New Holland Kobelco E335 Operation & Maintenance Instruction Manual 6042162201 - PDF DOWNLOAD

Operation and Maintenance Instruction Manual

E335

Operation and Maintenance Instruction Manual

E335

Print No. 604.21.622.01 English - Printed in Italy

PROVEN PERFORMANCE

PROVEN PERFORMANCE

E335 OPERATION AND MAINTENANCE INSTRUCTION MANUAL ENGLISH Print No. 604.21.622.01

Edition: 09/2005 English - Printed in Italy Printed by Studio ti - 39805

WARNING

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

WARNING

This symbol is your alert sign and is specifically intended for safety purposes. It means: $ 77( 1 7,2 1 %( &2 0 ( $ / ( 5 7 <2 8 5 6 $ ) ( 7< ,6 ,1 9 2 / 9 ( '

WARNING

Read and comply with all precautionary statements following the key-words ' $ 1 * ( 5 &$ 8 7,2 1 .

: $ 5 1 ,1 * and

WARNING

Machine-mounted safety signs are colour coded yellow with black borders and lettering when they refer to points where special $ 77( 1 7,2 1 must be paid as an $ &&,' ( 1 7 may occur. They are white with red borders and black lettering when they refer to a ) 2 5 %,' ' ( 1 practice.

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

WARNING 5 HDG W KLV P DQXDOEHIRUH RSHUDW LQJ W KH P DFKLQH

Most accidents occurring during work are due to non-observance of simple safety norms and elementary precautions.

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

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

WARNING

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

MACHINE SERIAL NO. ENGINE TYPE

MITSUBISHI 6D16-TLU2D

ENGINE SERIAL NO. NOTES VALID FOR MODELS

E335: LC08-06201~ E335LC: YC08-03001~ E335NLC: YC08-03001~

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

S.p.A.

FOREWORD GENERAL • This manual contains procedures to aid the operator gain peak performance through effective, economical machine operation and maintenance for the Hydraulic Excavators.

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

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

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

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

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

• Materials and specifications are subject to change without notice.

PERIODIC INSPECTIONS • After delivery of a machine, the authorized Dealer will make periodic service inspections. These inspections will be free of charge to the owner of the machine and will be at time intervals set by the Manufacturer. Contact an authorized Dealer for any service related questions not explained in this manual.

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

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

TABLE OF CONTENTS Section I – SAFETY PRECAUTIONS ........................................................................................................... 1-0 ~ 1-24 Section II – MACHINE FAMILIARIZATION ................................................................................................... 2-0 ~ 2-38 Section III – BASIC MACHINE OPERATION ................................................................................................. 3-0 ~ 3-24 Section IV – MAINTENANCE ......................................................................................................................... 4-0 ~ 4-54 Section V – TRANSPORTATION .................................................................................................................. 5-0 ~ 5-10 Section VI – SPECIFICATIONS ..................................................................................................................... 6-0 ~ 6-18 SectionVII – TROUBLESHOOTING ............................................................................................................... 7-0 ~ 7-6 Section VIII – OPTIONAL EQUIPMENT ........................................................................................................ 8-0 ~ 8-58 Section IX – SPECIAL PROCEDURES ........................................................................................................ 9-0 ~ 9-8

All rights reserved. Any use of editorial or pictorial content is strictly prohibited without express written permission from the Manufacturer.

Section I – SAFETY PRECAUTIONS Table of Contents 1.1 GENERAL SAFETY INFORMATION ...................................................................................................................... 1-1 1.2 SAFETY PRECAUTIONS ....................................................................................................................................... 1-1 1.3 PRE-START SAFETY ............................................................................................................................................ 1-4 1.4 SAFETY DURING OPERATION ............................................................................................................................. 1-6 1.5 INSPECTION & MAINTENANCE SAFETY ............................................................................................................. 1-9 1.6 BATTERY SAFETY .............................................................................................................................................. 1-12 1.7 WARNING LABELS & DECALS .......................................................................................................................... 1-13

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

1-0

Section I – SAFETY PRECAUTIONS 1.1 GENERAL SAFETY INFORMATION

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

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

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

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

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

1. Most accidents, which occur during operation, are due to neglect of precautionary measures and safety rules.

Sufficient care should be taken to avoid these accidents.

Erroneous operation, lubrication or maintenance services are very dangerous and may cause injury or death of personnel. Therefore all precautionary measures, NOTES, DANGERS, WARNINGS and CAUTIONS contained in this manual and on the machine should be read and understood by all personnel before starting any work with or on the machine.

1.2 SAFETY PRECAUTIONS

WARNING THE PROPER AND SAFE LUBRICATION AND MAINTENANCE FOR THIS MACHINE, RECOMMENDED BY THE MANUFACTURER, IS OUTLINED IN THE OPERATOR’S MANUAL FOR THIS MACHINE. IMPROPER PERFORMANCE OF LUBRICATION OR MAINTENANCE PROCEDURES ARE DANGEROUS AND COULD RESULT IN INJURY OR DEATH. READ AND UNDERSTAND THE OPERATOR’S MANUAL BEFORE PERFORMING ANY LUBRICATION OR MAINTENANCE.

2. Operation, inspection, and maintenance should be carefully carried out, and safety must be given the first priority. Messages of safety are indicated with marks.

The safety information contained in this manual is intended only to supplement safety codes, insurance requirements, local laws, rules and regulations.

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

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

WARNING

Because of the size of some of the machine components, the serviceman or mechanic should check the weights noted in this manual. Use proper lifting procedures when removing any components. Weight of components table is shown in Page 6-3 of SECTION VI – SPECIFICATIONS.

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

WARNING 1-1

Section I – SAFETY PRECAUTIONS THE FOLLOWING IS A LIST OF BASIC PRECAUTIONS THAT MUST ALWAYS BE OBSERVED.

8. Use steps and grab handles when mounting or dismounting a machine. Clean any mud, grease, oil or debris from steps, walkways or work platforms before using.

Always face the machine when using steps, ladders and walkways. When it is not possible to use the designed access system, provide ladders, scaffolds, or work platforms to perform safe repair operations.

1. Read and understand all warning plates and decals on the machine before operating, maintaining or repairing this machine.

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

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

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

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

3. Disconnect the battery and hang a “Do Not Operate” tag in the Operator’s compartment. Remove ignition keys.

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

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

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

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

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

WARNING DO NOT OPERATE THIS MACHINE UNLESS YOU HAVE READ AND UNDERSTAND THE INSTRUCTIONS IN THE OPERATOR’S MANUAL. IMPROPER MACHINE OPERATION IS DANGEROUS AND COULD RESULT IN INJURY OR DEATH.

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

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

6. Relieve all pressure in air, oil or water systems before any lines, fittings or related items are disconnected or removed. Always make sure all raised components are blocked correctly and be alert for possible pressure when disconnecting any device from a system that utilizes pressure.

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

16. Do not damage wiring during removal operations.

1-2

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

23. Caution should be used to avoid breathing dust that may be generated when handling components containing asbestos fibers. If this dust is inhaled, it can be hazardous to your health.

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

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

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

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

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

21. Do not operate a machine if any rotating part is damaged or contacts any other part during operation.

Any high speed rotating component that has been damaged or altered should be checked for balance before reusing.

22. Be careful when servicing or separating the tracks.

Chips can fly when removing or installing a track pin.

Wear safety glasses and long sleeve protective clothing. Tracks can unroll very quickly when separated.

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

1-3

Section I – SAFETY PRECAUTIONS 1.3 PRE-START SAFETY

GER DAN

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

F AR O CLE EA P E R KE ING A SW OP M A E R AT MA INTE ION NU NA NC AL E

CAUT

ION Bucke t can co d am ag nt e ca act and b m ac w h en hi CAUTIO ne equi N pped FOR some with attach INTER FERE ments .

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

WARNING

explode and cause personal injury.

2432 380 ¥ Keep sparks, openP3flames and cigarettes 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

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

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

WEAR PROTECTIVE CLOTHING STORAGE AREA

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

READ MANUAL / KEEP IN MACHINE CAB

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

E. HOW TO HANDLE LIFE HAMMER 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 the seat belt, etc.

HOW TO HANDLE LIFE HAMMER

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

PREPARE FOR EMERGENCIES

1-4

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

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

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

WORKSITE SAFETY – KNOW THE AREA

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

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

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

PRE-START INSPECTION OF MACHINE LOCKED (UP) POSITION

UNLOCKED (DOWN) POSITION

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

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

SAFETY LOCK LEVER

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

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

KEEP FIRE AWAY FROM FUEL & OIL

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

USE CAUTION NEAR NOISE

1-5

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

KEEP STEP CLEAN AND IN GOOD CONDITION

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

USE GRIP BARS AND STEP

MOUNTING/DISMOUNTING MACHINE

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

HOT SURFACES

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

USE PROPER ATTACHMENT

PREVENT FIRES– CLEAN UP SPILLS

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

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

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

SOUND HORN BEFORE STARTING

1-6

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

C. TRAVEL Make certain of the location of the travel motors before operating travel controls. Sound horn before moving the machine to inform persons that the machine is travelling. Position the attachment as shown in illustration before beginning travel.

Move the machine at slow speeds. Do not turn suddenly on rough terrain. Avoid travelling over obstacles. Should it become necessary to travel over an obstacle, keep the attachment low to the ground and travel at extremely slow speed.

NO PASSENGERS

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

TRAVEL MOTORS AT REAR OF MACHINE

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

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

KNOW TRAVEL MOTOR POSITION

ZL11M04116

SWING SAFETY/USE SWING FLASHERS

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

BUILD BANKING FOR SLOPE OPERATION

1-7

Section I – SAFETY PRECAUTIONS G. WORKING AROUND UTILITIES If it is suspected that utility lines such as gas, water, phone or electrical power are in the work area, contact the local utility authority for line location BEFORE beginning work in the area. Use extreme caution around electrical power lines.

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

Operation Voltage Safety distance up to 1000 V 1.0 m from 1 kV to 110 kV 3.0 m from 110 kV to 220 kV 4.0 m from 220 kV to 380 kV 5.0 m unknown 5.0 m KEEP A SAFE DISTANCE FROM UTILITIES

H. LIFTING This machine is an excavator. Use extreme caution when lifting or moving heavy loads. Use proper lifting equipment rated at a capacity to handle the load.

NEVER USE BUCKET TEETH TO LIFT OR MOVE HEAVY LOADS. I . FROZEN OR SNOW COVERED WORK SITES Use extreme caution when operating the machine on frozen or snow covered work sites. Operate all controls slowly and cautiously to prevent sudden movements that may cause the machine to unexpectedly shift, slide or move. Even on the slightest slope, when snow is present or work area is frozen can allow a machine to unexpectedly move.

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

USE PROPER LIFTING DEVICES

USE EXTREME CAUTION ON FROZEN OR SNOW J. FILLED OR UNSTABLE GROUND Be certain the condition of the work site is stable and capable of supporting the machine during operation. Do not operate attachment too close to the machine. Operation of the machine on shoulders or filled areas could cause the machine to become unstable presenting a work hazard.

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

WORK ON STABLE GROUND

1-8

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

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

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

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

BE AWARE OF OBSTACLES

120°

CHOCK TRACKS

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

PARKING SAFETY

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

STABILIZE ATTACHMENTS WHEN REMOVED

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

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

USE PROPER TOOLS

1-9

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

E. SET THE ATTACHMENT Always set the machine in the hydraulic oil check position on firm level ground before attempting any inspection or maintenance procedures to the machine. If it is not possible to put the machine in this position, secure the boom, arm and attachment to help prevent sudden movement.

ALWAYS PLACE ATTACHMENTS ON THE GROUND AND RAISE THE SAFETY LOCK LEVER BEFORE LEAVING THE CAB. F. CLEAN THE MACHINE Keep the machine clean and free of debris, excess or spilled lubricants, fuel and fluids. Use approved solvents, detergents and water to clean the machine and its components on a regular basis.

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

G. PRESSURIZED FLUIDS & LUBRICANTS Always release pressure from hydraulic reservoir, engine coolant, fuel system and all systems containing pressure before removing any caps or components.

BE CAUTIOUS OF HOT FLUIDS AND GASSES FROM SYSTEMS ON MACHINES THAT HAVE JUST BEEN STOPPED. ALLOW SUFFICIENT TIME FOR SYSTEMS TO COOL BEFORE PERFORMING ANY INSPECTION OR MAINTENANCE PROCEDURES. H. SUPPORT THE MACHINE If it becomes necessary to raise the machine for inspection or maintenance, always support the machine by positioning the machine as shown in the illustration and use safety supports or blocks, with a sufficient capacity rating to support the machine, under the tracks.

NEVER INSPECT OR PERFORM MAINTENANCE PROCEDURES UNDER A RAISED MACHINE THAT IS NOT SUFFICIENTLY SUPPORTED.

1-10

LOCKED (UP) POSITION

STOP ENGINE/ENGAGE SAFETY LOCK LEVER

HYDRAULIC OIL CHECK POSITION

KEEP MACHINE CLEAN DEPRESS RUBBER CAP TO RELEASE PRESSURE

RELEASE HYDRAULIC TANK PRESSURE

90 ° ~110 ° SUPPORT

SUPPORT THE MACHINE

Section I – SAFETY PRECAUTIONS I. REFUELING Move the machine to a well ventilated area for refueling. Use only specified fuel as described in the MAINTENANCE section of this operator’s manual.

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

J. HYDRAULIC PRESSURE Under normal conditions, all circuits of the hydraulic system are under extreme pressure. When inspecting for leaks, use a small piece of cardboard, wood or metal to locate leaks.

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

K. TRACK SHOE TENSION The grease used to adjust the track shoe tension is under extreme pressure in the cylinder. Use extreme caution when adjusting track shoe tension.

KEEP FACE, HANDS AND LEGS AWAY FROM THE GREASE NIPPLE AREA. Carefully and slowly loosen the grease nipple when lessening track shoe tension. Never loosen grease nipple more than one complete turn.

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

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

REFUELING

CHECKING FOR HIGH PRESSURE LEAKS

USE CAUTION WHEN ADJUSTING TRACKS

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

ELECTRICAL SYSTEM PRECAUTION

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

USE PROPER LIGHTING

1-11

Section I – SAFETY PRECAUTIONS 1.6 BATTERY SAFETY A. WEAR PROPER PROTECTIVE CLOTHES Wear long sleeve shirt, gloves and approved safety glasses or face shield when working with or around batteries. Battery electrolyte (acid) will cause severe burns if allowed to make contact with clothing, skin or eyes.

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

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

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

C. CHARGING BATTERY Charge battery off of and away from machine in a well ventilated area. When charging battery, remove cell covers to allow gasses to escape.

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

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

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

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

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

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

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

WEAR PROTECTIVE CLOTHES

KEEP AWAY FROM FIRE OR FLAMES NEGATIVE (-) CABLE

POSITIVE (+) CABLE

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

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

1-12

Section I – SAFETY PRECAUTIONS 1.7 WARNING LABELS & DECALS Warning labels and decals are affixed to the machine to remind operators and personnel specific safety precautions in certain areas of the machine. The following are illustrated examples of all warning labels and decals along with their locations.

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

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

Background: yellow Stripe and lettering: black

3. ACCUMULATOR CONTAINS PRESSURIZED GASCAUTION Located on top of engine radiator.

4. TAG ENGINE RUNNER Located on engine bonnet.

F14394

2. HYDRAULIC OIL BLEEDING PLATE Located on each hydraulic tank. It indicates that air should be bled from the pumps after every hydraulic oil change.

Danger of pump seizure.

Background: yellow Stripe and graphics: black

F14395

1-13

F15995

Section I – SAFETY PRECAUTIONS 5. BATTERY TAG DANGER WARNING Located on battery box access cover.

Flammable gas (hydrogen gas) is generated in the battery.

Do not produce sparks near the battery, and do not put bare flame close to it to avoid the battery from catching fire and explosion.

Background: yellow Stripe and graphics: black

F14400

6. BOOSTER CABLES TAG Located on battery box access cover. It warns about the danger of starting the motor with booster cables.

Background: yellow Stripe and graphics: black

F14398

7. PRESSURIZED FLUIDS & LUBRICANTS Located on top of engine radiator.

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

Background: yellow Stripe and graphics: black

F14397

1-14

Section I – SAFETY PRECAUTIONS 8. TAG DO NOT CLIMB Located on fuel tank.

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

F16323

9. ENGINE STOP TAG Located on engine radiator.

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

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

Background: transparent Stripe and graphics: black

F14407

10. HOT SURFACES TAG Located on engine bonnet.

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

Background: yellow Stripe and graphics: black

F14396

1-15

Section I – SAFETY PRECAUTIONS 11. STOP ENGINE - WARNING Located on top of engine radiator

F14406

12. DO NOT CLIMB UPON ENGINE COVER Located on engine bonnet.

13. HEAVY LIFT SWITCH Located inside cab R.H.

14. SWING PARKING BRAKE RELEASE SWITCH Located on rear cover.

1-16

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

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

Background: yellow Stripe and lettering: black

F14403

16. POWER BOOST SWITCH Located inside cab R.H.

F25733

17. NIBBLER & BREAKER OPERATION Located on left hand operator console. (OPT.)

18. DO NOT PINCH YOUR HAND(S) Located on operator seat support.

1-17

Section I – SAFETY PRECAUTIONS 19. SAFETY LOCK LEVER Located on control stand.

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

F16001

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

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

Background: yellow Stripe and lettering: black

F14393

21. DO NOT PINCH YOUR HAND(S) Located on operator seat support.

1-18

Section I – SAFETY PRECAUTIONS 22. TAG , REFERENCE TO MANUALS Located inside cab R.H. Caution: Do not allow anyone to operate the loader without proper instruction.

F16499

23. TAG FOR WINDOW LOCK Located inside cab front window.

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

Background: yellow Edge and graphics: black F14408

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

Danger of severe injuries.

Background: yellow Stripe and graphics: black

F14399

25. TAG , WARNING TO KEEP A SAFETY DISTANCE FROM ELECTRICAL LINES Located inside cab R.H. Always keep a safety distance from electrical lines. Also in case of work near overhead electrical lines, keep this safety distance.

Background: white and red Edge and lettering: black

F15999

1-19

Section I – SAFETY PRECAUTIONS 26. ENGINE OIL PAN DRAIN PLUG-CAUTION Located on frame.

27. ENGINE AUTO IDLING STOP Located inside cab R.H.

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

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

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

F24424

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

F24435

1-20

Section I – SAFETY PRECAUTIONS 1.8 PROHIBITED MACHINE OPERATION The following examples of machine abuse and misuse should never be attempted by even the most experienced operator. Such abuse and misuse of this machine and its attachments can result in serious bodily injury, death, severe equipment damage and shortened service life of the machine. Under no circumstance should any of these operations be attempted. Use common sense and follow proper operation procedures found in this operator’s manual while operating this equipment.

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

DO NOT USE TRACTIVE FORCE

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

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

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

USE ONLY FOR INTENDED PURPOSE

1-21

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

F. DO NOT OVER EXERT THE MACHINE’S CAPACITIES. Know the limitations of the machine and its attachments and operate the machine within those specifications. Do not exceed lift charts. Never tip or raise the machine to obtain power to move material. This could cause extensive damage to the machine and its components as well as result in serious bodily injury or death.

ALLOWANCES

DO NOT OPERATE CYLINDER TO STROKE END

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

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

B. Lower attachment to the ground.

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

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

E. Thoroughly clean and inspect the machine.

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

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

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

1-22

DO NOT OVER EXERT THE MACHINE

END OF WORK SHIFT SAFETY

Section I – SAFETY PRECAUTIONS 1.10

USE FOPS AND FRONT GUARD

For some jobs (e.g. demolition), a safety structure (e.g. FOPS, Front guard) is needed. When your machine does not have this safety structure, you are not allowed to use your machine for this kind of application.

Please check your local dealer in case of doubt.

FOPS : Falling Object Protective Structure

FOPS

FRONT GUARD

USE FOPS AND FRONT GUARD

1.11

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

Please check your local dealer in case of doubt.

1-23

Section I – SAFETY PRECAUTIONS NOTES

1-24

Section II – MACHINE FAMILIARIZATION Table of Contents 2.1 FOREWORD ........................................................................................................................................................ 2-1 2.2 IDENTIFICATION DATA ....................................................................................................................................... 2-2 2.3 NOISE LEVELS (2000/14/EC) .............................................................................................................................. 2-3 2.4 BASIC COMPONENTS OF THE EXCAVATOR .................................................................................................... 2-4 2.5 OPERATOR CAB NOMENCLATURE ................................................................................................................... 2-5 2.6 COMPONENT & CONTROLS NOMENCLATURE ................................................................................................. 2-6

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

2—0

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

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

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

Each machine is supplied complete with a copy of this Manual. Descriptions and illustrations herein are not binding.

The Manufacturer, provided that the basic characteristics of machine types described and shown in this Manual remain the same, reserves the right to change components, parts and accessories supplied without any commitment to timely update this publication; and this any time it deems it convenient for improvement purposes or due to commercial or manufacturing requirements. For exact information, please consult your Dealer or contact the Manufacturer’s Branch Offices.

