

1

1

Figure 48

BS04B023

5. Remove the four bolts and the lower debris screen access door (1).

6. Remove the wing bolts that secure the debris screen.

7. Rinse the components and compartments of dirt and debris.

BC04B095

Figure 50

3. Release hydraulic tank pressure by pressing the rubber cap (1).

IMPORTANT: Be careful not to bend or damage cooling fins of the radiator or oil cooler. Replace the debris screen if damage is found.

CAUTION: Do not use extremely high pressure washing equipment or damage to cooling fins may occur.

8. Replace the debris screen and secure with the wing bolts.

9. Replace the lower debris screen access door (1) and secure the four bolts.

10. Close the engine hood and air cleaner access door.

BS04B024

Figure 51

4. SLOWLY remove the six mounting bolts from the return cover plate.

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6-21

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

Every 50 Hours CHECK SWING MOTOR OIL Check the swing reduction oil at 50 hours of operation on a new machine. Then check every 120 hours of operation.

1 2 3

1

4

2

Figure 53

BC04B102

BC04B100

Figure 52

5. Remove the O ring (1), spring (2), bypass valve (3).

6. Remove the filter from the housing (4).

7. Install a new filter.

8. Clean and inspect the bypass valve and spring.

Replace if necessary.

9. Install a new O ring.

10. Install the return cover plate and torque the bolts.

1. Locate the dipstick (1) on the side of the swing motor. Pull the dipstick, wipe it clean and replace, making sure to bottom the dipstick out.

2. Pull and read the oil level.

3. If necessary to add oil, remove plug (2) from the oil fill port and fill to full level.

To Drain the Swing Motor: 1. Locate the drain port under the rear of the machine.

2. Place a 0.5 gal (2 liter) container under the port and remove the drain plug slowly.

3. Replace and tighten securely after all oil is drained.

4. Fill at the fill port and secure the plug.

WARNING: Never change oils or filters on a machine that has just finished working. Allow machine to cool first until oils and fluids are warm and NOT HOT. Figure 54

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

Every 50 Hours CHECK TRAVEL MOTOR OIL

INSPECT BELT TENSIONER (FAN AND AIR)

Check the travel reduction oil at 50 hours of operation on a new machine. Then check every 120 hours of operation.

1

Figure 55

BC04B104

1. Move the machine to a firm level surface.

Operate the travel function until FILL and LEVEL (1) plugs on the motors are at the top.

2. Lower the attachment, shut the engine off and remove the key.

3. Slowly remove the travel motor oil fill and level plug. If oil just seeps from the port the level is CORRECT. 4. If necessary, add oil until it begins to seep from the plug.

BC04B109

Figure 56

Inspect the belt tension on a new machine after the first 50 hours of operation. Then at every 250 hours of engine operation.

Use your finger to exert pressure of 22.0 lb (10 kg) force on the center of the belts.

Tension slack should be: .3 to .4 in (8 to 12 mm).

1. Measure belt tension on longest span of belt.

2. Loosen the attaching nuts, adjusting nut and adjust the belts.

5. Secure the plug. Teflon tape may be used for better sealing.

NOTE: Capacity of each travel motor is 0.7 gal (2.5 liter).

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6-23

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

Every 50 Hours COMPLETE BATTERY SERVICE 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.

Perform complete battery service on a new machine after the first 50 hours of engine operation. Then, check electrolyte (acid) every 120 hours and perform maintenance every 250 hours.

WARNING: Wear safety clothes, goggles or face shield, gloves and safety shoes when working with batteries.

Work in a well ventilated area.

Battery electrolyte (acid) is corrosive. if it comes in contact with skin, eyes or clothing, flush with large amounts of water and seek immediate medical attention.

Battery electrolyte (acid) produces hydrogen gas that is highly explosive. keep away sparks, fire or flames and do not smoke when working with batteries.

Figure 59

NOTE: Use hydrometer manufacturer’s instruction.

according

to

its

ATMOSPHERIC TEMPERATURE CHARGE 68°F (20°C)

32°F (0°C)

14°F (-10°C)

100%

1.26

1.27

1.28

90%

1.24

1.25

1.26

80%

1.22

1.23

1.24

75%

1.21

1.22

1.23

Figure 57

YM104BATWARNING

Figure 58

7. When disconnecting batteries, remove the negative (- ) cable first. When connecting batteries, connect the negative (-) cable last.

1. Open the battery access door and secure it open.

2. Remove battery cell caps and visually inspect electrolyte (acid) level. Proper level is 0.4 to 0.61 in (10to 15 mm) above cell plates.

3. If necessary, fill each cell to proper level with DISTILLED WATER ONLY. 4. Remove cables from terminals and clean with hot water. Coat each terminal with a thin layer of petroleum jelly. Clean cables in the same manner and reinstall onto battery.

5. If cables are found to be in poor condition, replace with new parts immediately.

6. Use a hydrometer to check the specific gravity of each cell. Compare readings to the chart below.

IMPORTANT: Battery life can be shortened by over charging and over discharging of the battery.

Replace any battery that will not hold charge or difficult to charge.

· Periodically check the specific gravity of the

Figure 60

SK32004077

8. When the battery requires charging:

· · · ·

Disconnect battery cables from terminals.

Remove all cell caps.

Check for proper electrolyte (acid) level.

Connect charger leads to the proper battery terminals.

WARNING: Make certain not to cross Positive (+) and negative (-) terminals when connecting charger.

· Stop charge if battery overheats. batteries when 100% charged.

batteries with a hydrometer. Stop charging 6-24

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

Every 50 Hours SWING GEAR BOLT TORQUE Check the swing ring bolts torque on a new machine after the first 50 hours of engine operation. Then, Check every 500 hours.

Figure 61

YM104SWINGBRG

1 Figure 62

BC04B112

Check the swing ring bolts for proper torque across each other and in sequence. If bolts are loose, remove one bolt at a time, clean it and apply Loctite #262 and torque accordingly.

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6-25

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

Every 50 Hours CHANGE HYDRAULIC RETURN FILTERS Change the hydraulic tank return filter on a new machine after the first 50 hours of operation and then change every 500 hours.

1 2

.

WARNING: Never change oils or filters on a machine that has just finished working. Allow machine and components to cool first. Oils and fluids should be WARM not HOT. Release hydraulic tank pressure before working with any hydraulic components.

3 4

Figure 63

1. Place the machine on firm, level ground with the attachment on the ground.

2. Shut the engine off and remove the key.

1 Figure 66

BC04B100

5. Remove the O ring (1), spring (2), bypass valve (3).

6. Remove the filter from the housing (4).

7. Install a new filter.

8. Clean and inspect the bypass valve and spring.

Replace if necessary.

BC04B095

Figure 64

9. Install a new O ring.

3. Release hydraulic tank pressure by pressing the rubber cap (1).

BS04B024

Figure 65

4. SLOWLY remove the six mounting bolts from the return cover plate.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

EVERY 100 HOURS

EVERY 120 HOURS

BUCKET LUBRICATION

CHECK SWING MOTOR OIL

1

2

Figure 68

BC04B102

Figure 67

CT02C281

1.