DANGER For clarity purposes, some figures in this Manual show the machine with protection panels or covers removed. Never operate the machine with any protection panels or covers removed.

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

2—1

Section II – MACHINE FAMILIARIZATION 2.2 IDENTIFICATION DATA

NOTICE: the numbers in the illustrations are for explanation only and differ from actuals numbers.

• ENGINE No.

EXCAVATOR MARKING DECAL 1. Machine technical type.

2. Identification number.

3. Machine total mass.

4. Machine manufacturing year.

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

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

2—2

Section II – MACHINE FAMILIARIZATION 2.3 NOISE LEVELS (2000/14/EC) Sound power level Lwa = 107 dB (A) Sound power level guaranteed, determined in compliance with European standard 2000/14/EC.

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

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

• The weighted average quadratic acceleration value to which the operator’s arms are subjected does not exceed 2,5 m/s2.

• The weighted average quadratic acceleration value to which the operator’s body is subjected does not exceed 0,5 m/s2.

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

2—3

Section II – MACHINE FAMILIARIZATION 2.4 BASIC COMPONENTS OF THE EXCAVATOR

32

1 2

17 31 13 3 4

30

25 7

27

29

5

26 9 28

8 11

24 23 22

12 21 18

14 19

10 6

15 16

20

FIGURE 2.1 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

Arm cylinder Boom Batteries Handrail Hydraulic oil tank Engine air cleaner Main control valve Pump access door Mitsubishi 6D16-TLU2D engine Oil cooler Hydraulic pump Counterweight

13.

14.

15.

16.

17.

18.

19.

20.

21.

Swing motor Engine radiator Engine coolant reservoir Travel motor Swivel joint Upper roller (2 each side) Track guide Radiator access door Lower roller (7 each side) (9 each side)-LC, NLC 22. Track spring (1 each side) 23. Track idler (1 each side)

2—4

24. Tracks shoe assembly (600 mm standard) 25. Fuel tank 26. Operator cab 27. Boom cylinder 28. Bucket 29. Bucket link 30. Idler link 31. Bucket cylinder 32. Arm

Section II – MACHINE FAMILIARIZATION 2.5 OPERATOR CAB NOMENCLATURE Study these areas and locate these components on the machine. Specific information regarding these components are explained on the following pages of section VI.

The operator cab nomenclature (Figure 2.2), points out locations of operator controls of the hydraulic excavator operator cab.

1

2

3

4

24

5

6

23

7

22

8 9

10

21

11

12 13

20

14

19

15

18

17

16

FIGURE 2.2 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

Left travel lever Right travel lever Left travel pedal Right travel pedal Right foot rest Gauge cluster Right hand operator control lever (power boost switch) 24 V cigarette lighter Ash-tray Engine emergency stop control Throttle potentiometer Swing flasher switch 12V power supply

2—5

Key switch Tuner (FM & AM) Head rest (adjustable) Swing parking brake release switch Operator seat (3 way adjustable) Arm rest Air-conditioner panel Left side switch panel Safety lock lever (for hydraulics) Left hand operator control lever (horn switch) Left foot rest

Section II – MACHINE FAMILIARIZATION 2.6 COMPONENT & CONTROLS NOMENCLATURE

KEY SWITCH POSITIONS

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

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

A. RIGHT HAND OPERATOR CONSOLE 1. Key Switch – FIGURE 2.3 The key switch is located on the right hand operator console and has 5 operating functions.

“HEAT” .... This position is used for starting the engine in cold climates. See section III. “OFF” ...... When key is turned to this position, the engine stops and electrical power to the machine’s electrical systems is stopped after approximately 4 seconds.

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

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

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

2. KPSS Mode Switch (1) – FIGURE 2.4 The KPSS mode switch is located on the gauge cluster switch panel and has 3 operating functions.

After starting the engine, the mode switch is turned to mode default.

Select an effective work mode complying with the working condition and working target from 3 modes.

Each time the work mode switch is pressed, the work mode indicator lamp is switched to , and in order.

FIGURE 2.3

(1)

FIGURE 2.4

a. A (assist) mode The mode is set meeting to the operator’s work condition.

The controller makes a distinction between works, digging, leveling, spreading, slope finishing, tamping etc. automatically, and displays the distinction results on the multi display per second.

And the power corresponding to the load is output, the engine speed is controlled to a constant speed, and consequently the noise is lowered.

Digging mode

Spreading mode

2—6

Leveling mode

Tamping mode

Standby mode

Section II – MACHINE FAMILIARIZATION b. M (manual) mode This mode catches the movement of control lever sensitively and is suitable for the heavy load digging work giving priority to the work load at high speed. c. B (breaker) mode When the attachments in option like breaker, etc. are used, the operator can adjust the max. flow rate.

FLOW RATE

(2)

Displayed flow rate (b)

L min

(3)

(1)

a. Flow rate display • After turning the key switch “ON” (the engine does not start) set it to B (Breaker) mode (a) by pressing mode select switch (1).

• Keep pressed the screen change switch (2) on the gauge cluster, after 3 to 10 seconds the mode is switched to the adjust mode.

FIGURE 2.5

The flow rate stored last time is displayed, but in case of the initial display, Maximum flow rate is displayed as standard value.

• Press the mode switch (1), and the displayed flow rate (b) is increased, and press the buzzer stop switch (3), and the displayed flow rate (b) is reduced.

• In operating switches (1), (3) the addition or reduction starts 2 seconds later and displays in graduation of 10 L/min, release the switches when the required flow rate is obtained.

The flow rate can be adjusted in the maximum up to minimum range.

(a)

• Pressing the screen change switch (2) again, the adjusted flow rate value is stored, and the adjust mode is dismissed.

3. Buzzer Stop Switch (3) – FIGURE 2.6 When the engine coolant temperature is too high, or various sensors of mechatro controller (self-diagnosis) fail, the alarm sounds intermittently. To stop sounding, press the buzzer stop button.

Displayed flow rate (b)

FLOW RATE

NOTE The buzzer sounding because of the preheat complete operation and because of engine oil low pressure warning, can be stopped only by turning the key switch OFF.

L min

(2)

(3)

(1) FIGURE 2.6

2—7

Section II – MACHINE FAMILIARIZATION 4. Screen Change Switch (4) – FIGURE 2.7 Each time the screen change switch on the gauge cluster is pressed, the engine rpm and the accumulated time since last replacement of engine oil, fuel filter, hydraulic oil filter, hydraulic oil are displayed in order.

After the engine starts, is displayed.

Press the gauge cluster screen change switch once (Engine rpm) p p p p in order.

(4)

1515 RPM

5. Wiper & Washer Switch (5), (6) – FIGURE 2.8 Press this switch, and the front window wiper starts moving.

FIGURE 2.7

a. Press it once .......... Wiper moves intermittently b. Press it again ......... Wiper moves continuously c. Press it once more . Wiper stops moving Press this switch, and washer fluid is sprayed on the front window while it is pushed. Wiper acts in the same time automatically.

The washer fluid reservoir is located behind the cab, in the air cleaner compartment.

(7)

(6)

(5)

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

FIGURE 2.8 6. Working Lights Select Switch (7) – FIGURE 2-8 Press switch, and frame, boom and rear working lights light up, and when the switch is “ON” the back-up lamp also lights up. a. Press switch once, and the frame and boom working lights light up. b. Press it one more time, and rear working light also light up. c. Press it again, the frame, boom and rear working lights go out.

2—8

Section II – MACHINE FAMILIARIZATION 7. Auto Accel Switch (8) – FIGURE 2.9 When this switch is activated (ON) the auto-accel system activates.

The auto-accel reduces the engine speed to the idle level reducing fuel consumption and noise under the following conditions: 1. The accel dial position is set over the idle level.

2. The control lever and/or pedal are not operated for 4 seconds or more.

When the control lever and/or pedal are operated, the engine speed rises back to the accel dial set level gradually, according to the respective operating pilot valve stroke.

Anytime this switch is deactivated (OFF) the engine speed rises to the accel dial set level, independently by other operations.

(8)

WARNING

FIGURE 2.9

WHEN LOADING OR UNLOADING MACHINE ON TRAILER, TURN THE AUTO ACCEL SWITCH OFF. IF IT IS OPERATED KEEPING THE ACCEL SWITCH ON, THE ENGINE SPEED CHANGES SUDDENLY.

8. Travel speed select switch (9) – FIGURE 2.10 The travel speed select switch is located on the gauge cluster switch panel. Each time engine is started, travel speed is automatically set to LOW 1st ( ) speed. Press the travel speed ( ) switch on the gauge cluster, and the speed is changed to the HIGH 2nd and the ( ) is indicated on the multidisplay.

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

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

HIGH (2nd) speed

(9)

WARNING FIGURE 2.10

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

2—9

Section II – MACHINE FAMILIARIZATION 9. Throttle Potentiometer – FIGURE 2.11 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.

THROTTLE POTENTIOMETER (CONTROL)

NOTE Auto accel operation and control. In operation, if the remote control pressure for the control lever and control pedal does not act for 4 seconds, the auto accel function is automatically activated when the accel dial position is at idle lever or over, and the engine speed drops to idle level.

Auto accel release condition When the attachment, swing, travel control lever or control pedal are operated, the engine speed returns to the accel dial set position gradually according to the respective operating pilot valve stroke.

10. Tuner (FM & AM) SUPPLEMENTARY EXPLANATION This operator’s manual doesn’t describe the operating method of tuner, because the tuner procured in EU area is applied on this machine.

2 — 10

FIGURE 2.11

Section II – MACHINE FAMILIARIZATION 11. 24 Volt Cigarette Lighter – FIGURE 2.12 The cigarette lighter is located on the right wall of cab. To use the cigarette lighter the key switch must be in the ON position. Push the lighter in and wait approximately 30 seconds for it to “POP” out. Pull lighter from the socket to use. Replace lighter back into its socket after use.

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

FIGURE 2.12 12. Swing Flasher Switch – FIGURE 2.13 The swing flasher switch is located on the right hand operator console. The swing flasher is a 2 position rocker switch which is used to turn on the swing flashers.

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

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

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

FIGURE 2.13 B. LEFT HAND OPERATOR CONSOLE 1. Air Conditioner – FIGURE 2.14 and 2.15 The climate control-AC provides a comfortable indoor environment and adjustable control of cab temperature. It removes moisture from humid air and reducing window glass frosting.

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

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

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

(C)

(A) (A)

(B) (D)

FIGURE 2.14

2 — 11

Section II – MACHINE FAMILIARIZATION I . Control Panel Description AIR OUTLET MODE SELECTOR SWITCH

DEFROSTER SWITCH

FRESH AND RECIRCULATE AIR SELECTOR SWITCH LCD DISPLAY

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

COMPRESSOR SWITCH

FAN SPEED SELECTOR SWITCH

AUTO CONTROL SWITCH

MAIN POWER SWITCH

FIGURE 2.15 Supplementary Explanation The LCD display indicates temperature, air outlet mode, compressor “ON” - “OFF”, “ AUTO”, recirculate and fresh air and fan speed.

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

II. Fundamental use – FIGURE 2.16 Before turning air-conditioner on, close doors of cab and windows to achieve the best performance.

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

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

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

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

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

2 — 12

FRESH AND RECIRCULATE AIR SELECTOR SWITCH

COMPRESSOR SWITCH

AUTO CONTROL SWITCH

FAN SPEED SELECTOR SWITCH

FIGURE 2.16

Section II – MACHINE FAMILIARIZATION III. Control Panel Functions 1. Main power switch and display – FIGURE 2.17 a. LCD display is illuminated when the climate control-AC is operating.

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

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

LCD DISPLAY

MAIN POWER SWITCH

FIGURE 2.17

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

2. Auto Control Switch and Display - FIGURE 2.18 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 switch is pressed again, the climate control AC will come on in the auto control mode. In the auto mode, the fan speed and air outlet openings are operated automatically.

LCD DISPLAY

AUTO CONTROL SWITCH

MAIN POWER SWITCH

FIGURE 2.18

3. Temperature Setting Switch and Display - FIGURE 2.19 a. The set temperature is indicated in digits on LCD display. Temperature set range is 18.5 °C (65.3 °F) to 31.5 °C (88.7 °F). b. Press the two temperature set switches simultaneously for 5 seconds to change the display from Centigrade (°C) to Fahrenheit (°F) or viceversa in the LCD display.

(Eg.) 25 °C p 77 °F or 77 °F p 25 °C c. Press temperature set switch DOWN or UP to change the set temperature.

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

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

2 — 13

LCD DISPLAY

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

FIGURE 2.19

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

Control beyond either of these limits is not possible.

4. Air outlet mode selector switch and display – FIGURE 2.20 a. Air outlet position is indicated by the arrow on LCD display. b. Press air outlet mode switch in the condition where auto display light is on, and the display mode is fixed, “AUTO” indicator lamp on LCD display goes out, and “AUTO” control of air outlet opening is released.

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

AIR OUTLET MODE SELECTOR SWITCH

LCD DISPLAY

FIGURE 2.20

LCD DISPLAY

Air outlet opening Air outlet direction

Vent Upper half of body

Bi-level Foot Upper half body, foot Foot, front glass

5. Defroster switch and display – FIGURE 2.21 a. Press defroster switch, defroster indicator lamp will be displayed. b. Press air outlet mode selector switch, and it returns to air outlet mode just before pressing defroster switch. c. Press defroster switch in the condition where AUTO display is lighting up, “AUTO” indicator lamp on LCD display goes out and the auto control of air outlet opening is released.

6. Recirculate and fresh air selector switch and display – FIGURE 2.21 a. Suction (fresh air intake) mode is indicated on LCD display b. Each time recirculate and fresh air capacity selector switch is pressed, the mode is switched to air recirculate or fresh air intake.

2 — 14

Face Upper half of body (Front),

FRESH AND RECIRCULATE AIR SELECTOR SWITCH LCD DISPLAY

DEFROSTER SWITCH

AIR OUTLET MODE SELECTOR SWITCH

FIGURE 2.21

Section II – MACHINE FAMILIARIZATION 7. Compressor switch and display – FIGURE 2.22 Press compressor switch in the condition where mark on LCD display is unlit, compressor starts operating and indicator lamp of mark on LCD display goes on.

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

8. Fan speed selector switch and display – FIG-

LCD DISPLAY

FAN SPEED DISPLAY

COMPRESSOR SWITCH

FAN SPEED SELECTOR SWITCH

URE 2.23 When it is set to MANUAL mode, fan speed on LCD display is as follows.

LCD DISPLAY FAN SPEED

DISPLAY

FAN SPEED

LCD 1 LAMP IS LIT UP.

LOW

LCD 2 LAMPS ARE LIT UP.

MEDIUM

LCD 3 LAMPS ARE LIT UP.

HIGH

LCD 4 LAMPS ARE LIT UP.

MAX

LOW

MEDIUM

HIGH

MAX.

FIGURE 2.23

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

2. Horn switch – FIGURE 2.23A The horn switch is a momentary push grey button located on the operator’s left control lever, see Figure 2.23 A for better reference.

NOTE Always sound horn before starting engine to alert personnel that the machine is going to be operated.

HORN SWITCH (GREY)

FIGURE 2.23A

2 — 15

Section II – MACHINE FAMILIARIZATION 3. Auto warm up selector switch – FIGURE 2.24 Place the ignition switch to the “on position” (Do not start the engine yet). Turn on the warm up switch located on the left panel and then start the engine. a. Warming up of engine The “WARMING UP” is displayed on the multi display after operating the engine for 3 minutes at auto accel speed (1,050 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.) b. Warming of hydraulic oil After performing the operation of pump max. flow rate at the engine speed (1,050 rpm) for 3 minutes p pump max. flow rate at the engine speed (1,600 rpm) for 5 minutes p pump max. flow rate and control valve full open at the engine speed (1,600 rpm) for 5 minutes p max. flow rate at the engine auto accel speed (1,050 rpm) for 10 minutes, “WARMING UP” is displayed on the multidisplay. c. Warming up complete After an elapse 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 multidisplay disappears, and concurrently buzzer sounds for 5 seconds. Turn the auto warm up switch “OFF”.

NOTE While warming up the engine, operate the pilot lever and the warming up is forcibly disconnected. Turn the auto warm up switch “OFF”, and the warming up is forcibly stopped. While warming the hydraulic oil, operate the lever and the warming is stopped temporarily, and after an elapse of 10 seconds of the neutral condition the warming operation restarts.

2 — 16

PRESS HERE FOR “OFF”

FIGURE 2.24

Section II – MACHINE FAMILIARIZATION 4. Auto idling stop select switch – FIGURE 2.24A Please symbol mark corresponding to this switch to turn “ON”, and the engine in operation stops automatically after a constant elapse of time with safety lock lever (1) remaining locked. Consequently the fuel consumption is reduced.

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

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

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

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

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

FIGURE 2.24A

(1)

WARNING WHEN YOU DO THE WORK WHICH HAS FEAR, SUCH AS FALL OF A LOAD, WHEN ENGINE STOPS, PLEASE BE SURE TO TURN OFF AN AUTO IDLING STOP SWITCH. FIGURE 2.24B

CAUTION CAUTION

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

The engine starter motor may be damaged.

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

CAUTION CAUTION

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

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

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

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

• When the warning of “HIGH E/G COOL TEMP” is given on LCD or by means of lamp, • When auto warm-up is being operated.

2 — 17

Section II – MACHINE FAMILIARIZATION 5. Over load alarm select switch – FIGURE 2.25 The over load alarm select switch is located on the right hand control console. The over load alarm switch is a 2 position rocker switch and used for lifting operations.

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

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

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

FIGURE 2.25 6. Cab working lights select switch – FIGURE 2.26 The cab working lights select switch is located on the left hand control console. The cab working light switch is a 2 position rocker switch and is used to turn working light “ON” and “OFF”.

“ON” ........ Push the symbol side of switch down to turn working light “ON”.

“OFF” ...... Push the empty side of switch down to turn working light “OFF”.

PRESS HERE FOR "ON"

PRESS HERE FOR "ON"

PRESS HERE FOR "OFF"

PRESS HERE FOR "OFF"

FIGURE 2.26 7. Rotary light switch – FIGURE 2.27 This switch is located to the rear on the left hand control console. Its basic function is to turn the rotary light “ON” and “OFF”.

Depress this side to turn rotary light “ON”.

Depress empty side of switch to turn rotary light “OFF”.

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

FIGURE 2.27

2 — 18

Section II – MACHINE FAMILIARIZATION 8. Heavy lift switch – FIGURE 2.28 The heavy lift switch is located on the left hand control console. The heavy lift switch is a 2 operating functions. The heavy lift function is used when precision control of heavy lifting operations is required.

“ON” ........ Push the symbol side of switch down to turn heavy lift function on.

“OFF” ...... Push back of switch down to turn heavy lift function off.

DEPRESS THIS SIDE TO TURN "ON" DEPRESS THIS SIDE TO TURN "OFF"

WARNING NEVER TURN OFF HEAVY LIFT SWITCH DURING ANY OPERATION. SUDDEN OR UNEXPECTED MOVEMENT COULD RESULT IN SERIOUS INJURY OR DEATH.

FIGURE 2.28

8. Diagnosis lamp (electronic governor controller judgement) red and orange – FIGURE 2.29 Red and orange lamps are installed on the switch panel of the left control stand to make possible to check that the electronic governor controller is normally operated.

The normal / abnormal condition can be knowledged by checking the lamp lighting condition. Therefore check that the controller is normal before stating the engine.

Normal condition

RED

ORANGE

Starter switch Starter switch "ON" "START" Lamp (Red)

ON

OFF

Lamp (Orange)

ON

OFF

Normal

Normal

Condition

Abnormal condition For abnormal condition, there are two cases, first the engine does not start, and second, the engine starts but the controller does not operate normally.

Then, contact our service shop for inspection immediately Starter switch Starter switch Starter switch "ON" "START" "ON" Lamp (Red) Lamp (Orange) Condition

ON

OFF

OFF

OFF

ON

ON

Don't start E/G

Start E/G

Start E/G

2 — 19

FIGURE 2.29

Section II – MACHINE FAMILIARIZATION C . REAR PANEL AND OTHERS 1. Swing Parking Brake Release Switch – FIGURE 2.30 After removing 4 cover set screws on the rear side of operator seat, release the locks (5 places) of cover section, and remove the upper and lower covers.

Swing parking brake is usually locked. The swing parking brake is released in swing and arm-in operation. When it cannot be unlocked due to trouble, turn toggle switch to “Release lock” (unlock), and the parking brake is released. Then, move machine to safe area immediately and contact our representative or service shop.

And return to toggle switch to “NORMAL” position in normal condition.

REAR PANEL

SET SCREW

FIGURE 2.30

2. Power Boost Switch – FIGURE 2.31 Located on the right hand control lever, this switch should only be used for increased break out force during digging.

POWER BOOST SWITCH (GREY)

NOTE Use of it is prohibited where an arm longer than the standard is installed.

FIGURE 2.31

3. Holder – FIGURE 2.32 This cup holder is located the right front of operator. Place a canned or a bottled drink.

Press lock button ...... cover open

LOCK BUTTON

COVER

FIGURE 2.32

2 — 20

Section II – MACHINE FAMILIARIZATION 4. Fuse Box – FIGURE 2.33 The fuse box is located behind the operator’s seat.

It contains all necessary fuses for the electrical circuits of the machine. Should it become necessary to inspect or change a fuse, remove the fuse box cover by gently pulling each end away from the box.

Should a fuse require replacement, use a replacement fuse of the same type and amperage.

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

Refer to the maintenance section of this manual for a detailed diagram and description of fuse box.

COVER

FUSE BOX

FIGURE 2.33 5. Hour Meter – FIGURE 2.34 This indicates the total time the engine has run. Even if the excavator is not moving, the meter continues to count as long as the engine is running.

HOUR METER

FIGURE 2.34

6. 12 Volt Power Supply – FIGURE 2.35 The 12 Volt power supply is located beside the right side switch panel.

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

CAUTION Do not use 12 Volt power supply as a cigarette lighter.

MAXIMUM CONTINUOUS OUTPUT – 2.5 Amps FIGURE 2.35

2 — 21

Section II – MACHINE FAMILIARIZATION D . OPERATING LEVERS AND CONTROLS 1. Engine Emergency Stop Control – FIGURE 2.36 The engine emergency stop control located at the lower right hand side of operator 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.

ENGINE EMERGENCY STOP CONTROL

FIGURE 2.36

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

2. Safety Lock Lever – FIGURE 2.37 The safety lock lever is located on the front outside of the left hand operator console and is red in color.

The safety lock lever is used to lock out the hydraulic controls disallowing the use of any hydraulic function. The safety lock lever has 2 operating positions.

“UP” ........ When placed in the up position the safety lock lever stops all hydraulic controls from functioning and allows the operator to enter and exit the operator seat.

“DOWN” .. When placed in the down position, the safety lock lever allows all operating functions of the hydraulic controls to resume and also locks the left hand operating console in operating position.

WARNING

SAFETY LOCK LEVER IN LOCKED (UP) POSITION

SAFETY LOCK LEVER IN UNLOCKED (DOWN) POSITION

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

FIGURE 2.37

2 — 22

Section II – MACHINE FAMILIARIZATION 3. Left Hand Operator Control Lever – FIGURE 2.38 L.H. CONTROL LEVER (ISO PATTERN)

ARM OUT

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

SWING LEFT SWING RIGHT

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

ARM IN

FIGURE 2.38 “FORWARD” ........ Variable speed arm out.

“BACKWARD” ..... Variable speed arm in.

“LEFT” .................. Variable speed left swing.

“RIGHT” ............... Variable speed right swing.

“CENTER” ............ Neutral position.

2 — 23

Section II – MACHINE FAMILIARIZATION 5. Right Hand Operator Control Lever – FIGURE 2.39 The right hand operator control lever is located at the top front of the R.H. operator console. Its purpose is to allow the operator to control operations of the boom and bucket. Operating speed of function is variable from stop to full stroke depending on how far lever is operated. The right hand operator control has 4 basic operational functions.

“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.

BOOM DOWN

R.H. CONTROL LEVER (ISO PATTERN)

BUCKET OUT BUCKET IN

BOOM UP

FIGURE 2.39

6. Left and Right Travel Lever & Pedal – FIGURE 2.40 The travel lever & pedal are located in front of operator seat. They are used to move the left or right track of the machine either forward or backward.

These controls have 2 basic operational functions.

“FORWARD” ........ Variable speed forward track movement.

“BACKWARD” ..... Variable speed reverse track movement.

“CENTER” ............ Neutral position.

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

LEFT HAND TRAVEL LEVER LEFT HAND TRAVEL PEDAL

RIGHT HAND TRAVEL LEVER RIGHT HAND TRAVEL PEDAL

FOOT REST

FOOT REST

FIGURE 2.40 7. Adjustment of Pilot Valve (Control Lever) Height – FIGURE 2.41 To adjust the height of the pilot control levers, use a 17 mm wrench and remove capscrew (M10) under the operator console. The 3-stage setting hole position is as follows: a. From factory, the hole is set to the highest position (H1). b. If it set to the medium position (H2), the valve (control lever) height is raised 15 mm (0.6”). c. When it is set to the lowest position (H3), the valve (control lever) height is raised max. 29 mm (1.1”).

NORMAL POSITION CAPSCREW M10

H1 H2 H3

FIGURE 2.41

2 — 24

Section II – MACHINE FAMILIARIZATION E. GAUGE CLUSTER The monitor displays information sent from sensors positioned at various places on the excavator, making it possible to monitor the excavator’s operating working conditions.

KPSS WORK MODE LAMP

FUEL LEVEL GAUGE

WATER TEMPERATURE GAUGE

LCD DISPLAY LCD DISPLAY

6

KPSS WORK MODE SWITCH SCREEN CHANGE SWITCH WASHER SWITCH BUZZER STOP SWITCH

TRAVEL SPEED SELECT SWITCH

WIPER SWITCH

AUTO ACCEL SWITCH

WORKING LIGHTS SELECT SWITCH

LED LAMP

FIGURE 2.42 1. Fuel Level Gauge This indicates the amount of remaining fuel.

F: Full tank is about 560 Liter (148 gal).

E: The remaining fuel oil is about 60 Liter (16 gal).

2.

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

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

3. KPSS Work Mode Lamp Press the work mode selector switch in order, and , or mode is selected and the selected work mode display green lamp goes on.

After the engine starts, the mode is always set to the A mode.

SUPPLEMENTARY EXPLANATION For guideline of work mode selector switch, see pages 2-3 ~ 2-4.

2 — 25

Section II – MACHINE FAMILIARIZATION 4. L.C.D. Display – FIGURE 2.43 The L.C.D. display is illustrated below and will display the icons listed on this page. Study these icons and their definitions so that possible problems will be quickly recognized and repairs made in a timely fashion.

a. Normal Displays The seven status are appear on the display by pressing the screen change switch ( ).

Utilize this function checking total cumulative time of inspection and maintenance.

1. System status icon This icon is display after key switch is turned “ON” and all machine systems and components are checked by CPU and found to be in good working order. It remains displayed for 5 seconds.

2. Engine R.P.M icon The engine speed (output) correspond2250RPM ing to the throttle potentio meter position is displayed.

3. Engine lubrication cumulative time For instance, 256 hours has elapsed since the change of engine oil.

This indication shows the total cumulative time since the engine oil has been changed.

4. Fuel filter cumulative time This indication shows the total cumulative time on since the engine fuel filter has been changed.

5. Hydraulic oil filter cumulative time This indications shows the total cumulative time since the hydraulic filter has been changed.

6. Hydraulic oil cumulative time This indication shows the total cumulative time since the hydraulic oil has been changed.

(2) 6

(3)

(1)

FIGURE 2.43 NOTE The languages on gauge cluster can be switched by the following procedure. And languages displayed on the gauge cluster are as follows.

“J” ................... Japanese “E” .................. English “EA” ................ English (For North America) “T” ................... Thai “I” .................... Indonesian “F” ................... French “S” .................. Spanish “EU” ................ Pictorial symbol (For EU) “G” .................. German “C” .................. Chinese • Switching procedure – FIGURE 2.43 1. While keeping screen change switch (1) pressed, turn the key switch “ON”.

2. The gauge cluster displays the initially set language.

“J” ... Japanese (This is displayed without fail).

3. Press buzzer stop switch (2) or mode change switch (3) and select and display the desired language.

4. Press screen change switch (1), and the setting is completed.

5. Turning the starter switch to “HEAT” position can identify the set language.

SUPPLEMENTARY EXPLANATION For the correcting method of accumulated time for engine oil, fuel filter, hydraulic oil filter, hydraulic oil, etc., see page 2-31. And while correcting the time, press the mode switch and buzzer stop switch for 5 seconds simultaneously, and all items are cleared.

2 — 26

Section II – MACHINE FAMILIARIZATION b. Warning Displays 6

WARNING DISPLAYS The buzzer will sound the instant 2, 4, 5, 6, 9 and 18 warning icons are displayed.

1.

1

2

4

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

7

2. Swing parking brake release icon 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 warning is displayed, the swing parking brake does not actuates.

So this switch should be used only in the event of emergency. Call the Dealer for assistance.

8

3. Engine pre-heating icon This symbol is displayed when key switch is turned to heat position and the engine preheat circuit is activated.

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

5

5

9

4. Engine pre-heat complete icon This icon is displayed when the PREHEAT is completed.

If the buzzer sounds and can’t be stopped, turn key switch to the OFF position and wait for 4 sec’s until the electrical system is turned off. Then start engine. Continuous preheat after this icon is displayed could cause damage to the engine.

10

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

2 — 27

5. Engine oil pressure icon This icon will display and the buzzer will sound should the engine oil pressure drop below safe operating pressure. If this icon is on display and buzzer is sounding, stop the engine immediately and check engine oil level. Fill engine to proper level with approved engine oil. In case of engine LOW OIL PRESSURE, the engine will automatically go to “LO” Idle RPM. This icon will display only if alternator is charging.

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

7. Engine oil filter restriction icon This icon will display, if the engine oil REST'D E/G filter becomes too clogged due to conOIL FILTER tamination. This symbol is only displayed when the alternator is charging. If this symbol is displayed, replace the engine oil filters immediately.

8. Engine air cleaner icon This icon will display the engine air cleaner element(s) (FILTERS) become too dirty to allow proper air flow to the engine. Should this icon display stop engine immediately and clean or replace engine air cleaner element(s) as required.

This icon will display only if alternator is charging.

9. Over load alarm icon The icon will display and the buzzer will sound if the boom cylinder circuit pressure exceeds the set, specified pressure. If this happens, the operator should be aware that he is operating the machine in a range of low machine stability. The operator should reduce the attachment reach in order to increase machine stability for safer operation.

Section II – MACHINE FAMILIARIZATION 10.Battery charging system icon This icon will display the electrical 11 charging system not function properly. Should this icon display has electrical charging system repaired immediately. Icon displays only when engine is running with normal oil pressure and a problem occurs in the charging system.

17.Auto warning up icon WARMING UP This icon is displayed to indicate the warming up operation of the engine and hydraulic oil when the engine rotates in decel condition after the key switch is turned on and the auto warming up selector switch on the left console is set to “ON” position.

Turn the auto warming up select switch, hydraulic oil temperature switch and the key switch OFF, and the warming up operation stops forcibly and the display disappears.

21

11. Fuel level icon This icon will display should the fuel 12 level in fuel tank reaches 54 liters (14 Gal.) or less. Should this icon display refill fuel tank immediately using approved fuel oil.

18.Auto warming up finish icon This icon is displayed when the warm28 FINISH ing up of the engine or hydraulic oil is finished or the warming up is stopped forcibly by operating the lever or turning the auto warm-up switch OFF forcibly, and concurrently the buzzer sounds continuously for about 5 seconds.

12.Hydraulic oil level icon This icon will display should the hy13 draulic oil level in hydraulic oil reservoir fall below safe operating level.

Should this icon display before starting engine, position the machine in hydraulic oil check position and check sight gauge for oil level. Full hydraulic reservoir to proper level using approved hydraulic oil. This icon will not display with engine running and a loss of hydraulic oil is experienced.

13.Engine coolant level icon This icon will display should the en14 gine coolant level fall below safe operating level. Should this icon display before starting the engine, check and fill coolant level in the radiator and coolant reservoir. Icon will not display if alternator is charging and a sudden loss of coolant is experienced.

19.Replace engine oil icon This icon will display at every 500 29 hours of machine operation to remind operator of scheduled engine oil change. The recommended oil change interval for MITSUBISHI engines is every 500 hours of operation.

When this icon is displayed, and a second time to reset the oil change interval to zero. Make sure to recalibrate the engine oil change interval as indicated in page 2-31.

SUPPLEMENTARY EXPLANATION For the correcting procedure of the accumulated time of engine fueling, see page 2-31.

14.Engine oil level icon This icon is displayed when the en15 gine oil level of the engine oil pan is low. Check the engine oil level immediately and make up the shortage of the engine oil.

19

20

15.Attachment boost pressure icon This icon will display when the power boost switch is depressed. This icon is displayed only when this system is activated during operation.

16.Heavy lift pressure icon This icon will display when the heavy lift switch is in the “ON” position. This icon is displayed only when this system is activated during operation.

2 — 28

Section II – MACHINE FAMILIARIZATION 20.Display of starting number of engine auto idling stop NO.1 MAIN CONT P/N STARTER CHG PROGRAM VER VER 4.00

Indicates the appeal of starter change

Recommended number of engine starting

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

Replace the starter motor.

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

2 — 29

Section II – MACHINE FAMILIARIZATION 5. How to Calibrate the Engine Oil Change Interval SUPPLEMENTARY EXPLANATION The accumulated time for fuel filter, hydraulic oil filter, hydraulic oil, etc. can be corrected by the procedure for correction of the accumulated time for engine oil supply after the adjusting items have been displayed. While correcting the time, press the mode switch and buzzer stop switch for 5 seconds simultaneously, and all items are cleared.

LCD DISPLAY

(Eg.) The procedure for correction of the accumulated 256Hr E/G OIL

AFT CH

MODE SWITCH

SCREEN CHANGE SWITCH

BUZZER STOP SWITCH

time for engine oil supply.

Procedure

Operating procedure

Display on multidisplay Clock is displayed

(Normal)

A

Turn the starter switch on.

Clock is displayed after 5 seconds

14 : 20

E/G speed is displayed

B

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

Press once

14 : 20

2250 RPM

Clock is displayed E/G speed is displayed Press once more 2250 RPM

C

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

D

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

100Hr E/G OIL

AFT CH

256Hr FUEL

E

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

100Hr E/G OIL

AFT CH

Cumulative time increases

F

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

100Hr E/G OIL

AFT CH

G

Press the gauge cluster screen change switch once the correcting time is stored, and exits from the correction mode is displayed and the correction is completed. and

99Hr E/G

AFT CH

OIL

100Hr E/G OIL

AFT CH

100Hr E/G OIL

AFT CH

101Hr E/G OIL

AFT CH

The cumulative time decreases

99Hr E/G

AFT CH

Complete the correction

256Hr FUEL

FIL

AFT CH

OIL

FIL

AFT CH

256Hr AFT FUEL FIL CH

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

2. To correct the each accumulated time of fuel filter, hydraulic oil filter and hydraulic oil, press the screen change switch and display the accumulated time screen for the items required to correct, then repeat the procedure D to G. 3. The engine oil change time is warned on the multidisplay by 500 hours, but no buzzer sounds.

4. For the fuel filter, hydraulic oil filter and hydraulic oil, press the screen change switch, and the “ ” is displayed, but no warning and no buzzer are given.

5. The time is displayed with 4 digits for hydraulic oil, and 3 digits for others.

2 — 30

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

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

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

SERVICE FUNCTION ICON SEQUENCE

LCD DISPLAY

Press it once after E/G starts.

BUZZER SOUNDING

1515 RPM

Press once

Press once

1920Hr AFT HYD OIL CH NORMAL DISPLAY

256Hr E/G OIL

Press once

AFT CH Press once

256Hr AFT HYD FIL CH

Press once

256Hr AFT FUEL FIL CH

NO SOUNDING Use to ensure the time of the replacement for the inspection, service, etc.

Supplementary Explanation: The screen can be switched into seven images by pressing the screen change switch.

ASSIST MODE DISPLAY

Digging mode

Leveling mode

Spreading mode

1

2

MECHATRO CPU CONT. FAIL SWINGBRAKE DISENGAGED

Tamping mode

9

10

Standard mode

REST'D AIR CLEANER

19

ATTACHMENT OVER LOAD

20

NO SOUNDING

POWER BOOST ON HEAVY LIFT

For the description of display of the assist mode, refer to Page 3-8.

Each display flickers during discrimination.

2, 5, 6, 7, 10, 28 buzzer sounds.

4

E/G PREHEAT

11

CHARGING PROBLEM

21

WARMING UP

5

FINISH PREHEAT

12

LOW FUEL LEVEL

28

FINISH

WARNING

6

7

8

LOW E/G OIL PRESS

13

HIGH E/G COOL TEMP

14

REST'D E/G OIL FILTER

15

LOW HYD OIL LEVEL

29

LOW E/G COOL LEVEL

NO.1 MAIN CONT P/N STARTER CHG PROGRAM VER VER 4.00

LOW E/G OIL LEVEL

2 — 31

CHANGE E/G OIL

Supplementary Explanation: Icons 5 and 6 are displayed and buzzers do not stop sounding even if the buzzer stop switch is pressed.

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

Icons 2, 10 and 28 are displayed and buzzers sound intermittently and stop sounding after 5 seconds.

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

Section II – MACHINE FAMILIARIZATION F . OPERATOR CAB AND OPERATOR SEAT 1. Locking/Unlocking Cab Door Use the key switch key to lock or unlock cab door.

Insert key into door lock and turn clockwise to unlock or turn counterclockwise to lock cab door. See Figure 2.44.

USE KEY SWITCH KEY TO LOCK & UNLOCK CAB DOOR

FIGURE 2.44

2. Cab Door Latch a. The cab door can be latched in an open position by opening door until it is locked open by the door latch located on the cab. See Figure 2.45.

CAB DOOR LATCH

FIGURE 2.45

b. Release door latch by pushing release lever down to release door from latch. See Figure 2.46.

PUSHING LEVER DOWN TO RELEASE DOOR

FIGURE 2.46

2 — 32

Section II – MACHINE FAMILIARIZATION c. Pull release lever near side, and door opens from the inside of cab. See Figure 2.47.

PULL RELEASE LEVER

FIGURE 2.47

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

LEVER (1 EACH SIDE)

CAUTION Securely insert the lever shaft of front window(upper) into the lock hole on the rear roof and lock it, or the wiper lock does not function, and consequently the wiper may be damaged because the wiper moves at the time when the wiper motor switch is turned on.

HANDLE FRONT INSIDE OF CAB

FIGURE 2.48 a. Pull levers on the right and left sides of front window upper section and levers are unlocked. See Figure 2.48. b. Hold handles on upper central and lower left sides of front window (upper), remove them up and move front window (upper), and after locking them to locking holes on rear side of ceiling securely, pull them down. See Figure 2.49.

CAUTION

LEVER

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

The lever shafts must be inserted securely into the right and left lock holes and lock them.

REAR INSIDE OF CAB

FIGURE 2.49

2 — 33

Section II – MACHINE FAMILIARIZATION 4. Removing & Storing Lower Front Window a. After placing upper front window in ceiling, hold lower front window by hands and remove it from window frame. b. Store the removed lower front window in holder on the rear side of cab securely. c. To store it, insert the right and left sides of glass in holder, and support it with holder on the lower section of window frame. See Figure 2.50.

HOLDER

HOLDER

HOLDER

FIGURE 2.50 5. Opening and closing door glass a. Open cab door glass (upper) sliding it to front side after unlocking it. b. Close the door glass sliding it to LOCK position, then lock it. See Figure 2.51.

LOCK LOCK

FIGURE 2.51 6. Opening and Closing Sunroof Pull locks on right and left sides inward, and sunroof opens through the aid of gas spring.

Close sunroof pulling locks inward, and lock it.

Also the roof can be left slightly open to ventilate air in cab by placing lock section on section. See Figure 2.52.

LOCK (1 EACH SIDE)

(B) (A)

FIGURE 2.52 7. Cab Dome Light a. Turn cab dome Light “ON” by pushing the dome light switch downward. b. Turn “OFF” by pushing switch all the way up. See Figure 2.53. c. Place dome light switch in the “CENTER” position and the light will be operated by the door switch.

When door is opened the light will come “ON” and when the door is closed the light will turn “OFF”.

OFF

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

ON

FIGURE 2.53

2 — 34

Section II – MACHINE FAMILIARIZATION 8. Storage Compartment The operator and parts manual storage compartment is a pouch located on the back of the operator’s seat. Keep the operator and parts manual for this machine in this location at all times for quick, easy reference. See Figure 2.54.

MANUAL STORAGE

FIGURE 2.54 9. Operator Seat Adjustments The operator seat incorporates several adjustment mechanisms to insure operator comfort, ease of operation and operator safety. The adjustment areas are as follows:

ROTATE TO SET OPERATOR WEIGHT

a. Operator weight adjustment – FIGURE 2.55 Rotate the adjustment knob until weight close to the operator’s weight is at the top end of the dial.

FIGURE 2.55 b. Seat height adjustment – FIGURE 2.56 1. Pull height adjustment lever up to raise or lower rear of seat.

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

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

FIGURE 2.56 c. Seat reclining adjustment – FIGURE 2.57 1. Pull reclining adjustment lever up to set desired reclining angle.

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

PULL UP TO ADJUST SEAT RECLINING POSITION

FIGURE 2.57

2 — 35

Section II – MACHINE FAMILIARIZATION d. Seat front to back adjustment – FIGURE 2.58 Pull up on seat adjustment bail and move seat forward or backward to desired position.

USE BOTTOM BAIL TO ADJUST CONTROL STAND

USE TOP BAIL TO ADJUST OPERATOR SEAT ONLY

FIGURE 2.58 e. Arm rest adjustment – FIGURE 2.59 Lower arm rest and with finger, turn adjustment wheel until arm rest is in desired position.