2.

3.

4.

Idler link and bucket pin Bucket cylinder rod end Arm top pin Bucket link pins

Use the following grease: EP NLGI grade 2 (for temperate and hot climates) -20°C to +60°C EP NLGI grade 0 (for cold climates) -40°C to +20°C The numbers within brackets mentioned on the right of the description indicate the number of lubrication points.

Check the oil level of the swing motor reduction unit every 120 hours.

1. Locate the dipstick (1) on the side of the swing motor. Pull the dipstick, wipe it clean and replace, making sure to bottom the dipstick out.

2. Pull and read the oil level.

3. If necessary to add oil, remove plug (2) from the oil fill port and fill to full level.

To Drain the Swing Motor: 1. Locate the drain port under the rear of the machine.

2. Place a 0.5 gal (2 liter) container under the port and remove the drain plug slowly.

3. Replace and tighten securely after all oil is drained.

4. Fill at the fill port and secure the plug.

WARNING: Never change oils or filters on a machine that has just finished working. Allow machine to cool first until oils and fluids are warm and NOT HOT. Figure 69

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6-27

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS Every 120 Hours TRAVEL MOTORS

1

BC04B104

Figure 70

Inspect oil level of travel motors every 120 hours.

1. Move the machine to a firm level surface.

Operate the travel function until FILL and LEVEL (1) plugs on the motors are at the top.

2. Lower the attachment, shut the engine off and remove the key.

3. Slowly remove the travel motor oil fill and level plug. If oil just seeps from the port the level is CORRECT. 4. If necessary, add oil until it begins to seep from the plug.

5. Secure the plug. Teflon tape may be used for better sealing.

NOTE: Capacity of each travel motor is 0.7 gal (2.5 liter).

CONTROL LEVER JOINT LUBRICATION

YQ104LUBHANDPILOTVALVE

Figure 71

Remove the rubber boots from the control levers and lubricate the universal joint and the top of the sliding area every 120 hours.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

EVERY 250 HOURS ATTACHMENT LUBRICATION

4

3

Figure 72

BC04B182

Place the machine, in the position shown, on a hard level surface. Perform all pre-start (every 8 and 50 hour) inspection and maintenance procedures along w i t h t h e fo l l o w i n g 2 5 0 h o u r i n s p e c t i o n a n d maintenance.

Figure 75

BC04B107

3. Boom cylinder rod pins . . . . . . . . . . . . . . . . . (2) 4. Arm cylinder head pin . . . . . . . . . . . . . . . . . . (1)

5

6

7 1

BC04B108

Figure 73

BC04B106

1. Boom cylinder bottom pins . . . . . . . . . . . . . . . (2)

Figure 76

5. Arm to boom pin . . . . . . . . . . . . . . . . . . . . . . (1) 6. Arm cylinder rod end . . . . . . . . . . . . . . . . . . . (1) 7. Bucket cylinder head pin . . . . . . . . . . . . . . . . (1)

2

Figure 74

BC04B107

2. Boom foot pins . . . . . . . . . . . . . . . . . . . . . . . . (2)

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

EVERY 250 HOURS AIR CONDITIONING FRESH AIR FILTER

INSPECT COUNTERWEIGHT ATTACHING BOLTS

Figure 79

BS04B074

BC04B093

Figure 77

1. Loosen the 3 bolts under the operator’s seat to remove the cover.

Check counterweight bolts and nuts for proper torque.

Torque should be: 950 lb ft

1

Machine Front BC04B190

Figure 78

2. Remove the cover and take the fresh air filter (1) out.

3. Use compressed air to clean the fresh air filter.

NOTE: This filter may be cleaned up to 10 times or every two years depending on the work environment.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

Every 250 Hours BELT TENSIONER (FAN AND AIR)

Figure 80

BC04B109

Inspect the belt tension on a new machine after the first 50 hours of operation. Then at every 250 hours of engine operation.

Use your finger to exert pressure of 22.0 lb (10 kg) force on the center of the belts.

Tension slack should be: .3 to .4 in (8 to 12 mm).

1. Measure belt tension on longest span of belt.

2. Loosen the attaching nuts, adjusting nut and adjust the belts.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

EVERY 500 HOURS ENGINE OIL AND FILTER CHANGE NOTE: Change the oil while the engine is still warm.

The oil will flow more easily.

1. Park the machine on flat, horizontal ground. Shut down the engine and remove the starter switch key.

2. Remove the oil filler cap (1).

3 3 1

Figure 83

CT02D021

5. Clean the area around the oil filters (3) and remove them, using a filter wrench.

CT02D019

Figure 81

3. Place a receptacle of a suitable capacity under the engine sump drain plug, remove the plug and allow the oil to flow out.

4. Put a new seal on the drain plug and install the plug.

6. Coat the seal of the new filter with a fine film of oil.

7. Install the new filters. Turn the filters until the seals come into contact with the filter head then tighten an extra half turn by hand.

IMPORTANT: Do not use a filter wrench to tighten the filters. Excessive tightening can damage the filters and the seals.

8. Fill the engine with new engine oil. Install the filling plug.

CT02D020

Figure 82

9. Run the engine for a few minutes and check that there are no leaks. Check the level again and top up if necessary.

NOTE: For accuracy, allow enough time for the oil to drain down to the sump before checking the level.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

Every 500 Hours ENGINE FUEL FILTER

BLEEDING AIR FROM THE FUEL SYSTEM If air contaminates the fuel system, the engine may become hard to start or malfunction. Bleed the air whenever the fuel tank has been empty, the water separator is drained or the fuel filter is replaced.

1. Fill the tank with fuel.

1 Figure 84

BC04B110

2

1. Use a filter wrench to remove the fuel filter.

2. Clean the seal face of the filter base. Before installing the fuel filter, apply clean fuel to the sealing surface.

3. Install the new filter and screw it by hand until it c on ta c ts t he fi lt er b as e. Th en ti gh te n a n additional 2/3 of a turn.

WARNING: You must clean all spilled fuel and follow environmental regulations. Fuel is highly flammable and spilled fuel can cause fires.

Figure 85

Figure 86

BC04B111

2. Loosen the air bleed screw (1).

3. Loosen the priming counterclockwise (2).

pump

by

turning

it

4. Move the priming pump up and down until fuel free of bubbles flows.

5. Tighten the air bleed screw (1).

6. Tighten the knob of the priming pump (2).

Completely wipe off any spilled fuel and start the engine, watching for leaks.

AIR INTAKE SYSTEM Check all hoses and clamp that maintain the integrity of the air cleaner housing and the air cleaner.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

Every 500 Hours CHANGE HYDRAULIC RETURN FILTERS Change the hydraulic tank return filter every 500 hours.

1

.

2

WARNING: Never change oils or filters on a machine that has just finished working. Allow machine and components to cool first. Oils and fluids should be WARM not HOT. Release hydraulic tank pressure before working with any hydraulic components.

3 4

Figure 87

1. Place the machine on firm, level ground with the attachment on the ground.

2. Shut the engine off and remove the key.

1

Figure 90

BC04B100

5. Remove the O ring (1), spring (2), bypass valve (3).

6. Remove the filter from the housing (4).

7. Install a new filter.

8. Clean and inspect the bypass valve and spring.

Replace if necessary.

BC04B095

Figure 88

3. Release hydraulic tank pressure by pressing the rubber cap (1).

BS04B024

9. Install a new O ring.

10. Install the return cover plate and torque the bolts.

Figure 89

4. SLOWLY remove the six mounting bolts from the return cover plate.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

Every 500 Hours GREASING THE SWING RING

Figure 91

CT02C246

1. Locate the grease fitting at the front of the swing bearing.

2. Lubricate the fitting and swing the machine in 90 degree incr ements until the entire r ing is lubricated.

FUEL INJECTION PRESSURE AND NOZZLE CONDITION C o n t a c t yo u r D e a l e r fo r t h i s i n s p e c t i o n a n d adjustment.

Figure 92

A. Refrigerant is the proper volume.

B. Refrigerant is overcharged. This will make both high and low pressure extreme and exert a bad influence on the pressure switch operation and the air conditioning system.

C. Refrigerant is insufficient.

CHECKING AIR CONDITIONER REFRIGERANT 1. Start the engine and after warm up set the throttle to middle position.

2. Set the following conditions: air conditioner switch . . . . . . . . . . . . . . . . . . . . . . . on fan switch. . . . . . . . . . . . . . . . . . . . . . . . . . . Hi (Max.) temperature adjustment. . . . . . . . . . .Lowest Position door / window . . . . . . . . . . . . . . . . . . . . . . . . . closed 3. Check the refrigerant volume by looking through the sight glass (inspection window) on the upper part of the receiver dryer. Use the following table for reference.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

Every 500 Hours AIR CONDITIONING RECIRCULATE FILTER

1 Figure 96

BC04B112

Figure 93

BC04B093

1. Loosen the 3 bolts under the operator’s seat to remove the cover.

Check the swing ring bolts for proper torque across each other and in sequence. If bolts are loose, remove one bolt at a time, clean it and apply Loctite #262 and torque accordingly.

1

Machine Front BC04B190

Figure 94

2. Remove the cover and take the recirculate air filter (1) out.

3. Use compressed air to clean filter.

CHECKING SWING GEAR ATTACHING BOLTS FOR PROPER TORQUE Check the swing ring bolts torque on a new machine after the first 50 hours of engine operation. Then, Check every 500 hours.

YM104SWINGBRG

6-36

Figure 95 Issued 02-04

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

Every 500 Hours CHANGE TRAVEL MOTOR OIL

CHANGE SWING MOTOR OIL

Change the travel motor oil at 500 hours of operation on a new machine. Then change the oil every 2000 hours.

Change the swing motor oil every 2000 hours of operation.

1 1

2

Figure 98

BC04B102

Figure 97

BC04B104

1. Move the machine to a firm level surface.

Operate the travel function until FILL and LEVEL (1) plugs on the motors are at the top.

2. Lower the attachment, shut the engine off and remove the key.

3. Slowly remove the travel motor oil fill and level plug.

4. Slowly remove the travel motor oil drain plug and drain into a suitable container.

5. Replace and secure the travel motor oil drain plug.

6. Add oil through the fill and level plug until it begins to seep from the office.

1. Locate the dipstick (1) on the side of the swing motor. Pull the dipstick, wipe it clean and replace, making sure to bottom the dipstick out.

2. Pull and read the oil level.

3. If necessary to add oil, remove plug (2) from the oil fill port and fill to full level.

To Drain the Swing Motor: 1. Locate the drain port under the rear of the machine.

2. Place a 0.5 gal (2 liter) container under the port and remove the drain plug slowly.

3. Replace and tighten securely after all oil is drained.

4. Fill at the fill port and secure the plug.

7. Secure the plug. Teflon tape may be used for better sealing.

8. Repeat the procedure for the other travel motor.

Capacity of each travel motor is 0.7 gal (2.5 liter).

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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 and NOT HOT.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

EVERY 1000 HOURS CHANGE ENGINE AIR FILTERS Change both air cleaner elements at 1000 hours of operation. In extreme conditions it may be necessary to change more often.

Figure 102

BS04B013

4. Remove the wing nut and air cleaner inner element from the housing.

CAUTION: Wear protective glasses or goggles when using compressed air.

5. Clean the filter housing and cover.

YQ104AIRRESTRICTION

Figure 99

1. Open engine air cleaner access door.

BS04B011

6. Assemble elements in the reverse order of disassembly.

IMPORTANT: Make sure to properly place the O-ring seal on the wing nut sleeve for the outer filter element. Failure to do so could cause engine failure.

Figure 100

2. Remove the air cleaner cover.

BS04B012

Figure 101

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

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

EVERY 2000 HOURS CHANGE ENGINE COOLANT WARNING: Be cautious of hot fluids and surfaces. Wear goggles, safety shoes, hart hat, work clothes and work gloves to perform inspection and maintenance on this machine.

Allow engine to cool before changing fluids.

Figure 103

1. Park the machine on hard, level ground and shut t h e e n g i n e o f f a l l ow i n g i t t o c o o l b e fo r e proceeding.

2. Raise the engine access cover using the safety struts and confirm the cover is secure in the open position.

BC04B191

Figure 106

5. Place a suitable container under the drain tube and turn the drain valve counterclockwise to open. Container should hold 5.0 gal (19 L).

6. After draining the system close the drain valve.

7. Fill the system with clean water and install the radiator cap.

8. Start the engine and run at a speed slightly higher than idle for 10 minutes to bring the temperature up to about 176° F (80° C).

9. Drain the system once more.

10. Repeat these steps until the water drained out is clear.

Figure 104

BC04B089

3. After the engine and related components cool, slowly remove the radiator cap.

11. Close the radiator drain valve and secure the access cover with the four bolts removed previously.

12. Fill the system, via the radiator, with the proper coolant solution and install the radiator cap.

Figure 105

BS04B023

4. Remove the four bolts to open the access cover located under the left-hand rear of the machine.

BC04B088

Figure 107

13. Fill the expansion reservoir to the Full mark and install the cap.

14. Start the engine and check for leaks.

15. Close the engine hood.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

Every 2000 Hours CLEAN SUCTION SCREEN

5. Slowly remove the six retaining bolts from the suction strainer cover plate.

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

Allow engine to cool before changing fluids.

1

Figure 108

2

BC04B094

Figure 109

1. Move the machine to firm, level ground and place the attachment in the hydraulic oil check position.

2. Follow the Releasing Hydraulic System Pressure on page 3-21 on this manual.

NOTE: If the machine is cold, warm the hydraulic oil by operating the attachment control before placing the machine in the hydraulic oil check position.

BC04B095

Figure 112

BC04B113

6. Remove the O ring (1) and suction strainer (2) from the hydraulic tank.

Figure 110

3. Release the hydraulic tank pressure depressing the rubber cap on the tank.

by Figure 113

4. Clean the area around the cover of dirt and debris.

7. Clean and inspect the suction strainer for damage. Replace if necessary.

IMPORTANT: It is vital not to contaminate the system during this procedure.