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

FIGURE 2.59

f. Head rest adjustment – FIGURE 2.60 1. Move head rest forward or backward to desired reclining angle.

2. Raise or lower head rest to desired height.

MANUALLY ADJUST HEAD REST HEIGHT AND RECLINING TO DESIRED POSITION

FIGURE 2.60

2 — 36

Section II – MACHINE FAMILIARIZATION G. SEAT BELT – FIGURE 2.61 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. Sit on the seat, and draw out the belt.

RED BUTTON

NOTE If the belt is stopped drawn out halfway, the belt is locked at the stopped position. Return it once to draw it out again.

BUCKLE

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 extended or shortened in about 25 mm (1 in) range so as not to fasten the body tightly.

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

FIGURE 2.61

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.

H. MACHINE ACCESS PANELS & DOORS 1. Engine Coolant Tank & Engine Air Cleaner Access Doors – FIGURE 2.62 Located on the L.H. side of the machine the engine coolant tank access door allows access to the engine coolant tank. It also holds the engine air cleaner access door closed.

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

ENGINE COOLANT TANK ACCESS DOOR

ENGINE AIR CLEANER ACCESS DOOR

RADIATOR SUB TANK ACCESS DOOR

FIGURE 2.62

2 — 37

Section II – MACHINE FAMILIARIZATION 2. Main Pump Access Door – FIGURE 2.63 Locate on the right side of the machine this door allows access to the main pump.

MAIN PUMP ACCESS DOOR

FIGURE 2.63 3. Battery Box Access Cover – FIGURE 2.64 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 by key switch key.

Use stay to leave the cover open.

BATTERY BOX ACCESS DOOR

FIGURE 2.64 4. Fuel cap – FIGURE 2.65 Stop engine and remove cap on fuel tank, then make it up with fuel.

5. Engine Bonnet – FIGURE 2.66 Open engine bonnet with key switch after stopping engine.

Use stay to support it.

FUEL CAP

FIGURE 2.65 ENGINE BONNET

FIGURE 2.66

2 — 38

Section III – BASIC MACHINE OPERATION Table of contents 3.1 PRE-START CHECK .............................................................................................................................................. 3-1 3.2 STARTING & STOPPING MACHINE ENGINE WITH TEMPERATURE ABOVE 0° C (32 °F) .................................. 3-1 3.3 STARTING & STOPPING MACHINE ENGINE WITH TEMPERATURE BELOW 0° C (32 °F) ................................. 3-2 3.4 STARTING MACHINE ENGINE WITH BOOSTER CABLES ................................................................................... 3-4 3.5 MACHINE WARM UP ............................................................................................................................................ 3-6 3.6 CONTROLS DECAL .............................................................................................................................................. 3-7 3.7 BASIC OPERATION OF HYDRAULIC CONTROLS ............................................................................................... 3-8 3.8 PRACTICES TO IMPROVE EFFICIENCY ............................................................................................................ 3-16 3.9 FLAGMAN HAND SIGNALS ................................................................................................................................ 3-19

WARNING READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS AND PROCEDURES FOUND IN THIS MANUAL BEFORE ATTEMPTING ANY OPERATION, INSPECTION OR MAINTENANCE OF THIS MACHINE, ATTACHMENT OR SYSTEMS.

3—0

Section III – BASIC MACHINE OPERATION 3.1 PRE-START CHECK Perform pre-start inspection and maintenance procedures before starting the machine. Refer to the maintenance section of this manual for specific instructions.

3.2 STARTING & STOPPING MACHINE ENGINE WITH TEMPERATURE ABOVE 0° C (32 °F) A . STARTING ENGINE 1. Move throttle control to “LO” position. See Figure 3.1.

2. Insert key into key switch and turn to the “ON” position. See Figure 3.1.

3. Sound horn to warn personnel that the machine is being started. See Figure 3.2.

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

THROTTLE IN "LO" POSITION

KEY SWITCH IN "ON" POSITION

FIGURE 3.1

SOUND HORN

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

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

FIGURE 3.2

AUTO IDLING STOP WARNING

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

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

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

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

3—1

Section III – BASIC MACHINE OPERATION B . STOPPING ENGINE – NORMAL CONDITIONS 1. Move machine to a firm, level area and place the attachment in the hydraulic oil check position. See Figure 3.3.

2. Move throttle control to “LO” position. See Figure 3.1. Allow engine to idle for 5 minutes.

3. Turn key switch to “OFF”.

MACHINE ON FIRM, LEVEL SURFACE

C . EMERGENCY ENGINE SHUT DOWN In only cases of emergency should this method be used.

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

2. Pull out the engine emergency stop control located on the lower right side of control stand. See Figure 3.4.

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

ATTACHMENT IN HYDRAULIC OIL CHECK POSITION

FIGURE 3.3 USE ONLY IN EMERGENCY

EMERGENCY ENGINE STOP CONTROL

3.3 STARTING & STOPPING MACHINE ENGINE WITH TEMPERATURE BELOW 0° C (32 °F) A . STARTING ENGINE 1. Move throttle control to “LO” position. See Figure 3.5.

2. Turn the key switch to “HEAT” and preheat for 20 seconds to make start-up easier. See Figure 3.6.

3. Sound horn to warn personnel that the machine is being started. See Figure 3.7.

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

FIGURE 3.4

THROTTLE IN "LO" POSITION

CAUTION

KEY SWITCH IN "ON" POSITION

FIGURE 3.5

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.

4 E/G PREHEAT

NOTE • In the cold weather, use the auto warm up switch described on page 3-6 of Section III, and warm the engine and hydraulic oil.

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

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

FIGURE 3.6

SOUND HORN

FIGURE 3.7

3—2

Section III – BASIC MACHINE OPERATION

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

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

B. STOPPING ENGINE - NORMAL CONDITIONS 1. Move machine to a firm, level area and place the attachment in the hydraulic oil check position. See Figure 3.8.

2. Move throttle control to “LO” position. See Figure 3.5. Allow engine to idle for 5 minutes.

3. Turn key switch to “OFF”.

MACHINE ON FIRM, LEVEL SURFACE

ATTACHMENT IN HYDRAULIC OIL CHECK POSITION

FIGURE 3.8

C. EMERGENCY ENGINE SHUT DOWN In only cases of emergency should this method be used.

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

2. Pull out the engine emergency stop control located on the lower right side of control stand. See Figure 3.9.

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

USE ONLY IN EMERGENCY

EMERGENCY ENGINE STOP CONTROL

FIGURE 3.9

3—3

Section III – BASIC MACHINE OPERATION 3.4 STARTING MACHINE ENGINE WITH BOOSTER CABLES

KEY SWITCH POSITIONS

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

WARNING 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. FIGURE 3.10

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

2. Make certain key switch of disabled machine is in the “OFF” position before proceeding with booster cable connection. See Figure 3.10.

NEGATIVE (-) CABLE

WARNING

POSITIVE (+) CABLE

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 Figure 3.11.

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

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

6. Connect other end of negative (-) cable to the upper frame of disabled machine as far away from battery as possible. See Figure 3.12.

FIGURE 3.11

CABLE CONNECTING ORDER

WARNING 12V

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.

12V

NORMAL BATTERIES

12V

12V

DISCHARGED BATTERIES

UPPER FRAME OF DISABLED MACHINE

FIGURE 3.12

3—4

Section III – BASIC MACHINE OPERATION B . STARTING BOOSTING MACHINE ENGINE 1. Start engine of boosting machine in normal manner according to climate conditions. Refer to pages 3-1 & 3-2 for specific starting instructions.

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

CABLE CONNECTING ORDER

C. STARTING DISABLED MACHINE ENGINE Start engine of disabled machine in normal manner according to climate conditions. Refer to pages 3-1 & 3-2 for specific starting instructions.

12V

12V

NORMAL BATTERIES

12V

12V

DISCHARGED BATTERIES

UPPER FRAME OF DISABLED MACHINE

FIGURE 3.13

D . DISCONNECTING BOOSTER CABLES 1. After disabled machine engine is running, disconnect the negative (-) cable from disabled machine upper frame. See Figure 3.14.

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. See Figure 3.14.

DISCONNECT NEGATIVE (-) CABLE FROM DISABLED MACHINE

FIGURE 3.14

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

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

3—5

Section III – BASIC MACHINE OPERATION 3.5 MACHINE WARM UP A . AUTO WARM UP – FIGURE3.15 1. Warming Up of Engine The “WARMING UP” is displayed on the multi display after operating the engine for 3 minutes at auto accel speed (1,050 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.

2. Warming of Hydraulic Oil After performing the operation of pump max, flow rate at the engine speed (1,050 rpm) for 3 minutes pump max. flow rate (control value closed) at pump the engine speed (1,600 rpm) for 5 minutes max. flow rate and control valve fully open at the engine speed (1,600 rpm) for 5 minutes max. flow rate at the engine auto accel speed (1,050 rpm) for 10 minutes, “WARMING UP” is displayed on the multidisplay.

3. Warming Up Complete After the warming up has gone by about 26 minutes, or when the oil tempeature switch (installed on the tank port of solenoid proportional block) senses 10 °C or higher and is turned off, the “WARM FINISH” is displayed on the multidisplay and the buzzer sounds intermitently.

In 5 minutes, the buzzer stops sounding, and the display on the multidisplay disappears.

Then, turn the auto warm up switch “OFF”.

B . MANUAL WARM UP

PRESS HERE FOR “OFF”

FIGURE 3.15 NOTE While warming up the engine, operate the lever and the warming up is forcibly finished.

Turn the auto warm up switch "OFF", and the warming up is foribly stopped. While warming the hydrauli c oil, operate the lever and the warming is stopped temporarily, and after and elapse of 10 seconds of the neutral condition the warming operation restarts.

ALLOW THE ENGINE TO RUN FOR 5 MINUTES IN LOW IDLE BEFORE WARM UP

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

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

See Figure 3.16. b. During warm up, visually and audibly inspect engine for abnormal conditions such as unusual exhaust color, excessive vibrations and excessive or unusual noises. c. Should problem areas be noticed, stop engine, locate and repair problem areas before restarting or operating the machine.

2. Warming of Hydraulic Oil a. Move throttle control to “HI” idle position. b. 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. Repeat this operation for 5 to 10 minutes to help oil to reach operating temperature.

FIGURE 3.16 c. Move throttle control to mid position and operate the boom and arm controls for 5 to 10 minutes each.

3—6

Section III – BASIC MACHINE OPERATION 3.6 CONTROLS DECAL

B . OPERATING PATTERN DECAL Figure 3.17 is a representation of the “CONTROLS” decal located on the right side window inside the operator cab. Study this decal and understand the directions each control can be operated and the functions associated with each movement of particular control.

Detailed instructions for each control and its functions are explained on the following pages of this section.

Should this decal become damaged or missing, install new decal.

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

WARNING CHECK AND MAKE SURE THAT OPERATION’S PATTERN CONTROL MATCHES THE DECAL PROVIDED INSIDE THE RIGHT SIDE WINDOW.

HYDRAULIC CONTROL LEVERS

LEFT CONTROL LEVERS

LEFT TRAVEL LEVER AND PEDAL

RIGHT TRAVEL LEVER AND PEDAL

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

FIGURE 3.17

3—7

RIGHT CONTROL LEVERS

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

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

TRAVEL MOTORS AT REAR OF MACHINE

WARNING FIGURE 3.18

NORMAL POSITIONING OF THE MACHINE FOR THE PURPOSE OF DETERMINING FRONT, REAR, FORWARD AND REVERSE ARE WITH THE TRAVEL MOTORS LOCATED BEHIND THE OPERATOR’S CAB. SEE FIGURE 3.18.

ALWAYS KNOW THE LOCATION OF TRAVEL MOTORS BEFORE OPERATING ANY HYDRAULIC CONTROLS.

A . SAFETY LOCK LEVER – FIGURE 3.19 1. Unlocked Position Before any hydraulic operation is possible the safety lock lever must be placed in the “UNLOCKED” (DOWN) position. Placing the safety lock lever in the UNLOCKED (DOWN) position also positions the L.H. operators console in its operating position.

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

SAFETY LOCK LEVER IN UNLOCKED (DOWN) POSITION

SAFETY LOCK LEVER IN LOCKED (UP) POSITION

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

FIGURE 3.19

3—8

Section III – BASIC MACHINE OPERATION B . KPSS (KOBELCO POWER SENSING SYSTEM) MODE SWITCH – FIGURE 3.20 Press the work mode selector switch in order, and , or mode can be selected.

Select the effective work mode according to the work condition and working target from the table shown below.

For the selected work mode, refer to the table shown below.

L.C.D. DISPLAY

KPSS WORK MODE SWITCH

FIGURE 3.20 KPSS WORK MODE SELECTION TABLE CONTROL MODE A (assist) mode

DISTINCTION Digging Ditch dipping Trench box digging

REMARKS • Since the mode is set appropriately according to the operator's work, the digging, slope finishing, tamping and spreading works are automatically discriminated and set by the controller without turning the switch.

Leveling Slope finishing

• While outputting the power equivalent to the load, the engine speed is kept constant and the noise is reduced.

• The distinction results are displayed on the multidisplay. (Updated

Spreading

every 5 seconds) • The display appears several seconds later. And the display may not always satisfy your intention. But it does not indicate a failure.

Tamping

M (manual) mode

Indicator lights on

lamp

This mode catches the movement of control lever sensively, and is suitable to carry out the heavy load work giving priority to the work load at high speed.

B (breaker) mode

Indicator lights on

lamp

When an attachment, like breaker, etc., is required, the max. flow rate is adjustable. All other modes get full flow regardless of the flow setting for breaker mode.

3—9

Section III – BASIC MACHINE OPERATION C . MACHINE TRAVEL CONTROLS This machine incorporates several travel controls for the convenience of the operator. Each track can be operated independently to turn the machine or simultaneously to spinturn the machine or to travel straight.

1. Operating Both Travel Levers Together a. Push both travel levers or press the pedals toward front of machine and machine will travel “FORWARD”. See Figure 3.21. b. Pull both travel levers or press the pedals toward operator seat and machine will travel “REVERSE”. See Figure 3.22. c. Return both travel levers to “NEUTRAL” (center) position and machine will stop. Parking brakes are automatically applied when travel levers are in neutral position.

FORWARD TRAVEL

FIGURE 3.21 REVERSE TRAVEL

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

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

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

2. Use of Travel Speed Select Switch - Figure 3.23 The travel speed select switch is located on the gauge cluster switch panel. The travel speed selector switch is installed on the switch panel section of gauge cluster. Press the travel 2-speed ( ) switch on the gauge cluster, and the speed is changed to the 2nd speed and the ( ) is indicated on the multidisplay. Each time engine is started, travel speed is automatically set to 1st ( ) speed.

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

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

HIGH (2nd) speed

FIGURE 3.22

14 : 20

TRAVEL SPEED SELECT SWITCH PRESS HERE FORE “FAST” & “SLOW”

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

Do not travel continuously for more than two hours. Stop for a period of 10 min. at low idle speed before resuming travel.

FIGURE 3.23

3 — 10

Section III – BASIC MACHINE OPERATION 3. Turning Machine a. Push the L.H. travel lever toward front of machine to turn machine RIGHT in forward motion. See Figure 3.24. b. Pull the L.H. travel lever back toward operator seat to turn machine to the LEFT in reverse motion. c. Push the R.H. travel Lever toward front of machine to turn machine to the LEFT in forward motion. See Figure 3.25. d. Pull R.H. travel lever toward operator seat to turn machine to the RIGHT in reverse motion.

FIGURE 3.24

4. Counter Rotating Machines a. Pull L.H. travel lever BACK and push R.H. travel lever FORWARD to counter rotate machine to the LEFT. See Figure 3.26. b. Pull R.H. travel lever BACK and push L.H. travel lever FORWARD to counter rotate machine to the RIGHT. See Figure 3.27.

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

FIGURE 3.25

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

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

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

FIGURE 3.26

4. The travel operation for 2 hours or more may cause the failure of travel motor due to the rise of operating temperature. Don’t travel it for 2 hours or more.

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

FIGURE 3.27

3 — 11

Section III – BASIC MACHINE OPERATION 5. Travel Safety a. Make certain travel motor location is known before performing any travel operation. b. Travel on firm, level surfaces as much as possible. c. When traveling on rough terrain, travel in SLOW ( ) speed with engine at a low idle. d. Travel with the travel motors in back of the machine for long distance travel. e. When traveling or operating machine on snow or icy surfaces, clean track shoes frequently to prevent clogging. This will help keep the machine from sliding unexpectedly. f. Keep a safe distance from stationary objects and electrical power lines. g. Be aware of load capacities of bridges and road shoulders. Reinforce if necessary. h. Use decking or plating to protect road surfaces as much as possible. Be careful when turning or spinning machine on asphalt pavement. i. Do not allow large or heavy objects to strike travel motors. j. Do not travel over large objects such as boulders rocks etc. k. If necessary to travel or operate machine in a river or other water, the bed must be firm and water current slow. Water must not be deeper than indicated in the chart in Figure 3.28.

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

Immediate replacement of grease in grease bath and overhaul of the slewing bearing is required. See maintenance section. l. On soft ground or mud the machine can sink. Stay constantly aware of undercarriage position.

3 — 12

WATER DEPTH

BED MUST BE FIRM & STABLE MODEL E335(LC)-(NLC)

MAXIMUM WATER DEPTH

800 mm (2' - 7") FIGURE 3.28

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

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

1. Boom Operation – FIGURE 3.29 Operation of the boom is performed by pushing and pulling the R.H. control lever forward and backward.

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

PULL BACKBOOM UP

PUSH FORWARDBOOM DOWN

FIGURE 3.29

2. Arm Operation – FIGURE 3.30 Operation of the arm is performed by pushing or pulling the L.H. control lever forward and backward.

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

PULL BACKARM IN

PUSH FORWARDARM OUT

3. Bucket Operation – FIGURE 3.31 Operation of the bucket is performed by moving the R.H. control lever to the right or left. a. Moving the R.H. control lever to the LEFT operates the bucket IN (digging). b. Moving the R.H. control lever to the RIGHT operates the bucket OUT (dumping).

PULL LEFTBUCKET IN (DIGGING)

FIGURE 3.30 PUSH RIGHTBUCKET OUT (DUMPING)

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

FIGURE 3.31

3 — 13

Section III – BASIC MACHINE OPERATION 4. Swing Operation - FIGURE 3.32

PUSH LEFT TO SWING LEFT

NOTE Use swing flashers during swing operations.

Swing operation is performed by moving the L.H. control lever to the right and left. Swing speed is determined by the amount the lever is moved. a. Moving the L.H. control lever to the LEFT swings the machine to the left. b. Moving the L.H. control lever to the RIGHT swings the machine to the right.

PULL RIGHT TO SWING RIGHT

c. Returning control to the neutral (center) position stops swing.

WARNING MAKE CERTAIN AREA IS CLEAR OF OBSTACLES AND PERSONS BEFORE BEGINNING SWING OPERATION OF THE MACHINE. SOUND HORN BEFORE BEGINNING SWING OPERATIONS. E. USING POWER BOOST FIGURE 3.32

The power boost switch is located on top of the R.H. operator control. It is a momentary switch which is activated by depressing with the thumb. This system is designed for use during bucket digging operations when extra “Break-Out” power is required to allow the bucket to break through a dig.

1. Operate the bucket in (digging) control. While bucket is digging, depress the power boost switch with right thumb. See Figure 3.33. This will increase bucket digging power by approximately 15%.

NOTE If the power boost switch is left depressed while performing other hydraulic operations the operator will experience slower operation of the hydraulic functions. While power boost switch is depressed the power boost icon ( ) will be displayed on the gauge cluster display.

3 — 14

DEPRESS WITH THUMB TO TURN "ON"

FIGURE 3.33

Section III – BASIC MACHINE OPERATION

LO

14 : 20

HI

F. USING AUTO ACCELERATION – FIGURE 3.34 Press the symbol mark on this switch to switch ON (LED is illuminated). If the remote control pressure of the operating pedal (in option) does not actuate for 4 seconds, when the accel dial is placed on the decel position (1,050 rpm) or higher, the auto accel actuates automatically resulting in the decel speed, consequently the fuel consumption and noise are reduced.

By operating the control lever and the operating pedal, the engine speed rises to the speed equivalent to the accel dial set position gradually corresponding to the motion of control lever or pedal.

And, when operating at decel speed, press the no symbol side to switch OFF, the engine speed rises to the speed equivalent to the accel dial set position.

FIGURE 3.34

G.TOWING THE MACHINE – FIGURE 3.35 & 3.36 Where you can not get the machine out of soft soil, place wire slings as shown on the right and pull it by an other machine. Always place wire slings around the frame section and put pads on each corner to prevent the wire slings from being damaged.

NOTE Do not pull the machine utilizing the holes provided for pulling lightweight objects. Otherwise the holes may break.

FIGURE 3.35

FIGURE 3.36

3 — 15

Section III – BASIC MACHINE OPERATION 3.8 PRACTICES TO IMPROVE EFFICIENCY

USE ARM HORIZONTALLY AS MUCH AS POSSIBLE

A. USE ARM IN ACTION – FIGURE 3.37 Operate the bucket at shallow depths and use the arm in action to fill the bucket. Setting the bucket too deep will decrease the machine’s efficiency.