8. Install the strainer assembly onto the suction tube.

9. Install a new O ring and install the suction strainer cover plate onto the tank. Make certain the plate boss in inside the suction strainer holder.

10. Torque the retaining bolts to 34 lb ft.

NOTE: This machine is shipped with ISO VG46 viscosity hydraulic oil.

BS04B024

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

Every 2000 Hours RELEASING HYDRAULIC SYSTEM PRESSURE WARNING: Never change oils or filters on a machine that has just completed working.

Allow the machine to cool until oils and fluids are warm, not hot.

Release hydraulic tank pressure before working with any hydraulic or engine fluids.

IMPORTANT: If the Draining Hydraulic Pressure procedure fails FAIL DRAIN HYD PRESS is displayed and the alarm will sound continuously.

5. Turn the ignition switch to OFF. The alarm will stop and after 4 seconds the display will clear.

6. Begin at step 3 again until pressure is released successfully.

Figure 114

Proceed as follows to release hydraulic system pressure:

Figure 117

Press the hydraulic tank pressure relief valve and proceed to service or change auxiliary attachments.

Figure 115

BS04B072

1. Select hard, flat ground and place the machine in the position shown.

2. Start the engine with the throttle set at LOW idle.

Always release the internal pressure of the hydraulic tank before performing inspection or maintenance procedures. Depress the stem or remove the cap slowly with engine off to relieve hydraulic tank pressure.

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

Figure 116

BC04B070

3. Press and hold the screen change switch and the buzzer stop switch simultaneously for at least 5 seconds.

The engine speed will switch to low idle and the monitor will display DRAINING HYD PRESSURE and the monitor alarm will sound intermittently.

4. Operate the control levers several times to release the system pressure.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

Every 2000 Hours CHANGE HYDRAULIC OIL Change the hydraulic oil and clean the tank every 2000 hours of operation.

NOTE: If the machine is cold, warm the hydraulic oil by operating the attachment controls before placing the machine in the hydraulic oil check position.

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.

Always allow hydraulic oil to cool before changing/ Figure 118

BC04B094

Figure 121

BS04B024

4. Slowly remove the bolts that secure the suction strainer cover plate.

Figure 119

1. Move the machine to firm, level ground and place the attachment in the hydraulic oil check position.

2. Release hydraulic system pressure as described on the previous page.

Figure 122

BC04B113

5. Remove the O ring, and suction strainer from the hydraulic tank.

BC04B095

Figure 120

3. Release the hydraulic tank pressure depressing the rubber cap on the tank.

by

Figure 123

BC04B114

6. Install the suction stopper over the tube inside the hydraulic tank.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

Every 2000 Hours CHANGE TRAVEL MOTOR OIL Change the travel motor oil every 2000 hours of operation.

1

Figure 124

BS04B076

7. Remove the cover plate under hydraulic tank and locate the tank drain plug.

BC04B104

8. Place a suitable container under the plug and drain the oil from the tank.

9. After all the oil has drained clean the tank.

10. Replace the tank drain plug and tighten securely.

11. Remove the suction stopper and clean the outside of the suction tube.

12. Inspect the strainer for damage and replace if necessary.

13. Install the strainer assembly onto the suction tube.

14. Install a new O ring, and install the suction strainer cover plate. Make certain the plate boss is inside the suction strainer holder.

15. Torque the retaining bolts to the proper value.

Figure 126

1. Move the machine to a firm level surface.

Operate the travel function until FILL and LEVEL (1) plugs on the motors are at the top.

2. Lower the attachment, shut the engine off and remove the key.

3. Slowly remove the travel motor oil fill and level plug.

4. Slowly remove the travel motor oil drain plug and drain into a suitable container.

5. Replace and secure the travel motor oil drain plug.

6. Add oil through the fill and level plug until it begins to seep from the orifice.

7. Secure the plug. Teflon tape may be used for better sealing.

8. Repeat the procedure for the other travel motor.

Capacity of each travel motor is 0.7 gal (2.5 liter).

Figure 125

BS04B014

16. Fill the hydraulic tank to proper level through the return filter.

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6-43

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

Every 2000 Hours CHANGE SWING MOTOR OIL

HYDRAULIC TANK BREATHER REPLACEMENT

Change the swing motor oil every 2000 hours of operation.

1. Release hydraulic tank pressure.

1

2

Figure 128

YQ101RELEASEPRESS

2. Remove cap.

Figure 127

BC04B102

1. Locate the dipstick (1) on the side of the swing motor. Pull the dipstick, wipe it clean and replace, making sure to bottom the dipstick out.

2. Pull and read the oil level.

3. If necessary to add oil, remove plug (2) from the oil fill port and fill to full level.

To Drain the Swing Motor: 1. Locate the drain port under the rear of the machine.

2. Place a 0.5 gal (2 liter) container under the port and remove the drain plug slowly.

3. Replace and tighten securely after all oil is drained.

4. Fill at the fill port and secure the plug.

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

Figure 129

HYDTANKRELIEF

3. Remove breather filter cover.

4. Remove old filter. Clean mounting surfaces and install new filter.

5. Install breather filter cover.

6. Install cap and tighten securely.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

Every 2000 Hours · For best results, strike all head bolts with a

CHANGE SWING RING GREASE BATH Change the Swing Ring grease bath every 2000 hours of machine operation. To properly replace the grease, it is necessary to remove the upper frame.

Refer to the Service Manual or Machine’s Shop Manual and/or contact your Dealer’s Ser vice Department for assistance. Proper tools have to be used and specific instructions must be followed to undeck the machine upper structure from the lower structure.

heavy hammer to seat them properly before final torque.

WARNING: Wear safety glasses whenever striking metal objects with a hammer.

· When new parts are used, the mating surfaces

· ·

will seat more uniformly and the bolts torque will be less than the standard value after a short period of operation. Make sure to check all bolts for proper tightness on new parts after eight (8) hours of operation.

Lower maintenance costs by replacing, turning, or rotating cutting edges before they reach their wear limits.

When finding loose bolts, check bolts for elongation and support mount holes for wear.

Replace bolts and repair any wear on support mount hole if needed. Torque bolts according to specifications.

GUIDELINES FOR ATTACHMENT LUBRICATION

Figure 130

YQ104GREASEBATH

IMPORTANT: If the Swing Ring ever becomes submerged in water, it is mandatory that the sump bath grease be changed.

IMPORTANT: GUIDELINES TO REPLACE GROUND TOOLS It is very important to keep bucket teeth and side cutters properly tighten. Loose or missing bolts will increase loads and eventually cause tool failure.

Fur th er mo re, ex tend ed op erati on wi th lo os e hardware can cause the bolts to stretch and wear on the suppor t mounting holes. Also, heating of hardware and support mounting holes will cause the same effect. All these factors will lead to more expensive corrective maintenance. Follow these general guidelines to insure proper tightness of hardware on bucket teeth and side cutters. · When installing new cutting edges, end bits, side cutters, and bucket teeth, make sure that all supporting surfaces are free of dirt, paint, debris, rust, scale or weld splatter. All mating surfaces must be clean and flat to insure that maximum clamping force is obtained. · Make sure that all bolts and nut threads are clean and dry. DO NOT APPLY ANY TYPE OF LUBRICANT. · When installing end bits, start at the center and work toward the outside edges. · Always torque bolts according to specifications.

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Lubricate attachment pins according to the intervals indicated in the Maintenance Chart. Use extreme pressure multipur pose grease No. 2 EP type.

Lubr icate all points until grease purges. The lubr ication inter vals are based on a standard excavator (see Specifications Section for the definition of Standard Excavator) working in an average duty cycle. Average duty cycle is defined as “Most typical digging application, road construction in natural bed clay, digging 50% ~ 60% of the daily work schedule”.

New pins and bushings, including new machines and repairs require special break-in procedures. While both pin and bushing have a special ground finish, they still have to be mated to each other to eliminate the machining high points. See Figure 131.

DC03K217

Figure 131

6-45

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS Because of these high spots, it is recommended that the front attachment or the repaired area be lubricated a minimum of once every eight (8) hours for the first one hundred (100) hours for a standard machine working in an average duty cycle. All other machine should be lubricated every 4 hours for the first twenty (20) hours and every eight (8) hours for the next eighty (80) hour s of operation. This lubrication procedure will reduce the possibility of a premature pin or bushing failure during the break-in period.

SPECIAL CONSIDERATIONS FOR HAND LUBRICATION While grease grooves in the bushings allow grease to move around the bushing, it does not insure that grease gets on all of the bushing surfaces. Any load on the joint will prevent the grease from getting to the wear surfaces in the loaded area. Due to the fact that a hand greaser does not provide the volume of grease that a power system does, there is a greater possibility of bushing galling, unless the standard lubrication procedure is modified. IMPORTANT: illustrate the pin load and grease cavity discussed above. No matter how much grease is pumped into the pin bushing cavity with a hand grease gun, the grease will tend to escape to the outside before filling the grease cavity. Therefore, to avoid this situation, the front attachment has to be repositioned during the lubrication process, to move the load area and allow the grease to cover the entire grease cavity between the pin and bushing.

DC03K219

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Figure 132

Issued 02-04

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

VARIABLE AND PERIODIC MAINTENANCE CHECKING AND CLEANING FUEL TANK AND STRAINER 1. Use ignition key and remove the fuel tank cap.

ENGINE FUEL INJECTION TIMING Check Engine Fuel Injection timing every 1000 hours of engine operation. Contact your Dealer for assistance WELDING SAFETY 1. Turn key switch to OFF position. Wait 4 seconds for electrical power to disconnect.

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

3. Attach the welder ground cable within 3 ft 3 in (1 M) from the component being welded.

Figure 133

YM104REMOVEFUELSCREEN

2. Check the cap seal and replace it if needed.

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

WARNING: Make certain that no bearing or seal separates the welder ground and the weld area.

3. Remove the fuel tank strainer and clean it. replace the strainer if it is damaged.

Figure 134

YM104CLEANFUELSCREEN

ENGINE VALVE CLEARANCE Check and adjust the engine valve clearance every 1000 hours of the engine operation. Contact your Dealer’s Service Department for assistance.

ENGINE COMPRESSION PRESSURE Check Engine Compression every 1000 hours of engine operation. Contact your Dealer’s Service Department for assistance.

INSPECTION OF STARTER AND ALTERNATOR Check Starter and Alternator every 1000 hours of engine operation. Contact your Dealer’s Service Depar tment for assistance. It is necessar y to disassemble these components for proper cleaning and inspection.

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6-47

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS HYDRAULIC LINES, TUBES, AND HOSE

HYDRAULIC SUCTION TUBES AND HOSES

S i n c e t h e r e i s n o d e f i n i t e t i m e t a bl e fo r t h e replacement of hydraulic lines, tubes, and hoses, inspect the following periodically for tightness and signs of damage. Replace all damaged lines, tubes, and hoses with new parts. Refer to the Parts Catalog for correct part numbers. when ordering.

Inspect all hydraulic tubes and hoses for damage, wear and loose connections.

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 to avoid any fire hazard.

Tighten all loose fittings and connections to the proper torque value.

Clean up all fuel and oil spills immediately to help prevent fires, slipping, accidents, attachment dropping, etc.

Never use hands to check for leaks.

Carefully inspect all lines, tubes, and hoses for: 1. Fittings and 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 fitting and connections.

Make certain all clamps, guards, and heat shields are in place and secured. this will help prevent vibration, excessive wear of components and excessive heat during operation.

REAR VIEW MIRRORS Inspect the rear view mirror. Make certain both sides rear view mirrors and internal rear view mirror are in place, proper ly adjus ted, clean, and in good condition. Secure them tight to prevent them from breaking.

Heater Hoses Inspect the heater hose between heater and engine for signs of damage and wear.

· Boom Cylinder Hoses and Tubes Inspect boom cylinder head and rod hoses and tubes for damage, wear and loose connections.

· Arm Cylinder Hoses and Tubes Inspect arm cylinder head and rod hoses and tubes for damage, wear and loose connections.

· Bucket Cylinder and Nibbler/Breaker Hoses & Tubes Inspect bucket cylinder head and rod hoses and tubes for damage, wear and loose connections.

Inspect also the Nibbler/Breaker tubes and hoses if equipped.

· 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.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS SPECIAL PROCEDURES The EH130LC machines incorporate automatically applied spring brake systems in the travel motors and swing motor. These systems will automatically engage the brakes when the engine is stopped, making it impossible to move the machine. Contact your dealer as this procedure must be performed by an authorized technican.

WARNING: Read, understand and follow all safety precautions and procedures found in this manual before attempting any operation, inspection, maintenance or repairs of this machine, attachment or any of its systems.

Figure 135

LOWERING THE ATTACHMENT WHEN SUDDEN ENGINE FAILURE OCCURS

4. Turn ignition key to START position to use starter motor to rotate the engine.

CAUTION: Only operate the Starter Motor in 20 second intervals and allow 3~5 minutes between intervals to allow the Starter Motor to cool.

5. While engine is rotating, slowly and carefully move the RH control lever forward (boom down) and lower boom completely to ground.

Should sudden engine failure occur, follow the following procedures to place the attachment on the ground.

WARNING: Make certain the area around the machine is clear of people and objects before attempting these procedures.

1. Locate the engine emergency stop control at the lower RH corner of the seat base and pull control out.

YM103BOOMDOWN

Figure 138

6. After Boom is completely down. leave the ignition key in ON position, operate the arm, bucket and swing controls to release hydraulic pressure in these circuits. Turn ignition key off.

7. Locate hydraulic tank air breather on top of the hydraulic tank. Remove cap and depress stem until all inter nal hydraulic tank pressure is released.

Figure 136

BC04B048

2. Place the hydraulic safety lock lever in the UNLOCKED (down) position. See Figure 137.

YQ101RELEASEPRESS

Figure 137

YQ102SAFETYLEVERDOWN

3. Sound horn to alert people in the area of machine movement.

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Figure 139

WARNING: Use caution when removing or repairing hydraulic components as hydraulic pressure may exist or be trapped in circuits.