FIGURE 3.37 B. OPERATE BOOM SMOOTHLY – FIGURE 3.38 Always begin and end boom operation slowly with smooth, careful movement of the control lever. Do not perform sudden starts and stops of the boom as this creates unnecessary stress on the machine and its components.

OPERATE BOOOM SMOOTHLY DURING ALL BOOM OPERATIONS

FIGURE 3.38 C. BUCKET TEETH DIRECTION – FIGURE 3.39 Always point bucket teeth in the direction the machine will be digging to reduce digging resistance and the possibility of bucket teeth damage.

ALWAYS POINT BUCKET TEETH IN DIRECTION OF DIGGING

FIGURE 3.39 D. MAXIMUM DIGGING FORCE POSITION – FIGURE 3.40 The attachment will provide maximum digging force when the arm and boom are at 90 ° ~ 110 ° of each other.

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

90˚~110˚

FIGURE 3.40

3 — 16

Section III – BASIC MACHINE OPERATION E. CLEANING SAND & SOIL FROM BUCKET – FIGURE 3.41 Operate arm to a near level position and bring the bucket to a dumping position. If sand and soil do not fall out, move the bucket lever right and left a few times.

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

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

F. STOP SWING MOTION EARLY – FIGURE 3.42 To stop slewing action, release the swing lever before you get to your final point of digging or dumping.

FIGURE 3.41 RELEASE SWING BEFORE REACHING DESIRED DIGGING POSITION

G. BACK FILLING & LEVELING – FIGURE 3.43 For back filling and leveling work after digging, move the bucket back and forth horizontally.

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

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

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

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

4. Never travel with attachment touching the ground.

Severe structural damage could occur.

H. OPERATING THE SHOVEL – FIGURE 3.44 Digging with the shovel differs slightly from digging with backhoe.

1. Using the arm cylinder, scrape the ground.

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

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

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

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

FIGURE 3.42 USE ARM TO MOVE BUCKET HORIZONTALLY FOR LEVELING

FIGURE 3.43 GRADE AT 2 ° ~ 3 ° SLOPE FOR DRAINAGE

2˚~ 3˚

FIGURE 3.44

3 — 17

Section III – BASIC MACHINE OPERATION I. MACHINE OPERATION IN ADVERSE WEATHER CONDITIONS 1. Operation in Extreme Cold a. Follow procedures on page 3-2 as starting engine may be difficult due to extremely cold temperatures. b. Use an engine oil, hydraulic oil and diesel fuel designed for use in cold climates. See maintenance section, page 4-8 for reference. Also, keep battery fully charged. c. Make certain to perform machine warm-up procedures as described on page 3-6 to prevent premature wear or damage to pumps, motors and other components.

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

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

3.

4.

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

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

3 — 18

5.

6.

c. Keep all belts properly tensioned. d. Make certain that the engine coolant mixture is sufficient to keep the machine safe. e. If the machine becomes overheated, idle the machine to help cool the engine, turn engine “OFF” and check coolant level. After filling to proper level the machine continues to over heat, stop engine, allow to cool, drain and flush entire cooling system and refill with the proper mixture of fresh, clean coolant. f. Check the battery electrolyte (acid) level frequently and fill as necessary with distilled water. g. Keep a close watch on the gauge cluster for warning icons during operation. Avoid unnecessary low speed running of the engine during operation.

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

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

Be aware of this fact when placing machine under heavy load in high altitude climates. b. Keep close watch on the engine temperature gauge to avoid overheating of the engine.

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

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

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

Section III – BASIC MACHINE OPERATION 3.9 FLAGMAN HAND SIGNALS 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.

A. 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 3.45.

FIGURE 3.45 B. LOWER LOAD VERTICALLY Face machine operator, extend right arm down, point index finger down and move hand in a small circular motion. See Figure 3.46.

FIGURE 3.46 C. MOVE LOAD IN HORIZONTALLY Face machine operator, extend right arm toward operator with hand facing operator and move hand in direction of movement required. See Figure 3.47.

FIGURE 3.47 D. MOVE LOAD OUT HORIZONTALLY Face machine operator, extend right arm toward operator with back of hand facing operator and move hand in direction of movement required. See Figure 3.48.

FIGURE 3.48

3 — 19

Section III – BASIC MACHINE OPERATION E. RAISE BOOM Face machine operator, extend right arm out horizontally from shoulder, make a fist with thumb up. See Figure 3.49.

FIGURE 3.49 F. LOWER BOOM Face machine operator, extend right arm out horizontally from shoulder, make a fist with thumb down. See Figure 3.50.

FIGURE 3.50 G. SWING LEFT Face machine operator, extend right arm out horizontally from shoulder, make a fist with index finger pointing in swing direction. See Figure 3.51.

FIGURE 3.51 H. SWING RIGHT Face machine operator, extend left arm out horizontally from shoulder, make a fist with index finger pointing in swing direction. See Figure 3.52.

FIGURE 3.52

3 — 20

Section III – BASIC MACHINE OPERATION I. ARM IN Face machine operator, bend at elbows with arms facing operator, make fists and point thumbs in toward each other. See Figure 3.53.

FIGURE 3.53 J. ARM OUT Face machine operator, bend at elbows with arms facing operator, make fists and point thumbs out away from each other. See Figure 3.54.

FIGURE 3.54 K. COUNTER ROTATE LEFT Face machine operator, place right hand on top of hard hat, bend left arm at elbow to the right, make a fist with left hand with index finger pointing out and rotate hand in a reverse circular motion. See Figure 3.55.

FIGURE 3.55 L. 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 3.56.

FIGURE 3.56

3 — 21

Section III – BASIC MACHINE OPERATION M. TRAVEL FORWARD Face machine operator, bend both elbows in, make fists and rotate fists one over the other in a reverse circular motion. See Figure 3.57.

FIGURE 3.57 N. 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 3.58.

FIGURE 3.58 O. CLOSE BUCKET (BUCKET IN OR DIG) Face machine operator, hold left hand in,closed and stationary, hold right hand in, make a fist with index finger pointing toward left hand and move right hand in a small reverse circular motion. See Figure 3.59.

FIGURE 3.59 P. OPEN BUCKET (BUCKET OUT OR DUMP) Face machine operator, hold left hand in,open and stationary, hold right hand in, make a fist with index finger pointing toward left hand and move right hand in a small forward circular motion. See Figure 3.60.

FIGURE 3.60

3 — 22

Section III – BASIC MACHINE OPERATION Q. 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 3.61.

FIGURE 3.61 R. TURN RIGHT Face machine operator, raise left forearm up, make fist with left hand and hold stationary, bend right arm in, make fist with right hand and rotate right fist in a small forward circular motion. See Figure 3.62.

FIGURE 3.62 S. MOVE THIS MUCH Face machine operator, raise both forearms up, hands open and facing each other , move hands in laterally indicating how far to go. See Figure 3.63.

FIGURE 3.63 T. MOVE SLOWLY Face machine operator, raise left arm out horizontally toward right shoulder with hand open and facing down, point right index finger up toward open left hand and rotate right hand in a reverse circular motion. (Raise load slowly is illustrated.) See Figure 3.64.

FIGURE 3.64

3 — 23

Section III – BASIC MACHINE OPERATION U. STOP Face machine operator, raise left arm out horizontally from shoulder with hand open and facing down, move arm in a horizontal motion back and forth. See Figure 3.65.

FIGURE 3.65 V. EMERGENCY STOP Face machine operator, raise both arms out horizontally from shoulders with hands open and facing down, move arms in a horizontal motion back and forth. See Figure 3.66.

FIGURE 3.66 W. STOP ENGINE Face machine operator, right arm at side, draw left thumb or index finger across throat. See Figure 3.67.

FIGURE 3.67

3 — 24

Section IV – MAINTENANCE Table of contents 4.1 GENERAL INFORMATION ..................................................................................................................................... 4-1 4.2 GENERAL SAFETY ............................................................................................................................................... 4-1 4.3 INSPECTION AND MAINTENANCE CHART .......................................................................................................... 4-5 4.4 FLUIDS AND FILTERS .......................................................................................................................................... 4-8 4.5 PRE-START(EVERY 8 HOURS) INSPECTION & MAINTENANCE ........................................................................ 4-10 4.6 50 HOUR (WEEKLY) & NEW MACHINE BREAK-IN INSPECTION & MAINTENANCE PROCEDURES ................. 4-21 4.7 120 HOUR INSPECTION & MAINTENANCE PROCEDURE ................................................................................. 4-30 4.8 250 HOUR (3-MONTH) INSPECTION & MAINTENANCE PROCEDURE ............................................................... 4-32 4.9 500 HOUR INSPECTION & MAINTENANCE PROCEDURES ............................................................................... 4-34 4.10 2000 HOUR INSPECTION & MAINTENANCE PROCEDURES ........................................................................... 4-38 4.11 MISCELLANEOUS ............................................................................................................................................. 4-50

WARNING READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS AND PROCEDURES FOUND IN THIS MANUAL BEFORE ATTEMPTING ANY OPERATION, INSPECTION OR MAINTENANCE OF THIS MACHINE, ATTACHMENT OR SYSTEMS.

4—0

Section IV – MAINTENANCE 4.1 GENERAL INFORMATION

WARNING READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS CONTAINED IN THIS MANUAL BEFORE PERFORMING ANY INSPECTION OR MAINTENANCE PROCEDURES TO THIS MACHINE, ITS SYSTEMS OR COMPONENTS. A. It is recommended by the Manufacturer. that an inspection and maintenance schedule be developed and maintained on a regular basis for this machine. Developing and maintaining such a schedule, helps to keep the machine in optimum operating condition. See Figure 4.1.

FIGURE 4.1

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

NOTE The inspection and maintenance charts provided give only general time intervals. It may be necessary to develope a custom schedule to perform machine maintenance at more frequent intervals based on the work conditions.

FIGURE 4.2

Dispose of Waste Properly

C. Use only oils, fluids, lubricants, filters and replacement parts recomended by the Manufacturer to keep machine in optimum operating condition. See Figure 4.2.

4.2 GENERAL SAFETY A. DISPOSAL OF HAZARDOUS WASTE – FIGURE 4.3 Dispose of waste oils, fluids, lubricants, filters and other hazardous waste properly.

FIGURE 4.3

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

B. KEEP MACHINE CLEAN – FIGURE 4.4 Thoroughly clean machine before performing inspection and maintenance procedures. It is easier and safer locate problems, perform maintenance and also reduces the risk of hydraulic system contamination when machine is clean.

FIGURE 4.4

4—1

Section IV – MAINTENANCE C . HOT SURFACES & FLUIDS – FIGURE 4.5 Use caution and wear the proper safety equipment when working around hot areas. Never change oils, engine coolant or filters immediately after a machine has been stopped. Allow machine to cool before performing maintenance procedures.

D . WARM ENGINE OIL Engine oil should have a temperature of between 20 °C ~ 40 °C (68 °F ~ 104 °F) before the oil is changed. If necessary run engine until the oil is warm within the recommended oil change temperature.

FIGURE 4.5

E . “TAG-OUT” MACHINE – FIGURE 4.6 Before beginning any inspection or maintenance procedures, secure a “DO NOT OPERATE” tag to the operator’s console to inform the operator that the machine will be inoperable for inspection and maintenance.

This tag will help prevent accidental starting of the machine.

DO NOT OPERATE

F . INSPECT WASTE OILS AND FILTERS – FIGURE 4.7 Before disposal, inspect all waste oils, fluids and filters for debris and foreign material.

It is recommended to cut open the oil filters to determine any abnormal wear.

FIGURE 4.6

G. PREVENT CONTAMINATION – FIGURE 4.8 Always cap or plug lines when hydraulic components are removed to help prevent hydraulic system contamination that can be caused by dirt, dust and debris entering a line or port.

CHECK FOR DEBRIS

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

FIGURE 4.7

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

FIGURE 4.8

4—2

Section IV – MAINTENANCE I. STOP ENGINE Never attempt any MAINTENANCE with engine running.

Always stop the engine and allow machine to cool.

J. WEAR SAFETY EQUIPMENT – FIGURE 4.9 Wear hard hat, safety goggles or face shield, work gloves, safety shoes and well fitting work clothes when performing inspection and maintenance procedures on this machine.

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

FIGURE 4.9

DEPRESS RUBBER CAP TO RELEASE PRESSURE

WARNING NEVER USE GASOLINE, DIESEL FUEL OR OTHER FLAMMABLE SOLVENTS TO CLEAN PARTS. ALWAYS CLEAN PARTS IN A WELL VENTILATED AREA. L. HYDRAULIC TANK PRESSURE Always release the internal pressure of the hydraulic tank before performing inspection or maintenance procedures.

HYDRAULIC TANK

FIGURE 4.10

1. Push rubber cap “DOWN” to release air pressure in the reservoir. See Figure 4.10.

CAUTION Gasses from hydraulic tank may be hot.

Wear safety equipment.

M. WELDING SAFETY KEY SWITCH IN "OFF"- POSITION

1. Turn key switch to “OFF” position. Wait 4 seconds for electrical power to disconnect. See Figure 4.11.

FIGURE 4.11 2. Remove negative (-) cable from battery terminal.

See Figure 4.12.

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

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

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

FIGURE 4.12

4—3

Section IV – MAINTENANCE N. RELEASING INNER PRESSURE IN HYDRAULIC SYSTEM

WARNING NEVER CHANGE OILS OR FILTERS ON A MACHINE THAT HAS JUST FINISHED WORKING. ALLOW MACHINE TO COOL FIRST UNTIL OILS AND FLUIDS ARE WARM NOT HOT. RELEASE HYDRAULIC TANK PRESSURE BEFORE WORKING WITH ANY HYDRAULIC COMPONENT. FIGURE 4.13 1. Select the hard and flat area and place the machine in the position shown in Figure 4.13.

DEPRESS RUBBER CAP TO RELEASE PRESSURE

2. Stop the engine.

3. Immediately after the engine stops, shift the R.H. and L.H. travel control levers shift forward and backward, operate the R.H. and L.H. control levers in full stroke several times, and release the internal pressure remaining in the hydraulic system.

4. Press valve with rubber cap on the upper surface of hydraulic tank several times (5 or 7 times) and release the pressure in the hydraulic tank. See Figure 4.14.

HYDRAULIC TANK

FIGURE 4.14

5. Make sure that the pressure in the hydraulic tank is released completely, and after that carry out the inspection and maintenance of hydraulic tank.

4—4

Section IV – MAINTENANCE 4.3 INSPECTION AND MAINTENANCE CHART

WARNING

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

SYSTEM

MAINTENANCE TO PERFORM

READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS FOUND IN THIS MANUAL BEFORE PERFORMING INSPECTION & MAINTENANCE.

COMPONENT LOCATION

INTERVAL (HOURS ON HOUROMETER) 8

50

120

250

CHECK OIL LEVEL CHECK COOLANT LEVEL CHECK FOR FLUID LEAKS CHECK BELT TENSION

ON SIDE OF ENGINE RESERVOIR COMPLETE ENGINE FRONT OF ENGINE FUEL TANK CHECK FUEL LEVEL GAUGE CLUSTER AIR CLEANER CHECK AIR CLEANER CHECK ENGINE ELECTRICAL COMPLETE ENGINE DRAIN WATER FROM FUEL FUEL TANK BOTTOM OIL PAN CHANGE ENGINE OIL L.H. SIDE OF ENGINE CHANGE OIL FILTER L.H. SIDE OF ENGINE CHANGE FUEL FILTER ENGINE

DRAIN WATER SEPARATOR CHECK AIR INTAKE SYSTEM CHECK FAN ASSEMBLY CHECK BELT TENSIONER

R.H. SIDE OF ENGINE HOSES & CLAMPS FRONT OF ENGINE FRONT OF ENGINE RADIATOR CLEAN RADIATOR BETWEEN RADIATOR CLEAN DEBRIS SCREEN AND OIL COOLER CHANGE ENGINE COOLANT RADIATOR & ENGINE CHANGEAIRCLEANERELEMENTS

AIR CLEANER

ADJUST VALVE CLEARANCE CHECK ENGINE COMPRESSION CHECK INJECTION PRESSURE CHECK INJECTION TIMING LUBRICATE WATER PUMP

ENGINE TOP ENGINE ENGINE ENGINE ENGINE

CHECKSTARTERANDALTERNATOR

ENGINE HYDRAULIC TANK SIDE OF HYD TANK

PILOT LINE FILTER HYDRAULIC OIL LEVEL CHECK HYD FUNCTIONS

HYDRAULIC

OPERATOR'SCONTROLS

HYDRAULIC SYSTEM

CHECK FOR OIL LEAKS CHECK HOSES/LINES CLEAN SUCTION SCREEN

HYDRAULIC SYSTEM HYDRAULIC TANK

CHANGE RETURN FILTERS

HYDRAULIC TANK (Breaker)

CHANGE RETURN FILTERS

HYDRAULIC TANK

CHANGE HYDRAULIC TANK BREATHER

HYDRAULIC TANK

CHANGE HYDRAULIC OIL CLEAN HYDRAULIC TANK

HYDRAULIC TANK HYDRAULIC TANK

••• Regular inspection & maintenance required.

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

4—5

(Breaker) (Breaker)

500 1000 2000

Section IV – MAINTENANCE SYSTEM

MAINTENANCE TO PERFORM

INSPECT ALL WIRING ELECTRICAL BATTERY ELECTROLYTE BATTERY SERVICE HYD. FUNCTION OPERATION

UPPER FRAME

COMPONENT LOCATION

INTERVAL (HOURS ON HOUROMETER)

COMPLETE MACHINE BATTERIES BATTERIES OPERATOR'SCONTROLS

CHECK SWITCHES CHECK SWING BRAKE

CONTROL PANELS

CHECK WARNING LIGHTS CHECK GAUGES CHECK HORN CHECK GAUGE CLUSTER CHECK SWING REDUCTION OIL LEVEL & FILL CHECK BOLTS/TORQUE CHECK SLEWING RING & PINION GEAR CHECK SLEWING RING SEAL CHECK SWIVEL JOINT SEALS

CAB/FRAME/BOOM GAUGE CLUSTER HORN SWITCH GAUGE CLUSTER

OPERATOR'SCONTROLS

UPPER FRAME SLEWING RING SIGHT WINDOW ON CENTER SECTION

SLEWING RING SWIVEL JOINT DRAIN WATER FROM SLEWING LOWER FRAME CAVITY DRAIN PORT RING GREASE BATH SLEWING RING GREASE SLEWING RING CHANGE GREASE IN SLEWING REMOVE UPPER FRAME RING GREASE BATH

CHANGE SWING REDUCTION SWING MOTOR UNIT OIL CHECK BOLTS/TORQUE COUNTERWEIGHT CHECK FOR OIL LEAKS COMPLETE SYSTEM CHECK LINES FOR DAMAGE FRAME CAVITY CHECK STEPS & HANDRAILS FRAME RAILS CHECK FRAME STRUCTURE ENTIRE FRAME TRACKS CHECK TRACKS & LINKS CHECK SPROCKET WEAR REAR OF TRACKS CHECK IDLER WEAR FRONT OF TRACKS

LOWER FRAME

CHECK ROLLER WEAR CHECK TRACK TENSION ADJUST TRACK TENSION CHECK TRAVEL REDUCTION UNIT OIL LEVEL & FILL CHANGE TRAVEL REDUCTION UNIT OIL CHECK BOLTS/HARDWARE

TRACKS RAISE TRACKS FRAME RAILS TRAVEL MOTORS TRAVEL MOTORS ENTIRE MACHINE

••• Regular inspection & maintenance required.

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

4—6

8

50

120

250

500 1000 2000

Section IV – MAINTENANCE

SYSTEM

MAINTENANCE TO PERFORM CHECK BOOM & ARM STRUCTURE CHECK BUCKET TEETH & SIDE CUTTERS

ATTACHMENT GREASE BOOM PINS

ACCESSORIES

COMPONENT LOCATION BOOM & ARM BUCKET BOOM

GREASEARM PINS

ARM

GREASE BUCKET PINS

ARM & BUCKET LINK

CHECK A/C REFRIGERANT CHECKA/C COMPRESSOR BELT & ADJUST CHECKA/C CONDENSER AND CLEAN CHECKA/C FRESH AIR FILTER CHECKA/C RECIRCULATE AIR FILTER CHECK WIPER WASHER FLUID LEVEL CHECK BOLTS/TORQUE

CLIMATE CONTROL-A/C ENGINE RADIATORCOMPARTMENT

CAB CAB AIR CLEANER COMPARTMENT CLIMATE CONTROLA/C SYSTEM

••• Regular inspection & maintenance required.

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

4—7

INTERVAL (HOURS ON HOUROMETER) 8

50

120

250

500 1000 2000

Section IV – MAINTENANCE 4.4 FLUIDS AND FILTERS The following charts list all the necessary lubricants, oils, greases, fuels, coolants and filters required for the hydraulic excavators. Also a chart is provided giving specific information for the proper lubricants, oils, greases, fuels and coolants to be used in certain climates. Contact the Dealer to order the required filters, fluids and lubricants.