Figure 140

6-49

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

NOTES

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CHAPTER 7 - ELECTRICAL

CHAPTER 7

ELECTRICAL TABLE OF CONTENTS ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-3 7-3 7-3 7-3 7-4

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CHAPTER 7 - ELECTRICAL

NOTES

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CHAPTER 7 - ELECTRICAL

ELECTRICAL COMPONENTS ALTERNATOR Ask your Dealer to check the Alternator.

Make sure that the terminal protectors are correctly installed.

Do not use steam cleaning equipment or a cleaning solvent to clean the alternator.

STARTER MOTOR Ask your Dealer to check the Starter Motor.

Make sure that the terminal protectors are correctly installed.

Figure 3

DC03M064

FUSES Follow the following procedures to replace “blown” or “faulty” fuses.

1. Move seat and seat base completely forward.

No.

AMPS

1A/1B

20A

Mechatro Controller (CPU)

2

10A

Wiper, Washer Relay

3

10A

Cigarette Lighter 24V

4

10A

DC-DC Converter

5

10A

Horn

6

NONE None

7

10A

Mechatro Controller & Hr. meter (Back up)

8

20A

Fuel Supply Pump

9

10A

E n g i n e C o m p. L a m p, D C - D C Converter (Back up)

10

20A

Starter Switch

11

20A

Fuel Pump

12

20A

Travel Alarm

13

10A

Gauge Cluster (Monitor)

14

20A

Wiper, Washer

15

10A

Solenoid Valve (Lever Lock)

16

20A

Working Light (Front)

17

10A

Resistor

18

20A

Air Conditioner

19

10A

Controller (A/C)

20

20A

Spare 24V

Figure 1

BC04B046

2. Open the fuse compartment and remove fuse box cover from fuse box.

3. Locate and remove faulty fuses. Replace any fuse needed with the same type and amperage.

WARNING: Never replace a faulty fuse with a higher amperage fuse. Never use a jumper in place of a fuse. never splice accessories directly into fuse terminals.

Figure 2

4. Refer to fuse box cover for fuse amperage and their functions.

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FUNCTION

7-3

CHAPTER 7 - ELECTRICAL BATTERIES Perform complete battery service on a new machine after the first 50 hours of engine operation. Then, check electrolyte (acid) every 50 hours and perform maintenance every 250 hours.

WARNING: Battery acid causes severe burns. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing. Antidote EXTERNAL: flush with water.

INTERNAL: drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil. Call physician immediately.

EYES: flush with water for 15 minutes and get prompt medical attention.

1. Open the battery access door and secure it open.

2. Remove battery cell caps and visually inspect electrolyte (acid) level. Proper level is 1 ~ 15 mm (0.4” ~ 0.6”) above cell plates.

Figure 4

WARNING: Before any operation on the components of the electrical circuit, put the key switch in the shut down position. When disconnecting the battery cables, always disconnect the negative (-) cable first. When reconnecting the battery cables, always connect the negative (-) cable last.

Figure 7

BATCOMP

.

Figure 5

WARNING: Sparks or flame can cause hydrogen gas in a battery to explode. To prevent an explosion, do the following: 1. When you DISCONNECT the battery cables, always disconnect the negative (1) battery cable first.

2. When you CONNECT the battery cables, always connect the negative (-) cable last.

3. Do not short circuit the battery posts with metal items.

4. Do not weld, grind, or smoke near a battery.

Figure 6

Figure 8

YQ104BATACIDLEVEL

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.

6. Use a hydrometer to check the specific gravity of each cell. Compare readings to the chart below.

ATMOSPHERIC TEMPERATURE CHARGE

7-4

68°F (20°C)

32°F (0°C)

14°F (-10°C)

100%

1.26

1.27

1.28

90%

1.24

1.25

1.26

80%

1.22

1.23

1.24

75%

1.21

1.22

1.23

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CHAPTER 7 - ELECTRICAL 7. When disconnecting batteries, remove the negative (-) cable first. W hen connecting batteries, connect the negative (-) cable last. See Figure 9.

WARNING: Batteries give off explosive gases. Keep all open flames, sparks and cigarettes away. Ensure adequate ventilation when charging batteries or when using in a confined place. Always protect your eyes when working near batteries.

Figure 9

SK32004077

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.

NOTE: Make certain not to cross Positive (+) and negative (-) terminals when connecting charger. e. Stop charge if battery overheats. f. Periodically check the specific gravity of the batteries with a hydrometer. Stop charging batteries when 100% charged.

NOTE: Battery life can be shortened by over charging and over discharging of the battery.

Replace any battery that will not hold charge or difficult to charge.

WARNING: Before you service a battery, always wear face protection, protective gloves and protective clothing. Battery acid or battery explosion can cause serious injuries.

Figure 10

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CHAPTER 7 - ELECTRICAL

NOTES

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CHAPTER 8 - SPECIFICATIONS

CHAPTER 8

SPECIFICATIONS TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Machine Overall Dimensions 9 ft 8 in (2.95 m) Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bucket selection chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-3 8-4 8-4 8-5

LIFTING CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 Standard Lift - Machine with 3.10 m Arm, 0.52 cu. m Bucket, 500 mm Triple Grouser Shoes . . . . . . . . . . . . 8-7

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CHAPTER 8 - SPECIFICATIONS

SPECIFICATIONS Engine Make and Model ................................................................................................................................. Isuzu A-4BG1T Type .................................................................................... 4-cycle, water cooled, direct injection with turbo charger Number of Cylinders..................................................................................................................................................4 Bore/Stroke............................................................................................................ 4.13” x 4.92” (105 mm x 125 mm) Displacement.................................................................................................................................264 cu in.³ (4.33 L) Power ........................................................................................................................... 94 hp (70.6 kW) @ 2200 rpm Electrical System ..........................................................................................................................................D.C. 24 V Batteries ......................................................................................................................................................... 2 - 12 V Alternator ..................................................................................................................................................... 24 V 40 A Engine Dry Weight...............................................................................................................................810 lb (368 kg) Hydraulic Components Hydraulic Pump ..................................................... Tandem, variable displacement,axial piston with pilot gear pump Rated Oil Flow .........................................................................................................................2 x 31.4 gpm (2 x 118) Operating Pressure Implement ........................................................................................................................4 980 psi (34.30 MPa) Travel................................................................................................................................4 980 psi (34.50 MPa) Pilot .......................................................................................................................................710 psi (4.90 MPa) Swing Motor.............................................................................................................................................. Axial piston Swing Speed.........................................................................................................................................11.7 rpm Swing Torque .............................................................................................................. 28 175 lb ft (38.00 kN-m) Tail Swing Radius......................................................................................................................4 ft 8 in (1.43 m) Travel Motor .............................................................................................................................................. Axial piston Control Valve .......................................................................................................................... 6 spool multiple control Cylinders................................................................................................................................................ Double acting Speed and Gradeability Travel Speed Low ................................................................................................................................................2.2 mph (3.5 km/h) High ...............................................................................................................................................3.7 mph (6.0 km/h) Gradeability ...................................................................................................................................... 35 degree (70%) Refill Capacities Fuel Tank ............................................................................................................................................44.4 gal (168 L) Hydraulic Reservoir ..............................................................................................................................24.8 gal (94 L) Hydraulic System...................................................................................................................................37 gal (140 L) Cooling System ......................................................................................................................................4.8 gal (18 L) Engine Oil ...............................................................................................................................................3.4 gal (13 L) Working Forces with 9ft 8 in (2.95 m) Arm Bucket Digging Force SAE .........................................................................................................................................19 000 lb (8 620 kg) ISO ..........................................................................................................................................21 357 lb (9 687 kg) Arm Digging Force SAE .........................................................................................................................................12 569 lb (5 700 kg) ISO ..........................................................................................................................................13 061 lb (5 924 kg)

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CHAPTER 8 - SPECIFICATIONS MACHINE OVERALL DIMENSIONS 9 FT 8 IN (2.95 M) ARM

Figure 1

BC04A173

A. B. C. D. E. F. G. H. I. J. K. L.

Overall Length...........................................................................................................................24 ft 6 in (7.47 m) Overall Width...............................................................................................................................8 ft 6 in (2.59 m) Overall Height to Top of Boom ....................................................................................................9 ft 0 in (2.74 m) Overall Height to Top of Handrail ................................................................................................9 ft 3 in (2.81 m) Overall Height to Top of Cab .......................................................................................................9 ft 0 in (2.74 m) Ground Clearance of Upperstructure ...........................................................................................35.8 in (0.91 m) Center to Center, Idler to Sprocket............................................................................................9 ft 11 in (3.04 m) Overall Length of Track .............................................................................................................12 ft 3 in (3.74 m) Track Gauge................................................................................................................................6 ft 6 in (1.99 m) Shoe Width ...............................................................................................................................23 ft 6 in (0.60 m) Ground Clearance of Undercarriage ...............................................................................................18 in (0.46 m) Tail Swing Radius........................................................................................................................4 ft 8 in (1.43 m)

NOTE: Height Dimensions exclude the height of the grouser.

OPERATING WEIGHT with 23.6 inch (600 mm) shoes ........................................................................................... 32 192 lbs (17 300 kg) ground pressure .................................................................................................................... 5.33 psi (0.37 kg/cm´

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CHAPTER 8 - SPECIFICATIONS BUCKET SELECTION CHART

Application

Capacity yd ³ (m³)

Width inches (m)

Weight lbs (kg)

Arm

9 ft 8 in (2.95 m)

General Purpose

Heavy Duty

0.3 (0.23)

18 (0.46)

650 (295)

H

0.44 (0.34)

24 (0.61)

720 (327)

H

0.58 (0.44)

30 (0.76)

835 (379)

M

0.73 (0.56)

36 (0.91)

905 (411)

L

0.88 (0.67)

42 (1.07)

1015 (460)

L

0.3 (0.23)

18 (0.46)

705 (320)

H

0.44 (0.34)

24 (0.61)

780 (354)

H

0.58 (0.44)

30 (0.76)

900 (408)

M

0.73 (0.56)

36 (0.91)

975 (442)

L

0.88 (0.67)

42 (1.07)

1090(494)

X

H - Used with material weight up to 3 000 lbs/yd³ (1 780 kg/m³ M - Used with material weight up to 2 500 lbs/yd³ (1 483 kg/m³ L - Used with material weight up to 2 000 lbs/yd³ 1 196 kg/m³ X - Not recommended.

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CHAPTER 8 - SPECIFICATIONS

LIFTING CAPACITIES 1. Do not attempt to lift any load that exceeds the rated values at their specified load radii and height.

2. Lifting capacities assume a machine standing on a level, firm, and uniform supporting surface.

Operator must make allowance for job conditions such as soft or uneven ground, out of level conditions, side loads, sudden stopping of loads, hazardous conditions, inexperienced personnel, weight of various other buckets, lifting slings, attachment, etc.

3. Rating at bucket lift hook.

4. The rated loads are in compliance with SAE Hydraulic Excavator Lift Capacity Standard J1097. They do not exceed 87% of hydraulic lifting capacity or 75% of tipping load. Rated loads marked with asterisk (*) are limited by hydraulic capacity rather than tipping load.

5. Operator should be fully acquainted with the O p e r a t o r ’s M a n u a l b e fo r e o p e ra ti n g t h i s machine. Rules for safe operation of equipment should be followed at all times.

6. Capacities apply to the machine as originally manufactured and normally equipped by New Holland Construction.

CAUTION: The operator must consider the weight of any device utilized for lifting to properly calculate the total lifting capacity of the machine. example: 1. If the excavator uses the same bucket size indicated in the lifting chart, and a lifting cable, etc. weighing 100 kg (220 lbs) is used for lifting, then you have to subtract this additional 100 kg (220 lbs) from every value indicated in the lifting chart accordingly.

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

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

Lifting Capacities Chart Legends:

Figure 2

BS04A196

A - Reach swing center line to bucket hook (Load Radius).

B - Bucket hook height above/below ground.

C - Lifting capacities in pounds (lb) and kilograms (kg).

Front Lifting.

8-6

Side Lifting.

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CHAPTER 8 - SPECIFICATIONS STANDARD LIFT - MACHINE WITH 3.10 M ARM, 0.52 CU. M BUCKET, 500 MM TRIPLE GROUSER SHOES EH 130 LC Lifting Capacities based on machine with: 15 ft 1 in (4.6 m) Boom , 9 ft 8 in (2.95 m) Arm, 0.50 yd³ (0.38 m³) Bucket, 23.6 in (600 mm) triple grouser shoes A

5 ft

10 ft

B

C

15 ft (4.6 m)

lb kg

10 ft (3.0 m)

lb kg

5 ft (1.5 m)

lb kg

*14900 *6700

Ground Level

lb kg

-5 ft (-1.5 m)

lb kg

*10200 *4600

-10 ft (-3.0 m)

lb kg

*15900 *7200

-15 ft (-4.6 m)

lb kg

6-82410NA

15 ft

20 ft

*5800 *2600

4800 2100

*7300 *3300

*7300 *3300

*6400 *2900

4600 2000

12900 5800

*9400 *4200

6800 3100

7000 3100

4300 1900

*18200 *8200

11700 5300

10600 4800

6300 2800

6700 3000

4000 1800

*10200 *4600

*18300 *8300

11400 5100

10300 6210

6830 3100

8340 3780

4150 1880

*15900 *7200

*16300 *7400

11500 5200

10300 4600

6000 2700

*11400 *5100

*11400 *5100

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CHAPTER 8 - SPECIFICATIONS

NOTES

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CHAPTER 9 - INDEX

Chapter 9

INDEX A Air Cleaner ................................................ 6-10, 6-38 Alternator ............................................................. 7-3 Arm Cylinder Hoses and Tubes ......................... 6-48 Arm Operation ................................................... 4-14 Arm Rest Adjustment ........................................... 3-7 Auto Warm Up ..................................................... 4-8