A. REQUIRED FLUIDS AND QUANTITIES TYPE OF FLUID

LOCATION OF USE

206 Liters (54 GAL)

HYDRAULIC SYSTEM

351Liters (93 GAL)

ENGINE OIL PAN (H LEVEL)

28 Liters (7.4 GAL)

ENGINE OIL PAN (L LEVEL)

23 Liters (6.1 GAL)

UPPER ROLLER

100cc X 4 (6.1cu.in X 4)

LOWER ROLLER

430cc X 14 (26cu.in) X 14 430cc X 18 (26cu.in) X 18...LC,NLC

IDLER

350cc X 2 (21.4cu.in X 2)

ENGINE OIL

SWING MOTOR REDUCTION UNIT

21.5 Liter (5.7 GAL)

TRAVEL MOTOR REDUCTION UNIT

10.5 Liter X 2 (2.8 GAL X 2)

OPERATING LEVER JOINT

"U" JOINT EACH SIDE

ATTACHMENT PINS

16 PLACES

EP GREASE SLEWING RING GEAR TRACK TENSION ADJUSTMENT WITH LITHIUM SWING GEAR BASE MoS2 SUMP (BATH) GREASE ENGINE COOLANT

DIESEL FUEL

QUANTITIES REQUIRED

HYDRAULIC TANK HYDRAULIC

GEAR OIL

B. REQUIRED FILTERS LOCATION OF FILTER USE RETURN FILTER ELEMENT KIT (STD)

RETURN FILTER ELEMENT KIT (BREAKER)

HYDRAULIC RETURN FILTER ELEMENT KIT (STD & BREAKER)

TANK SUCTION STRAINER TANK BREATHER FILTER ELEMENT PILOT LINE FILTER ELEMENT ENGINE OIL FILTER CARTRIDGE AIR CLEANER ENGINE INNER ELEMENT AIR CLEANER OUTER ELEMENT ENGINE FUEL FILTER CARTRIDGE FUEL ENGINE FEED PUMP GAUZE FILTER AIR-CON FILTER OPERATOR (OUTER) CAB AIR-CON FILTER (INNER)

1 PLACE 90° X 4 2 PLACES AS REQ'D 15.7 kg (34.6 lbs)

RADIATOR

15 Liters (4 GAL)

COOLING SYSTEM TOTAL VOLUME

34 Liters (9 GAL)

FUEL TANK

SYSTEM

C. FLUIDS AND LUBRICANTS DESCRIPTION ENGINE OIL-SAE 15W/40 (1 GALLON) ENGINE OIL-SAE 15W/40 (5 GALLON) ENGINE OIL-SAE 15W/40 (55 GALLON) HYDRAULIC OIL-AW 46 (5 GALLON) HYDRAULIC OIL-AW 46 (55 GALLON) GREASE EP/2-14 OUNCE GREASE EP/2-35 POUNDS GREASE EP/2-120 POUNDS GEAR OIL 80W90-5 GALLONS

560 Liters (148 GAL)

4—8

Section IV – MAINTENANCE D. LUBRICANT SPECIFICATIONS The following information is designed to allow usage of the proper oils, greases, fuels and coolants in various climates and certain working conditions.

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

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

FRIGID -20°C~30°C (-4°F~86°F)

ISO VG22

ISO VG32

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

LUBRICANT ENGINE OIL (FOR GENERAL PURPOSE LUBRICATION)

LUBRICANT GEAR OIL

ISO VG32S*

ISO VG46

VERY HOT 5°C~55°C (41°F~131°F) ISO VG68

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

WARM -5°C~40°C (23°F~104°F)

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

SAE10W30

SAE15W40

SAE15W50

LUBRICANT FUEL

WARM FRIGID~WARM -5°C~40°C -25°C~40°C (-13°F~104°F) (23°F~104°F)

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

WARM -5°C~-15°C (23°F~5°F)

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

ASTM D975 No.2

ASTM D975 No.2

FOR ROLLERS AND IDLERS ON ALL MODELS. A.P.I. Classification for "Service CD"-SAE30 FOR SWING MOTOR REDUCTION UNIT AND TRAVEL MOTOR REDUCTION UNITS ON THE FOLLOWING MODELS : E335(LC), (NLC) EXTREME PRESSURE GEAR OIL #90 GRADE GL-4 BY A.P.I. CLASSIFICATION

LUBRICANT

GENERAL LUBRICATION

SWING GEAR SUMP (BATH)

GREASE

EXTREME PRESSURE MULTIPURPOSE GREASE No.2 EP TYPE GREASE

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

LUBRICANT ENGINE COOLANT (50% MIXTURE)-EU (30% MIXTURE)-OCEANIA

ANTIFREEZE (LLC) -34°C (-29.2°F) MIXTURE RATIO SHOULD PROSPECT TO 5°C (41°F) LOWER THAN THE COLDEST TEMPERATURE THE MACHINE WILL EXPERIENCE. TAKE INTO CONSIDERATION WIND CHILL FACTORS.

NOTE: Use of Bio-degradable Oils When you use Bio-degradable Oil (BIO OIL), refer to the following information.

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

2. Do not mix either type of BIO OIL with the original factory-filled mineral oil. The hydraulic system has to be flushed three times if you want to use BIO OIL instead of the factory-filled mineral oil.

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

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

4—9

Section IV – MAINTENANCE 4.5 PRE-START(EVERY 8 HOURS) INSPECTION & MAINTENANCE The following procedures are to be performed every 8 hours or daily, before the machine is started.

ENGINE OIL FILLER CAP

WARNING ENGINE OIL DIPSTICK ON SIDE OF ENGINE

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.

H

A. ENGINE OIL LEVEL L

1. Raise engine bonnet.

BETWEEN LOW & HIGH IS 5 LITER

2. Locate and pull engine dipstick. Clean it with a clean, dry, lint free cloth. Reinsert into engine. Pull out and visually inspect the engine oil level on dipstick. See Figure 4.15.

FIGURE 4.15

3. If necessary to add oil, remove oil filler cap and fill engine oil to proper level. See Figure 4.15 and refer to page 4-9 for oil specifications.

ENGINE COOLANT RESERVOIR

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

FULL PROPER LEVEL

B . ENGINE COOLANT LEVEL

LOW

1. Open engine access cover and inspect coolant level in engine coolant reservoir. See Figure 4.16.

FIGURE 4.16 2. Proper coolant level is between “FULL” and “LOW” marks. See Figure 4.16.

RADIATOR CAP

3. If necessary to add coolant, remove reservoir cap and fill to proper level with fresh coolant. See Figure 4.16 and refer to page 4-8 for proper coolant specifications.

4. If no coolant is in reservoir, check coolant level in radiator. Fill radiator with proper coolant mixture and replace cap. See Figure 4.17. Then fill reservoir to proper level.

WARNING DO NOT REMOVE WHEN ENGINE IS HOT

NEVER REMOVE RADIATOR CAP WHEN ENGINE IS HOT. ALLOW ENGINE TO COOL BEFORE REMOVING RADIATOR CAP.

FIGURE 4.17

4 — 10

Section IV – MAINTENANCE C . ENGINE FLUID LEAKS

USE TOTO CHECK USECARDBOARD CARDBOARD CHECK FOR LEAKS FORPRESSURE PRESSURE LEAKS

1. Inspect complete engine for signs of fluid leaks.

2. When inspecting around pressure lines and hoses use a stiff piece of cardboard. See Figure 4.18.

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

FIGURE 4.18 D . FAN BELT WEAR AND TENSION Inspect belt tensioner assembly on a new machine after the first 50 hours of operation. Then at every 250 hours of engine operation.

FAN PULLEY

ALTERNATOR

1. Measure belt tension on longest span of belt. Belt deflection should be 8mm ~ 15mm.

BELT Fan belt Air conditioner

Force: approx. 98N (22lbf, 10kgf)

DEFLECTION 8 mm ~ 15 mm (0.3“ ~ 0.6“) 7 mm ~ 10 mm (0.3“ ~ 0.4“)

2. Loosen mounting nut and adjusting nut, and adjust tension of belt. See Figure 4.20.

COMPRESSOR

CRANK PULLEY

FIGURE 4.19 3. Loosen adjusting bolt, adjust fan belt to the specified tension, and tighten mounting nut and adjusting nut. See Figure 4.20.

ADJUSTING BOLT

MOUNTING NUT 8,4 ± 1,0 kgf•m (61 ± 7 lbf•ft)

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

5. Adjust the tension of belt of air conditioner turning adjusting bolt of idle pulley. Figure 4.20.

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

ADJUSTING NUT 7,7 ± 1,5 kgf•m (56 ± 11 lbf•ft)

Force: approx. 98N (22lbf, 10kgf)

FIGURE 4.20

4 — 11

Section IV – MAINTENANCE E . AIR CLEANER

9

CAUTION

REST’D AIR CLEANER

Wear protective glasses or goggles when using compressed air.

NOTE • 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 4.21, inspect, clean, and/or replace the air cleaner elements.

• The removal and cleaning of inner element are not allowed. It may cause engine trouble due to the entry of dust.

• When replacing element, cover the engine intake port

FIGURE 4.21

ENGINE AIR CLEANER ACCESS DOOR

SUPPLEMENTARY EXPLANATION Cleaning and replacement of outer element.

Cleaning ......... When warning is indicated on multidisplay Replacement .. After cleaning of 6th time or an elapse of 1 year

FIGURE 4.22

1. Cleaning or Replacement of Outer Element WING NUT

a. Open engine air cleaner access door with starter switch key. See Figure 4.22 b. Loosen the wing nut, remove the cover. See Figure 4.23. c. Loosen the wing nut, and then pull out the outer element. See Figure 4.24.

COVER

FIGURE 4.23

d. Clean the inside of air cleaner housing. e. To clean the outer element, blow compressed air {less than 7 kgf/cm2 (100psi)} up and down along the folds of the filter element interior to remove clogged dust or other contaminants. See Figure 4.25.

OUTER ELEMENT

f. After cleaning, use a light to check the inside of the element for tearing, pinholes, or packing damage.

Replace with a new element if necessary.

WING NUT

FIGURE 4.24

4 — 12

Section IV – MAINTENANCE g. Set outer element, and install cover. h. If the restricted icon appears on the multi display within the 6 times cleaning of outer element, replace the element with new one.

FIGURE 4.25

2. Replacement of Inner Elements a. Loosen the wing nut, remove the inner element. See Figure 4.26. b. Set new inner and outer elements, and install the cover.

WING NUT

GEAR OIL CAN INNER ELEMENT

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

See Figure 4.24 and 4.26.

FIGURE 4.26

F . ENGINE ELECTRICAL 1. Visually and manually inspect all engine electrical wiring, connectors and components for signs of damage and malfunction. See Figure 4.27.

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

WARNING

NEGATIVE (-) CABLE

REMOVE CELL CAPS

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 4.27

4 — 13

Section IV – MAINTENANCE G. FUEL LEVEL 1. Right hand fuel tank side and view the fuel level gauge on side of fuel tank. See Figure 4.28.

2. The fuel tank can be filled through the fuel filler cap located on top of the fuel tank or by using the auxiliary fuel pump located the Battery access cover in side.

FUEL LEVEL GAUGE

a. Filling tank through fuel filler cap Open fuel filler cap with key switch key and fill tank to proper level with diesel fuel. See Figure 4.29 and refer to page 4-8 for fuel specifications.

FIGURE 4.28 b. Filling tank using auxiliary fuel pump 1. Open battery access cover, remove the filter end of the fuel pump suction hose from its storage housing and insert the fuel suction hose into fuel supply reservoir. See Figure 4.29.

2. Locate the auxillary fuel pump switch inside the storage box access door. Place the switch in the “ON” position. See Figure 4.30. Place pump switch in the “OFF” position when fuel tank is full.

FUEL PUMP SUCTION HOSE

NOTE Delivery rate of the auxiliary fuel pump is 30 liters per minute.

• Do not pump petrol on products with flashpoints below 37 °C (98.6 °F).

• Do not run dry for more than 30 seconds.

FIGURE 4.29 3. After removing fuel delivery hose from fuel supply reservoir, coil hose and place filter into its storage housing. Replace fuel strainer and fuel filler cap.

NOTE • The suction head of fuel pump is approx. 2.5 m (7.5 feet) locate the fuel drum as near as possible to the machine.

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

FUEL PUMP SWITCH FUEL PUMP SWITCH

FIGURE 4.30

NOTE The capacity of fuel pump was changed to 50 Liter/min.

4 — 14

Section IV – MAINTENANCE H . HYDRAULIC OIL LEVEL 1. Place the machine in the oil check position on a firm surface as shown in Figure 4.31.

HYDRAULIC OIL CHECK POSITION

FIGURE 4.31 2. Right hand hydraulic oil tank side cover and view the hydraulic oil level in the sight glass on side of hydraulic oil tank. See Figure 4.32.

WARNING FOR SAFE OPERATION ON INCLINES, THE HYDRAULIC OIL LEVEL MUST BE MAINTAINED BETWEEN “PROPER LEVEL” AND “UPPER LIMIT” MARK.

UPPER LIMIT PROPER LEVEL LOW (ADD OIL)

3. Use the following instructions to add hydraulic oil: FIGURE 4.32 a. Release hydraulic tank pressure. See Figure 4.33.

DEPRESS RUBBER CAP TO RELEASE PRESSURE

CAUTION Gasses from hydraulic tank may be hot. Wear safety equipment. b. Remove the six mounting bolts from the hydraulic suction screen cover plate. See Figure 4.34. c. Add hydraulic oil through the suction screen, filling hydraulic tank to the proper level. See Figure 4.34.

HYDRAULIC TANK

FIGURE 4.33 d. Before replacing filter cover, replace “O”-ring. See Figure 4.34. e. Place new “O”-ring in seat. Place cover over opening and install mounting bolts with lockwashers.

REPLEACE “O”-RING

SLOWLY REMOVE BOLTS & COVER

f. Torque mounting bolts to proper value. Refer to torque specifications table.

WARNING

ADD CLEAN OIL

CLEAN UP ALL SPILLED OIL TO PREVENT FIRES. DISPOSE OF HAZARDOUS WASTE ACCORDING TO ENVIRONMENTAL LAWS AND REGULATIONS. FIGURE 4.34

4 — 15

Section IV – MAINTENANCE I . HYDRAULIC FUNCTIONS

CHECK ALL CONTROLS FOR PROPER FUNCTION

1. Check all hydraulic controls for proper function before operating the machine. See Figure 4.35.

WARNING NEVER OPERATE THE MACHINE WITH A FAULTY CONTROL OR FUNCTION. MAKE ALL NECESSARY REPAIRS BEFORE ALLOWING ANY OPERATION. J . HYDRAULIC OIL LEAKS FIGURE 4.35 1. Check complete hydraulic system for leaks. Use a small piece of cardboard when checking areas with high pressure. See Figure 4.36.

USE CARDBOARD TO CHECK FOR PRESSURE LEAKS

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

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

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

FIGURE 4.36

WARNING CHECK AND REPLACE ANY BROKEN WIRES

CLEAN UP ALL SPILLED OIL TO PREVENT FIRES. DISPOSE OF HAZARDOUS WASTE ACCORDING TO ENVIRONMENTAL LAWS AND REGULATIONS. K . MACHINE ELECTRICAL 1. Check all switches for proper operation.

CHECK ALL GAUGES AND LCD DISPLAY

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

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

4. Check all gauges and LCD display on the gauge cluster panel for proper operation. See Figure 4.37.

WARNING DAMAGED OR FAULTY ELECTRICAL COMPONENTS CAN CAUSE SEVERE DAMAGE TO THE MACHINE AND CAUSE SERIOUS PERSONAL INJURY OR DEATH. FIGURE 4.37

4 — 16

Section IV – MAINTENANCE L . STEPS AND HANDRAILS

KEEP STEP CLEAN AND IN GOOD CONDITION

1. Carefully inspect all mounting steps and handrails on the machine to make sure they are clean and in safe working condition. See Figure 4.38.

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

CAUTION

USE GRIP BARS AND STEP RAILS

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

FIGURE 4.38

M. FRAME STRUCTURE DISCONNECT BATTERY NEGATIVE (-) CABLE WHEN INSPECTING ELECTRICAL OR WELDING

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

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

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

FIGURE 4.39

CHECK FOR BEND

WARNING DISCONNECT BATTERIES BEFORE WELDING ON THIS MACHINE. SEE FIGURE 4.39. CONNECT WELDER GROUND CABLE 1 M (3’ - 3”) AWAY FROM AREA TO BE WELDED.

CHECK SHOE WEAR

FIGURE 4.40 N . TRACKS AND COMPONENTS 1. Track shoes a. Visually inspect track shoes for signs of excessive wear or damage. See Figure 4.40. b. Have all repair or replacement work done by the Dealer.

TORQUE BOLTS

c. Check tightness of shoe attaching bolts and nuts.

If loose, torque to 120 ± 12 kgf·m (867 ± 87 lbf·ft).

See Figure 4.41.

FIGURE 4.41

4 — 17

Section IV – MAINTENANCE 2. Track links a. Inspect links for signs of excessive wear or damage. See Figure 4.42.

INSPECT TRACK LINK ASSEMBLIES

b. Have all repair or replacement work done by the Dealer.

FIGURE 4.42 INSPECT THESE BOLTS

3. Sprockets a. Inspect sprockets for excessive wear and damage. See Figure 4.43. b. Should the sprockets require service, contact the Dealer. c. Check and make sure all sprocket bolts are properly tightened.

INSPECT THESE SURFACES

FIGURE 4.43 4. Idlers a. Inspect idlers for excessive wear and damage. See Figure 4.44. b. Should the idlers require service, contact the Dealer.

INSPECT THESE SURFACES

FIGURE 4.44 5. Rollers

LOWER ROLLER

UPPER ROLLER INSPECT THESE SURFACES

a. Inspect rollers for excessive wear and damage.

See Figure 4.45. b. Should the rollers require service, contact the Dealer.

INSPECT THESE SURFACES

FIGURE 4.45

4 — 18

Section IV – MAINTENANCE O. TRACK TENSION 1. Operate swing, arm, bucket and boom controls until machine is set up as shown in Figure 4.46.

MACHINE POSITION

WARNING SUPPORT LOWER FRAME WITH SUITABLE BLOCKS. 2. In center of track, measure the distance between the bottom of frame rails and surface of shoe. See Figure 4.47.

FIGURE 4.46

3. Perform steps 1 and 2 on right track.

4. To increase track tension, set machine as shown in Figure 4.46 and with grease gun inject extreme pressure No.2 grease into idler adjustment grease nipple until proper tension is reached. See Figure 4.48. Perform this procedure on both tracks.

NOTE After injecting grease, operate the travel control forward and reverse for the track being adjusted. This will balance the tension between the idler and the sprocket. Then re-measure as shown in Figure 4.47.

320 ~ 350 mm (12.6” ~ 13.8”)

FIGURE 4.47

5. To decrease track tension, set machine up as shown in Figure 4.46.

6. Carefully loosen the adjusting grease nipple to allow grease to escape. See Figure 4.48.

WARNING GREASE IN TRACK TENSIONING MECHANISM IS UNDER EXTREME PRESSURE AND CAN PENETRATE SKIN CAUSING SEVERE INJURY. KEEP FACE AND BODY AWAY FROM GREASE NIPPLE AREA. NEVER LOOSEN GREASE NIPPLE MORE THAN ONE COMPLETE TURN. IF GREASE DOES NOT RELEASE AFTER ONE TURN OF THE NIPPLE, CALL AN AUTHORIZED SERVICE DEALER FOR ASSISTANCE.

TRACK ADJUSTING GRASE NIPPLE

FIGURE 4.48

7. Tighten grease nipple, measure track tension as shown in Figure 4.48.

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

4 — 19

Section IV – MAINTENANCE P . BOOM AND ARM 1. Inspect boom and arm structures for signs of excessive wear and damage. See Figure 4.49.

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

INSPECT BOOM & ARM FOR DAMAGE

FIGURE 4.49

WARNING DISCONNECT BATTERIES BEFORE WELDING ON THIS MACHINE. SEE FIGURE 4.50. CONNECT WELDER GROUND CABLE 1 M (3’ - 3”) AWAY FROM AREA TO BE WELDED.

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

FIGURE 4.50

Q. CUTTING EDGE, BUCKET TEETH & SIDE CUTTERS 1. Inspect bucket teeth and side cutters for signs of excessive wear and damage. See Figure 4.51.

INSPECTING TEETH AND SIDE CUTTER FOR DAMAGE

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

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

FIGURE 4.51

3. Should repair or replacement be required, contact the Dealer for proper advice.

4 — 20

Section IV – MAINTENANCE 4.6 50 HOUR (WEEKLY) & NEW MACHINE BREAK-IN INSPECTION & MAINTENANCE PROCEDURES

LOOSEN BOLTS TO LOWER COVER

Change the engine oil and filter on a new machine after the first 50 hours of operation. Then change the engine oil at every 500 hours of operation.

NOTE One new oil filter is shipped with the machine in the support kit. This is to be used at the 50 hour oil & filter change.

REMOVE BOLTS AND LOWER COVER

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

FIGURE 4.52

WARNING DO NOT CHANGE OIL ON A MACHINE THAT HAS JUST STOPPED WORKING. THE OIL WILL BE EXTREMELY HOT. ALLOW THE ENGINE TO COOL UNTIL OIL IS JUST WARM BEFORE CHANGING.

NOTE • Check the waste oil. If there are metal chips or powder mixed in the oil, contact the Dealer.

• The oil filter can not be reused because it is cartridge type.

2. Remove the four mounting bolts from the engine lower cover plates. See Figure 4.52.

3. Place the oil container under the filter.

4. Remove the oil filter by turning counterclockwise.

See Figure 4.53.

5. To install the oil filter, apply a thin coat of engine oil to the gasket of the oil filter, and then secure the filter by tightening prescribed number of rotations after the gasket comes in contact with the oil filter head. See Figure 4.54.

6. When replacing the element only, and not the engine oil, the amount of oil to be added is shown below.

Partially fill filter with oil before installing.

Oil volume ...... Approx. 1.1 Lit (0.29 Gal) 7. Start engine, operate it at idling operation for several minutes. Then check filter fitting section for oil leakage.

8. Install cover just below the engine to the regular position.

4 — 21

ENGINE OIL FILTER

FIGURE 4.53

APPLY CLEAN ENGINE OIL

FIGURE 4.54

Section IV – MAINTENANCE B . ENGINE OIL 1. Move the machine to a firm, level surface and run engine for 5 minutes to warm the oil.

LOOSEN BOLTS TO LOWER COVER

WARNING DO NOT CHANGE OIL ON A MACHINE THAT HAS JUST STOPPED WORKING. THE OIL WILL BE EXTREMELY HOT. ALLOW THE ENGINE TO COOL UNTIL OIL IS JUST WARM BEFORE CHANGING. REMOVE BOLTS AND LOWER COVER

2. Remove the six retaining bolts from the oil pan access cover on the bottom, rear center of machine. See Figure 4.55.

3. Raise engine bonnet and remove oil filler cap.

See Figure 4.56.

4. Place a 30 liter (7.9 Gal) capacity container under oil pan. Remove engine oil drain plug. See Figure 4.57.

5. Install engine oil drain plug.

6. Refer to page 4-8 for the proper oil to use and fill engine oil to proper level.

• Total oil volume to be replaced: 28 liters (7.4 Gal) 7. Install oil filler cap. Clean up all spilled oil.

8. Start engine, run for 5 minutes. While running, check for oil leaks.

9. Should any oil leaks be found, repair immediately and refill with proper oil.

10.Check oil level and close cover.

FIGURE 4.55

ENGINE OIL FILLER CAP ENGINE OIL DIPSTICK ON SIDE OF ENGINE

H L

CAUTION

BETWEEN LOW & HIGH IS 5 LITER

Dispose of all hazardous waste in accordance with government environmental regulation.

FIGURE 4.56

CAUTION ENGINE OIL DRAIN PLUG Do not over tighten at install plug standard tightening torque = 5~8 kgf·m. (After tightening by hand, tighten with ratchet wrench at angle of 15°~30°.) standard tool : l = 250 mm middle type ratchet wrench

ENGINE OIL DRAIN PLUG

FIGURE 4.57

4 — 22

Section IV – MAINTENANCE C . FUEL TANK DRAIN 1. Locate and open fuel tank drain valve on bottom of fuel tank. See Figure 4.58.

2. Allow all water and sediment to drain from fuel tank into a waste container, then close the drain valve.

FIGURE 4.58 AIR PLUG

D . WATER SEPARATOR The water separator isolates water that mixes in with the fuel. The case is equipped with a float. When water accumulates, the float rises. When the float rises to the level line, drain the water. See Figure 4.59.

WATER SEPARATOR

1. Loosen the drain plug to drain the water.

2. When the float comes down to the bottom, close the drain plug.

3. Check that fuel is not leaking.

Drain water whenever the float rises to the level line, regardless of inspection time.

LEVEL LINE FLOAT (RED)

DRAIN PLUG

FIGURE 4.59

CAUTION Clean up all spilled fuel to avoid a fire.

Dispose of all hazardous waste in accordance with govemment environmental regulation, laws and codes.

E . AIR INTAKE SYSTEM Inspect all hoses and clamps of the air intake system on a new machine after the first 50 hours of operation.

Then at every 500 hours of engine operation.

1. Inspect all hoses for damage and tighten all hose clamps. See Figure 4.60.

2. Replace any hose found to be damaged before allowing any operation of the machine.

HOSE & CLAMPS FROM AIR CLEANER

FIGURE 4.60

4 — 23

Section IV – MAINTENANCE F . RADIATOR, OIL COOLER AND DEBRIS SCREEN

ENGINE COOLANT TANK ACCESS DOOR

1. Clean radiator after every 50 hours of operation using pressurized water.

2. Open engine air cleaner access door and engine bonnet for cleaning the radiator and oil cooler. See Figure 4.61.

RADIATOR SUB TANK ACCESS DOOR ENGINE AIR CLEANER ACCESS DOOR

FIGURE 4.61 3. Open engine bonnet and remove the wing bolts retaining the debris screen. See Figure 4.62. Carefully remove debris screen and clean with pressurized water.

ENGINE BONNET

ENGINE RADIATOR ACCESS DOOR

FIGURE 4.62 4. Remove wash out access cover from bottom of machine. See Figure 4.63.

5. Rinse all dirt and debris from engine compartment.

Reinstall debris screen and wash out access cover.

OIL COOLER

CAUTION Be careful not to bend or damage cooling fins of the radiator or oil cooler. Replace debris screen if damage is found. Repair damaged cooling fins of radiator and oil cooler.

A/C CONDENSER

FIGURE 4.63 NOTE To remove or install the screen, remove three wing bolts on the upper section of radiator, and pull out the screen on the front side then pull the rear screen frontward and remove.

After cleaning it, install it by the reverse procedure.

DEBRIS SCREEN WASH OUT COVER

REMOVE BOLTS

FIGURE 4.64

4 — 24

Section IV – MAINTENANCE G. HYDRAULIC RETURN FILTERS Change the hydraulic tank return filter on a new machine after the first 50 hours of engine operation then change every 500 hours.

DEPRESS RUBBER CAP TO RELEASE PRESSURE

NOTE One new hydraulic return filter is shipped with the machine in the support kit. This is to be used at the 50 hours filter change.

Move machine to firm leveled ground and place attachment in oil level check position.

HYDRAULIC TANK

FIGURE 4.65 1. Release hydraulic tank pressure. See Figure 4.65.

WARNING NEVER CHANGE OILS OR FILTERS ON A MACHINE THAT HAS JUST FINISHED WORKING. ALLOW MACHINE TO COOL FIRST UNTIL OILS AND FLUIDS ARE WARM NOT HOT. RELEASE HYDRAULIC TANK PRESSURE BEFORE WORKING WITH ANY HYDRAULIC COMPONENT.

SLOWLY REMOVE BOLTS & COVER

2. Remove the six mounting bolts from the hydraulic return cover plate. See Figure 4.66.

CAUTION

FIGURE 4.66 BOLT COVER

SPRING WASHER

Slowly remove the mounting bolts. The filter cover plate is under spring tension.

O-RING

3. Remove “O”-rings, filter springs and bypass valves.

See Figure 4.67.

4. Remove the filter from the housing. See Figure 4.67.

5. Install new filter, bypass valve and spring into housing.

6. Install new “O”-ring.

Lubricate “O”-ring befor installing.

7. Install cover plates and torque attaching bolts to proper value. Refer to specifications section for torque value.

SPRING

BYPASS VALVE

FILTER

SUPPLEMENTARY EXPLANATION The machines, are equipped with long-life hydraulic filters.

For the return filter replacement procedure, see page 4-26.

FIGURE 4.67

4 — 25

Section IV – MAINTENANCE H . HYDRAULIC RETURN FILTERS Change the hydraulic tank return filter on a new machine after the first 50 hours of engine operation then change every 1,000 hours.

DEPRESS RUBBER CAP TO RELEASE PRESSURE

NOTE One new hydraulic return filter is shipped with the machine in the support kit. This is to be used at the 50 hours filter change. Move machine to firm leveled ground and place attachment in oil level check position.

HYDRAULIC TANK

1. Release hydraulic tank pressure. See Figure 4.65A.

FIGURE 4.65A

WARNING NEVER CHANGE OILS OR FILTERS ON A MACHINE THAT HAS JUST FINISHED WORKING. ALLOW MACHINE TO COOL FIRST UNTIL OILS AND FLUIDS ARE WARM NOT HOT. RELEASE HYDRAULIC TANK PRESSURE BEFORE WORKING WITH ANY HYDRAULIC COMPONENT. SLOWLY REMOVE BOLTS & COVER

2. Remove the six mounting bolts (1) and spring washer (2) from the hydraulic return cover (3). See Figure 4.67A.

FIGURE 4.66A

CAUTION (1)

(4)

Slowly remove the mounting bolts. The filter cover plate is under spring tension.

(2)

3. Remove “O”-ring (5) and spring (4). See Figure 4.67A. 4. Disassemble element assy (A) while turning the handle.

Disassembling parts ...... (B), (C), (D), (E), (F) 5. Replace “O”-ring (C) of check valve (B).

6. Replace packing (F) of plate (E).

7. Replace element, and assemble element assy (A) disassembled in procedure (4) again.

8. Attach element in reverse procedure of the (3) and (4) above-mentioned.

9. Install cover (3).

Tightening torque: 46.1 ± 4.9 N·m {4.7 ± 0.5 N·m} 10.Start engine, put the machine on hydraulic oil level check position while moving each operating lever, and check hydraulic oil level.

NOTE Long-life return filter is used.

Place an order of return filter element kit.

4 — 26

(3)

(B) (C) ELEMENT ASSY (A)

(5) (5)

(D)

(C) (E) (F)

(D)

(F) ELEMENT KIT

FIGURE 4.67A

Section IV – MAINTENANCE I . BATTERIES Perform complete battery service on a new machine after the first 50 hours of engine operation.

Then, check electrolyte (acid) every 50 hours.

WARNING 1. WEAR SAFETY CLOTHES, GOGGLES OR FACE SHIELD, GLOVES AND SAFETY SHOES WHEN WORKING WITH BATTERIES. 2. WORK IN A WELL VENTILATED AREA. 3. BATTERY ELECTROLYTE (ACID) IS CORROSIVE. IF IT COMES IN CONTACT WITH SKIN, EYES OR CLOTHING, FLUSH WITH LARGE AMOUNTS OF WATER AND SEEK IMMEDIATE MEDICAL ATTENTION. SEE FIGURE 4.68.

4. BATTERY ELECTROLYTE (ACID) PRODUCES HYDROGEN GAS THAT IS HIGHLY EXPLOSIVE. DO NOT ALLOW NEAR SPARKS, FIRE OR FLAMES AND DO NOT SMOKE WHEN WORKING WITH BATTERIES. SEE FIGURE 4.68.

FIGURE 4.68

1. Open battery box access cover. See Figure 4.69.

2. Remove battery cell caps and visually inspect electrolyte (acid) level. Proper level is 10~15 mm (0.4” ~ 0.6”) above cell plates. See Figure 4.70.

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.

BATTERY BOX ACCESS COVER

FIGURE 4.69

WARNING

NEGATIVE (-) CABLE

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.

REMOVE CELL CAPS

FIGURE 4.70

4 — 27

Section IV – MAINTENANCE 6. Use a hydrometer to check the specific gravity of each cell. Compare readings to the chart below.

NOTE Use hydrometer according to its manufacturer’s instructions.

CHARGE % 100 % 90 % 80 % 75 %

AMBIENT TEMPERATURE 20°C 0°C -10°C (68°F) (32°F) (14°F) 1.26 1.24 1.22 1.21

1.27 1.25 1.23 1.22

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

FIGURE 4.71

1.28 1.26 1.24 1.23

7. When disconnecting batteries, remove the negative (–) cable first. When connecting batteries, connect the negative (–) cable last. See Figure 4.71.

8. When the battery requires charging; a. Disconnect battery cables from terminals. b. Remove all cell caps. c. Check for proper electrolyte (acid) level. d. Connect charger leads to the proper battery terminals.

CAUTION Make certain not to cross positive and negative terminals when connecting charger.

e. Stop charge if battery overheats. f. Periodically check the specific gravity of the batteries with a hydrometer. Stop charging batteries when 100% charged.

NOTE Battery life can be shortened by overdischarging and over discharging of the battery. Replace any battery that will not hold charge or is difficult to charge.

4 — 28

Section IV – MAINTENANCE J . ATTACHMENT LUBRICATION Lubricate attachment pins every 8 hours of engine operation. Use extreme pressure multi-purpose grease No. 2 EP type grease. Lubricate all points until grease oozes.

1. Boom cylinder head pins. See Figure 4.72.

NOTE If attachment is sank in water, it is recommended to lubricate it every 8 hours.

BOOM CYLINDER HEAD PINS

FIGURE 4.72 2. Boom foot pin. See Figure 4.73.

BOOM CYLINDER ROD ENDS

3. Boom cylinder rod pins. See Figure 4.73.

ARM CYLINDER HEAD ENDS

4. Arm cylinder head pin. See Figure 4.73.

BOOM FOOT PIN EACH END

BOOM FOOT PIN (CENTER)

CENTRALIZED GRASE NIPPLES ON BOOM

FIGURE 4.73 5. Arm cylinder rod pin. See Figure 4.74.

BOOM

6. Arm to boom pin. See Figure 4.74.

7. Bucket cylinder head pin. See Figure 4.74.

ARM TO BOOM PIN ARM CYLINDER ROD END

ARM

BUCKET CYLINDER HEAD PIN

FIGURE 4.74 IDLER LINK TO ARM PIN ARM TO BUCKET PIN

8. Bucket link pins. See Figure 4.75.

9. Idler link to arm pin and arm to bucket pin. See Figure 4.75.

BUCKET CYLINDER ROD END

10.Bucket cylinder rod pin. See Figure 4.75.

BOTTOM BUCKET LINK PIN

TOP BUCKET LINK PIN

FIGURE 4.75

4 — 29

Section IV – MAINTENANCE 4.7 120 HOUR INSPECTION & MAINTENANCE PROCEDURE A . SWING MOTOR REDUCTION OIL Check the oil level of the swing motor reduction unit on a new machine after the first 50 hours of engine operation.

Then check every 120 hours.

DIPSTICK FILL PLUG

1. Locate the dipstick on the side of the swing motor.

See Figure 4.76. Pull dipstick, wipe clean and reinsert all the way in.

2. Pull dipstick and read oil level.

FIGURE 4.76 3. If necessary to add oil, remove plug from oil fill port and fill to full level with proper oil. See Figure 4.76 and refer to page 4-8 for oil specifications.

CAUTION Reduction unit may be under pressure.

Remove plug slowly.

4. To drain oil from swing motor reduction unit; a. Locate drain port under rear of machine. See Figure 4.77. b. Place a 25 liter (6.6 gallon) container under drain port and remove plug allowing oil to drain into container.

Total Oil Volume: 21.5 liter (5.7 Gal)

c. Replace plug and tighten securely after all oil is drained. d. Fill through fill port using proper oil. See Figure 4.76 and refer to page 4-8 for oil specifications.

WARNING NEVER CHANGE OILS OR FILTERS ON A MACHINE THAT HAS JUST FINISHED WORKING. ALLOW MACHINE TO COOL FIRST UNTIL OILS AND FLUIDS ARE WARM NOT HOT.

4 — 30

DRAIN PORT

FIGURE 4.77

Section IV – MAINTENANCE B . TRAVEL MOTORS REDUCTION OIL Inspect oil level of travel motor reduction unit on a new machine after the first 50 hours of engine operation. Then check every 120 hours.

FILL / LEVEL PLUG

1. Move machine to a firm, level surface. Operate travel until “FILL / LEVEL” plugs on travel motors are at top. See Figure 4.78.

2. Stop engine and remove the travel motor reduction unit oil level plug. See Figure 4.78. If oil just seeps from the port, oil level is correct.

DRAIN PLUG

WARNING

FIGURE 4.78

TRAVEL REDUCTION UNTIL COULD BE UNDER PRESSURE. CAREFULLY LOOSEN PLUG AND REMOVE SLOWLY TILL AIR PRESSURE IS RELEASED.

3. To add oil, remove the oil FILL / LEVEL plug and add extreme pressure gear oil #90 grade GL-4 until oil just begins to flow from level plug.

FILL / LEVEL PLUG

NOTE Capacity of each travel motor reduction unit is 10.5 liters (2.8 Gallons).

DRAIN PLUG

4. Replace all plugs and tighten securely.

FIGURE 4.79

4 — 31

Section IV – MAINTENANCE 4.8 250 HOUR (3-MONTH) INSPECTION & MAINTENANCE PROCEDURE

ALTERNATOR

FAN PULLEY

ADJUSTING BOLT

NOTE Perform all pre-start (every 8 hour and 50 hour) inspection & maintenance procedures along with the following 120 hour inspection and maintenance procedures.

A . BELT TENSIONER (FAN & AIR CONDITIONER) Inspect belt tensioner assembly on a new machine after the first 50 hours of operation. Then at every 250 hours of engine operation.

Force: approx. 98N (22lbf, 10kgf)

1. Measure belt tension on longest span of belt. Belt deflection should be 8mm ~ 15mm.

BELT

DEFLECTION

Fan belt

8 mm ~ 15 mm (0.3" ~ 0.6")

Air conditioner

7 mm ~ 10 mm (0.3" ~ 0.4")

CRANK PULLEY

COMPRESSOR

FIGURE 4.80

2. Loosen mounting nut and adjusting nut, and adjust tension of belt. See Figure 4.81.

ADJUSTING BOLT

ATTACHING NUT 8.4 ± 1.0 kgf·m (61 ± 7 lbf·ft)

3. Loosen adjusting bolt, adjust fan belt to the specified tension, and tighten mounting nut and adjusting nut. See Figure 4.81.

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

5. Adjust the tension of belt of air conditioner turning adjusting bolt of idle pulley. Figure 4.80.

ATTACHING NUT

FIGURE 4.81

4 — 32

Section IV – MAINTENANCE B . AIR CONDITIONER FILTERS Cleaning recirculate and fresh air filters.

SCREW

SCREW

REAR COVER

SCREW

Recirculate air filter ........ Every 500 hours Fresh air filter ................. Every 250 hours 1. Cleaning Fresh Air Filter a. Remove 4 machine screws of rear cover on the rear side of operator seat, release the lock, and remove the rear cover. See Figure 4.82. b. Remove the fresh air filter.

NOTE Water washing is not allowed to clean air filter because it is paper filter. c. Cleaning about 10 times is allowed, or replace it with new one every two years.

LOCK LOCK

REAR COVER

FIGURE 4.82

RECIRCULATE AIR FILTER FRESH AIR FILTER

2. Cleaning Recirculate Air Filter a. Raise recirculate air filter slightly, and pull it out. b. Clean it with water or compressed air blow.

COVER

NOTE Washing with organic solvent (gasoline, trichlene, thinner, etc.) is strictly prohibited.

c. When frequently clogged, or damage is serious, replace it with new one. d. After drying, set outside and recirculate air filters and install cover.

MACHINE FRONT

FIGURE 4.83

C . INSPECTING COUNTERWEIGHT ATTACHING BOLTS FOR LOOSENING – FIGURE 4.84 Check bolts and nuts for proper torque. Correct torque is 300 ± 30 kgf•m (2,167 ± 217 lbf•ft).

CAUTION Striking counterweight against obstruction may cause loosening of bolts. Check bolts for loosening after 50 hours the first time, and every 250 hours after that.

COUNTERWEIGHT ATTACHING BOLT

Unit: kgf·m (lbf·ft) MODEL

TORQUE SPECIFICATION (Apply Loctite #262)

E335

300 ± 30 (2,167 ± 217)

FIGURE 4.84

4 — 33

Section IV – MAINTENANCE 4.9 500 HOUR INSPECTION & MAINTENANCE PROCEDURES NOTE Perform all pre-start (every 8 hour and 50 hour) inspection & maintenance procedures along with the following 250 hour inspection and maintenance procedures.

APPLY CLEAN FUEL

REMOVAL

A . FUEL FILTER FILTER WRENCH

WARNING CLEAN UP ALL SPILLED FUEL. FUEL OIL IS HIGHLY FLAMMABLE. SPILLED FUEL CAN CAUSE FIRES. EXTENSION BAR

1. Put the oil pan under the filter cartridge.

2. Set filter wrench, extension bar and ratchet handle supplied with the machine and remove the fuel filter turning it counterclockwise. See Figure 4.85.

RATCHET HANDLE

FIGURE 4.85

NOTE The fuel filter is cartridge type, and so cannot be reused.

3. Clean the filter base and apply clean fuel on the gasket section of new fuel filter lightly.

4. Push it in until the filter gasket of fuel filter comes into contact with the filter base by hand, and tighten it with filter wrench 3/4 to 1 turn.

5. Start the engine and idle it several minutes, then make sure that there is no leakage of fuel.

B . WATER PUMP BEARING LUBRICATION Lubricate the water pump bearing on a new machine after the first 50 hours of engine operation. Then check and lubricate every 500 hours.