B Basic Operation of Hydraulic Controls ............... 4-11 Batteries .............................................................. 7-4 Battery Box Access Cover ................................. 3-30 Before Operating the Machine ............................. 4-3 Boom ................................................................. 6-48 Boom Cylinder Hoses and Tubes ...................... 6-48 Boom Operation ................................................ 4-14 Bucket Cylinder and Nibbler/Breaker Hoses & Tubes ..................................................................... 6-48 Bucket Operation ............................................... 4-15 Bucket Selection Guide ..................................... 4-19 Burn Prevention ................................................... 2-8

C Cab Dome Light ................................................... 3-5 Cab Door ............................................................. 3-3 Cab Door Latch ................................................... 3-3 Change Swing Ring Grease Bath ...................... 6-45 Checking and Cleaning Fuel Tank and Strainer 6-47 Components, Machine ......................................... 1-3 Connecting Booster Cable ................................... 4-7 Control Decal ..................................................... 4-10 Control Lever Joint Lubrication .......................... 6-28 Control Stand Front to Back Adjustment ............. 3-7 Counter Rotating Machine ................................. 4-13

D Daily inspections .................................................. 6-3 Decals ................................................................ 2-11

E Engine Compression Pressure .......................... 6-47 Engine Coolant Level .......................................... 6-8 Engine Cover ..................................................... 3-31 Engine Electrical ................................................ 6-14 Engine Fluid Leaks .............................................. 6-9 Engine Fuel Injection Timing ............................. 6-47 Engine Oil Level .................................................. 6-8 6-82410NA

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Engine Valve Clearance .....................................6-47 Environment .........................................................6-4

F Frame Structure .................................................6-16 Fuel Cap .............................................................3-30 Fuel Filter Cumulative Time ...............................3-17 Fuel Gauge .........................................................3-14 Fuel Handling Precautions ...................................2-8 Fuel Lines and Hoses .........................................6-48 Fuses .......................................................... 6-15, 7-3

G General Information ..............................................1-1 Guidelines for Attachment Lubrication ...............6-45 Guidlines to Rplace Ground Tools .....................6-45

H Hand Signals ......................................................2-21 Hazardous Chemical Precautions ........................2-8 Head Rest Adjustment .........................................3-7 Heater Hoses .....................................................6-48 How to Handle Life Hammer ................................2-9 How to Handle life Hammer .................................2-9 Hydraulic Breaker ...............................................4-21 Hydraulic Oil Leaks ............................................6-13 Hydraulic Oil Level .............................................6-11 Hydraulic Suction Tubes and Hoses ..................6-48 Hydraulic Tank Pressure ....................................6-41

I Identification Numbers ..........................................1-4 Idlers ...................................................................6-18 index .....................................................................3-3 Inspection of Starter and Alternator ....................6-47

K Key Switch ............................................................3-9 KPSS Work Mode Switch ...................................4-11

L L.C.D. Display ....................................................3-16 Lifting Capacities ..................................................8-6 Lowering Attachment When Sudden Engine Failure Occurs ..........................................................6-49 Lowering the Attachment with Engine Failure ....4-14

9-1

CHAPTER 9 - INDEX

M

S

Machine Access Compartments and Doors ...... 3-30 Machine Attachment and Swing ........................ 4-14 Machine Components .......................................... 1-3 Machine Dimensions ........................................... 8-4 Machine Electrical ............................................. 6-14 Machine Operation in Adverse Weather Conditions ..................................................................... 4-17 Machine Storage ............................................... 4-25 Machine Travel Controls .................................... 4-12 Machine Warm Up ............................................... 4-8 Main Pump Access Door ................................... 3-30 Maintenance Precautions .................................... 2-7 Manual Warm Up ................................................. 4-8 Mounting and Dismounting Precautions .............. 2-5

Safety Area ...........................................................2-3 Safety Lock Lever ...............................................4-11 Safety Rules .........................................................2-3 Seat Belt ...............................................................3-7 Seat Belt Precautions ...........................................2-9 Seat Front to Back Adjustment .............................3-6 Seat Height Adjusment .........................................3-6 Seat Reclining Adjustment ...................................3-6 Serial Numbers .....................................................1-4 Servicing instructions ...........................................6-3 Sides of the machine Right-hand, left-hand, front, and rear ...............1-2 Special Considerations for Hand Lubrication .....6-46 Specific machine precautions .............................2-10 Sprockets ...........................................................6-17 Standard Lift - Machine with 3.10 m Arm, 0.52 cu. m Bucket, 500 mm Triple Grouser Shoes ..........8-7 Starter Motor ........................................................7-3 Starting & Stopping Machine Engine with Temperature above 32°F (0°C) .....................4-6 Starting & Stopping Machine Engine with Temperature below 32°F (0°C ) .....................4-6 Starting and Stopping Precautions .......................2-5 Starting Engine .....................................................4-6 Starting Machine Engine with Booster Cable .......4-7 Steps and Handrails ...........................................6-16 Stopping Engine - Normal Conditions ..................4-6 Storage Compartment ..........................................3-5 Swing Operation .................................................4-15

O Opening and Closing Door Glass ........................ 3-5 Opening and Closing Sunroof ............................. 3-5 Opening and Closing Windshield ........................ 3-4 Operating Both Travel Levers Together ............ 4-12 Operating Pattern .............................................. 4-10 Operating Pattern Decal .................................... 4-10 Operating Precautions ......................................... 2-6 Operating the machine ........................................ 4-4 Operating the Machine in Water ........................ 4-18 Operation at Seashore or Salty Climate ............ 4-17 Operation in Extreme Cold ................................ 4-17 Operation in Extreme Heat ................................ 4-17 Operation in High Altitudes ................................ 4-17 Operation in Humid Climate .............................. 4-17 Operation in Sandy and Dusty Areas ................ 4-17 Operator Cab Nomenclature ............................... 3-9 Operator Precautions .......................................... 2-5 Operator Seat Adjustments ................................. 3-6 Operator Weight Adjustment ............................... 3-6 Operator’s Compartment Controls and Accessories ....................................................................... 3-8

T

P

Throttle Potentiometer ........................................3-10 Track Links .........................................................6-17 Track Shoes .......................................................6-17 Track Tension .....................................................6-12 Transportation ....................................................4-24 Transporting Precautions .....................................2-9 Travel Safety ......................................................4-13 Travel Speed Select Switch ...............................3-16

Personal Safety ................................................... 2-3 Product Identification Number ............................. 1-4

U

R Rear View Mirrors .............................................. 6-48 Recommendation for Longer Undercarriage Life ..................................................................... 4-19 Removing and Storing Lower Front Window ....... 3-4 Rollers ............................................................... 6-18 Roll-Over Protective Structure (If equipped) ........ 2-9 9-2

Use Arm in Action ...............................................4-16 Use of Optional Attachment ...............................4-20 Utility Safety .........................................................2-4 Utility Safety Rules Message ................................2-4

W Warming of Hydraulic Oil ......................................4-9 Washer Switch ...................................................3-15 Welding Safety ...................................................6-47 Issued 02-04

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CNH America LLC 245 E NORTH AVENUE CAROL STREAM, IL 60188 U.S.A

Part Number North American English Printed in U.S.A.

6-82410NA March 04 Bur