1. Open the engine bonnet, lock it open, and locate grease nipple for the water pump bearing, in front of the engine. See Figure 4.86.

2. Wipe all dust and mud off the grease nipple.

3. Use N.L.G.I. No. 2 (Lithium soap) wheel bearing grease to lubricate the bearing.

4. Close engine bonnet.

NOTE Do not over grease the water pump bearing. It only requires about one shot of a manual grease gun, which is equivalent to aprox. 6.1 cc. NEVER USE A PNEUMATIC GREASE GUN.

4 — 34

FIGURE 4.86

Section IV – MAINTENANCE C . BLEEDING AIR FROM THE FUEL SYSTEM

AIR PLUG

WARNING FUEL FILTER

CLEAN UP ALL SPILLED FUEL. FUEL OIL IS HIGHLY FLAMMABLE. SPILLED FUEL CAN CAUSE FIRES. If air contaminates the fuel system, the engine may become hard to start or it malfunction. Bleed the air whenever the fuel tank is empty, the water separator is drained, or the fuel filter element is replaced. See Figure 4.87.

PRIMING PUMP

KNOB

AIR PLUG

1. Loosen the knob of the priming pump.

2. Loosen the air plug of the fuel filter.

3. Moving the knob up and down by hand, supply fuel until air bubbles stop issuing from the air plug.

NOTE Cover the air plug with a cloth before performing this operation.

AIR PLUG

4. Tighten the air plug when the air bubbles stop issuing from it.

5. Move the knob up and down a few times, then set it in the down position and screw it in to secure it.

NOTE Wipe away all spilled fuel before starting up the engine. After engine has started, check for fuel leaks.

6. The air in the injection pump will automatically be forced out when the engine starts.

TO UPPER RIGHT

FIGURE 4.87

4 — 35

Section IV – MAINTENANCE D.GREASING THE SLEWING RING

GREASING SWING →BEARING

1.→EXTREME-PRESSURE. → MULTIPURPOSE GREASE. → N.L.G. I No.2 LITHIUM BASE → GREASE EP TYPE. 2.→ADD GREASE EVERY 500 HOURS. 3.→ROTATE UPPER FRAME ADDING → GREASE EVERY 90¡ (TOTAL 4X)

1. Locate the grease nipple at the front of the slewing ring. See Figure 4.88.

2. Using grease gun filled with general purpose EP grease (refer to page 4-8), lubricate slewing ring with several shots from grease gun.

3. Swing machine 90° right, and repeat step 2. See label on frame.

4. Continue to swing machine at 90° increments and lubricating slewing ring until ring has been completely greased.

E. CHECKING SLEWING RING FITTING BOLTS FOR LOOSENING Check that bolts securing slewing ring are not loosened.

If loosened, remove bolts once, apply Loctite #262 or equivalent, and tighten them again.

2432P2689

SLEWING RING GREASE NIPPLE

FIGURE 4.88 BALL

SLEWING RING

BOLTS

Torque specification 95 ± 9.5 kgf·m (686 ± 69 lbf·ft) Alternately tighten bolts facing each other in order. See Figure 4.89.

NOTE Since the tightening of slewing ring requires special tools, contact the Dealer for assistance.

F . FUEL SYSTEM INJECTION PRESSURE AND NOZZLE CONDITION (ATOMIZATION) Perform this inspection and adjustment every 500 hours of engine operation. Contact the Dealer for assistance.

Initial injection pressure: 180 kgf/cm2 (2,560 psi)

4 — 36

LOWER FRAME

FIGURE 4.89

Section IV – MAINTENANCE G. CHECKING THE AIR CONDITIONER REFRIGERANT

AIR CAPACITY SELECTOR SWITCH

COMPRESSOR SWITCH

1. Start the engine. Set the engine speed to the middle speed position.

2. Set the machine to the conditions shown below when checking the refrigerant. See Figure 4.90.

• Air conditioner switch ... ON • Fan switch .................... HI position (Maximum ) • Temp. adjustment switch . Lower temp position ( ) • Door / Window .............. Close • Compressor switch ...... ON (The lamp lit up) 3. Follow the procedure below and check the refrigerant volume by looking through the sight glass (inspection window) on the upper part of the receiver dryer. a. Figure (A) shows that the refrigerant volume is proper. b. Figure (B) shows that the refrigerant is over charged. This will make both high and low pressure extreme and exert a bad influence on the pressure switch operation and the air conditioning system. c. Figure (C) shows that the refrigerant is insufficient. Have the refrigerant recharged at your Dealer.

NOTE • New refrigerant (HFC-R134a), whose characteristics are different from conventional CFC-12, is used in this machine. Do not mix HFC-R134a with CFC-12.

• Keep the air conditioner ready for use all year round.

Operate the air conditioner at least once every week for several minutes to rotate the compressor regardless of the season. This will prevent the refrigerant gas from leaking from the compressor sealing.

4 — 37

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

MAIN POWER SWITCH

FIGURE 4.90

Refrigerant volume

Description

(A) Proper After the air conditioner is turned ON, little bubbles appear. The refrigerant becomes transparent, then turns a light milky white.

(B) Overcharged

After the air conditioner is turned ON, no bubbles appear.

(C) Insufficient

After the air conditioner is turned ON, bubbles appear continuously.

Bubbles: Refrigerant gas is mixed with refrigerant fluid.

No Bubbles: Whole refrigerant becomes fluid and transparent.

Cloudy: Refrigerant is separated from oil. The fluid becomes a light milky white.

Section IV – MAINTENANCE 4.10 2000 HOUR INSPECTION & MAINTENANCE PROCEDURES

REMOVE CAP SLOWLY

Perform all other inspection & maintenance procedures as previously described in this section.

A . CHANGE ENGINE COOLANT - 2000 HOURS

WARNING BE CAUTIOUS OF HOT FLUIDS AND SURFACES. WEAR GOGGLES, SAFETY SHOES, HARD HAT, WORK CLOTHES AND WORK GLOVES TO PERFORM INSPECTION AND MAINTENANCE ON THIS MACHINE. ALLOW ENGINE TO COOL BEFORE CHANGING FLUIDS.

ALLOW ENGINE TO COOL BEFORE OPENING

FIGURE 4.91 DEBRIS SCREEN WASH OUT COVER

1. Raise engine bonnet and slowly remove radiator cap.

See Figure 4.91.

2. Locate coolant drain access cover under L.H. rear of machine. See Figure 4.92. Remove the four retaining bolts.

3. Locate radiator drain valve, place a 40 liter (10 Gal) capacity container under drain tube and turn drain valve counterclockwise to open. See Figure 4.93.

4. After drainage, close drain valve and drain plug, and feed water in it.

REMOVE BOLTS

FIGURE 4.92 5. Open drain valve and drain plug. And clean it with flowing water for 10 minutes in low idling state. Be careful that water hose is not disconnected from water feeding port of radiator while cleaning and flowing water.

6. After cleaning, stop engine, and also stop water feeding. Then after draining water, close drain valve and drain plug.

ENGINE DRAIN PLUG

7. After draining, clean it with radiator flush. Clean it following instruction manual for flush in use.

FIGURE 4.93

8. After cleaning, open drain valve and drain plug, then close them after completely draining water, and fill it with water close to the water supply port.

NOTE Never spill the coolant on the ground that can cause the environmental pollution.

RADIATOR DRAIN VALVE

NOTE Expected minimum temperature - 14.5 °C (5.9 °F) - 34°C (-29.2 °F)

Long life coolant 30% mixed 50% mixed

Change contaminated and foamy coolant with new one as soon as possible. Cooling water other than long life coolant should be changed two times a year, in spring and autumn.

4 — 38

Section IV – MAINTENANCE 9. Fill radiator with water, open drain valve and drain plug, and clean it flowing water with engine in a low idling state until clean water is flowing out. Adjust water feeding and draining so as to keep radiator in full condition.

10.After clean water has drained out, stop engine and close drain valve and drain plug. See Figure 4.94.

Fill with "long life coolant" in appropriate concentration.

Refer to pages 4-8.

ENGINE DRAIN PLUG

RADIATOR DRAIN VALVE

FIGURE 4.94 11.Run engine at low idling for 5 minutes and high idling for 5 minutes to bleed air contaminated in coolant (with cap of radiator removed).

12.Drain coolant in reservoir, clean inside of reservoir and fill it up with long life coolant in appropriate concentration to mid point of FULL and LOW. See Figure 4.95.

13.Stop engine, fill it with water to the top of radiator about 3 minutes later, and tighten cap.

14.Return engine bonnet and access door to the closed position respectively.

NOTE Total cooling system volume is approximately 34 liters (9.0 Gal).

4 — 39

ENGINE COOLANT RESERVOIR

FULL

LOW

FIGURE 4.95

Section IV – MAINTENANCE B . REMOVAL AND INSTALLATION OF ENGINE RADIATOR – SEE FIGURE 4.96 The radiator removal and installation procedure is described below.

RADIATOR OIL COOLER

(3)

(1)

1. Remove one under cover on the lower side of radiator.

(3) (2)

2. Open cap and radiator drain cock and pour the cooling water into container.

3. Loosen two wing bolts (1) and remove insect proof net in front of the radiator.

SHROUD

4. Loosen four capscrews (M10) (2) and remove pads (3) on the RH and LH sides of radiator shoulder.

Loosen four capscrews (M10) (4) of the shroud and remove the cover.

5. Remove four securing capscrews (M10) (5) on the upper of radiator.

(6)

(4) INSECT PROOF NET

6. Remove two securing capscrews (M10) (6) on the lower side of radiator.

7. After making sure that the cooling water is completely gone out, loosen hose band (7) of radiator and remove it on radiator side only.

8. Shift the radiator to the oil cooler side, and hang it paying attention not to damage the insulation.

Radiator weight: 36 kg (79 lb)

(5)

(6)

PULL UP

SHIFT TO THE OIL COOLER SIDE

WARNING

9. After cleaning, install it by the reverse procedure.

BE CAUTIOUS OF HOT FLUIDS AND SURFACES. WEAR GOGGLES, SAFETY SHOES, HARD HAT, WORK CLOTHES AND WORK GLOVES TO PERFORM INSPECTION AND MAINTENANCE ON THIS MACHINE. ALLOW ENGINE TO COOL BEFORE CHANGING FLUIDS.

FIGURE 4.96

4 — 40

Section IV – MAINTENANCE C . CHANGE HYDRAULIC OIL

HYDRAULIC OIL CHECK POSITION

NOTE The following procedures are to be used for normal changing of the hydraulic oil only. If necessary to change the hydraulic oil viscosity, change hydraulic oil due to hydraulic component failure or changing main pump, contact the Dealer for assistance.

FIGURE 4.97 DEPRESS RUBBER CAP TO RELEASE PRESSURE

WARNING BE CAUTIOUS OF HOT FLUIDS AND SURFACES. WEAR GOGGLES, SAFETY SHOES, HARD HAT, WORK CLOTHES AND WORK GLOVES TO PERFORM INSPECTION AND MAINTENANCE ON THIS MACHINE. ALLOW HYDRAULIC OIL TO COOL BEFORE CHANGING.

HYDRAULIC TANK

FIGURE 4.98

1. Move the machine to a firm, level surface with the attachment in the hydraulic oil check position. See Figure 4.97.

NOTE If machine is cold, warm the hydraulic oil by operating attachment controls before placing machine in the hydraulic oil check position. See Sec. III (page 3-5) 2. Release hydraulic tank pressure. See Figure 4.98.

SLOWLY REMOVE BOLTS & COVER

3. Slowly remove the six retaining bolts from the suction strainer cover plate. See Figure 4.99.

FIGURE 4.99 BOLT

4. Remove “O”-ring, and suction strainer from hydraulic tank. See Figure 4.100.

SPRING WASHER COVER

NOTE Never spill the hydraulic oil on the ground, that can cause the environmental pollution.

O-RING

SUCTION STRAINER

FIGURE 4.100

4 — 41

Section IV – MAINTENANCE 5. Install special suction stopper, over suction tube insidehydraulic tank. See Figure 4.101.

HYDRAULIC TANK

6. Place a 206 liter (54 Gal) capacity container under drain plug. Remove plug and allow all oil from hydraulic tank to drain into container.

SUCTION STOPPER ASSEMBLY

SUCTION TUBE

FIGURE 4.101

7. Remove the hydraulic drain plug on bottom of hydraulic tank. See Figure 4.104.

8. After all oil has drained, carefully and thoroughly clean inside of hydraulic tank.

9. Replace drain plug and tighten securely.

10.Remove suction stopper and clean outside of suction tube with a clean, dry cloth.

11.Carefully inspect suction strainer for damage. If any damage is found, replace strainer with new part.

DRAIN PLUG

FIGURE 4.104

12.Install strainer assembly onto suction tube.

6 66

FIGURE 4.105

4 — 42

m m

) 2” 6.

(2

Section IV – MAINTENANCE 13.Install new “O”-ring, in cover plate mounting surface groove and install suction strainer cover plate onto hydraulic tank. Make certain plate boss is inside suction strainer holder. See Figure 4.106.

BOLT SPRING WASHER

COVER

14.Torque retaining bolts to proper value. Refer to specifications section.

O-RING

15.Fill hydraulic tank to proper level with fresh, clean hydraulic oil through hydraulic return filter. See Figure 4.106.

SUCTION STRAINER

CAUTION Use same viscosity oil in hydraulic tank as was drained.

Refer to page 4-8 for oil specifications.

FIGURE 4.106

NOTE This machine was shipped from the factory with ISO VG32S viscosity hydraulic oil in hydraulic system.

4 — 43

Section IV – MAINTENANCE D. HYDRAULIC TANK BREATHER

DEPRESS RUBBER CAP TO RELEASE PRESSURE

1. Release hydraulic tank pressure. See Figure 4.107.

HYDRAULIC TANK

FIGURE 4.107

2. Remove rubber cap and nut. See Figure 4.108.

RUBBER CAP

3. Remove breather housing. See Figure 4.108.

NUT

FILTER

BREATHER HOUSING

FIGURE 4.108

4. Remove old filter, clean mounting surfaces and install new filter. See Figure 4.109.

REMOVE FILTER

5. Install breather housing.

6. Install retaining nut and tighten securely.

Torque: 1.0 ~ 1.4 kgf·m (7.2 ~ 10 lbf·ft) 7. Install rubber cap.

FIGURE 4.109

4 — 44

Section IV – MAINTENANCE E . CHANGE OIL IN TRAVEL MOTOR REDUCTION UNITS Change the travel reduction units oil on a new machine after the first 500 hours of engine operation then change every 2000 hours.

FILL / LEVEL PLUG

WARNING NEVER CHANGE OILS OR FILTERS ON A MACHINE THAT HAS JUST FINISHED WORKING. ALLOW MACHINE TO COOL FIRST UNTIL OILS AND FLUIDS ARE WARM NOT HOT.

DRAIN PLUG

1. Move machine to a firm, level surface. Operate travel until “FILL / LEVEL” plugs on travel motors are at top. See Figure 4.110.

2. Stop engine and remove the travel motor reduction unit “DRAIN” plug. See Figure 4.110.

3. To add oil, remove the oil fill plug and add extreme pressure gear oil #90 grade GL-4 until oil just begins to flow from level plug.

4. To drain oil, remove “FILL / LEVEL” plug and drain plug. Allow oil to drain into a 12 liter (3 Gal) capacity container. Replace drain plug, remove level plug and fill through fill port using extreme pressure gear oil #90 grade GL-4.

FIGURE 4.11

WARNING WARNING TRAVEL REDUCTION UNTIL COULD BE UNDER PRESSURE. CAREFULLY LOOSEN PLUG AND REMOVE SLOWLY TILL AIR PRESSURE IS RELEASED.

NOTE Capacity of each travel motor reduction unit is 10.5 liters (2.8 gallons).

5. Replace all plugs and tighten securely.

F . PILOT LINE FILTER When cleaning or replacing the filter, move the control lever several times and release the internal pressure in the pilot line completely.

Prepare an oil pan.

WARNING

ELEMENT

NEVER CHANGE OILS OR FILTERS ON A MACHINE THAT HAS JUST FINISHED WORKING. ALLOW MACHINE TO COOL FIRST UNTIL OILS AND FLUIDS ARE WARM NOT HOT. RELEASE HYDRAULIC TANK PRESSURE BEFORE WORKING WITH ANY HYDRAULIC COMPONENT.

O-RING

CASE

FIGURE 4.112

1. Open the main pump access door and locate the pilot manifold mounted to the side of the hydraulic Tank. See Figure 4.111.

4 — 45

Section IV – MAINTENANCE 2. Loosen the manifold block case with spanner 24 mm (0.94”).

3. Clean the removed parts and fit new element and O-ring in the case.

ELEMENT

4. After the case is installed on the filter base, tighten it with spanner 24 mm (0.94”).

Tightening torque: 2.5 to 3.5 kgf·m (18 to 25 lbf·ft).

O-RING

CASE

5. Lock the main pump access door.

FIGURE 4.112

G. CHANGE OIL IN SWING REDUCTION UNIT Change the swing reduction unit oil on a new machine after the first 500 hours of engine operation then change every 2000 hours.

DIPSTICK FILL PLUG

WARNING NEVER CHANGE OILS OR FILTERS ON A MACHINE THAT HAS JUST FINISHED WORKING. ALLOW MACHINE TO COOL FIRST UNTIL OILS AND FLUIDS ARE WARM NOT HOT. 1. Remove the drain plug on the rear lower side of the swing reduction unit to drain oil to the container. See Figure 4.114.

FIGURE 4.113

2. Clean the drain plug seal it with teflon tape, and install.

3. Remove the oil filler plug and fill with extreme pressure gear oil #90 grade GL-4.

4. Using the dipstick, confirm that the extreme pressure gear oil #90 grade GL-4 levels is within the designated range. See Figure 4.113.

DRAIN PORT

5. Clean the fill plug and install.

FIGURE 4.114 NOTE Capacity of each swing reduction unit is 21.5 liters (5.7 Gallons).

4 — 46

Section IV – MAINTENANCE H . ATTACHMENT & DUST SEALS

STABILIZE BUCKET ON GROUND

1. Bucket Clearance Inspect bucket clearance frequently for wear. If clearance between bucket and bucket link and/or between arm and bucket is greater than 1.2 mm (0.05”) adjust clearance according to instructions.

2. Reversing Backhoe Bucket a. Move the machine to a firm ,level surface and rest the bucket on the ground, making certain the bucket is stable. See Figure 4.115. b. Roll “O”-rings onto bucket boss. See Figure 4.116. c. Remove jam nuts, nuts and pin retaining bolts.

See Figure 4.117. d. Clean pins and pin hole, and apply grease on it. e. Carefully remove main pins mounting arm and bucket link to bucket. f. Rotate bucket 180° or move machine, install arm and bucket link in their respective positions. See Figure 4.118.

NOTE Make certain “O”-rings are on bucket boss for reinstallation.

FIGURE 4.115

ROLL "O"-RING ONTO BUCKET BOSS

FIGURE 4.116

g. Roll “O”-rings into grooves between bucket / arm and bucket / bucket link. h. Align each pin holes, insert bucket pin, and fit flexible ring and pin.

BOLT

NOTE Inspect “O”-rings for damage or excessive wear. If worn or damaged replace with new parts to protect seals, pins and surfaces from dirt and debris which can cause premature failure.

JAM NUT NUT MAIN PINS

BUCKET LINK HERE

FIGURE 4.117 BUCKET LINK HERE

ARM HERE

FIGURE 4.118

4 — 47

Section IV – MAINTENANCE 3. Dust Seals a. The attachment incorporates several dust seals that should be periodically checked for damage and excessive wear. See Figure 4.119. b. If excessive wear or damage is found remove seal and replace with new parts.

ATTACHMENT LUBRICATION POSITION

(8)

(7) (1)

(2)

(8)

(6)

(5)

NOTE Order the following parts for replacement seals: 1. Boom Foot 2. Arm to Boom 3. Arm to Idler Link 4. Bucket Cylinder to Bucket Link 5. Arm to Bucket 6. Boom Cylinder Head 7. Boom Cylinder Rod 8. Arm Cylinder Head and Rod 9. Bucket Cylinder Head and Rod 10. Bucket to Bucket link

(10) (3)

(9)

(4)

FIGURE 4.119

LIP OUT

BOSS

c. Install replacement seals as shown in Figure 4.120. d. Make certain pin surface and tapered end are smooth and free from all burrs or imperfections.

Rough pin surfaces can cause damage to the new seals.

BUSHING SEAL

FIGURE 4.120

OPEN ENGINE AIR CLEANER ACCESS DOOR

I . WINDSHIELD WASHER RESERVOIR Fill the windshield washer fluid reservoir as required using approved windshield washing fluid.

WINDSHIELD WASHER RESERVOIR CAP

1. Open engine air cleaner access door to locate washer fluid reservoir. See Figure 4.121.

2. Pull cap off and fill with proper windshield washing fluid.

3. Replace cap and reposition engine air cleaner access door.

FIGURE 4.121

4 — 48

Section IV – MAINTENANCE J . CHANGE GREASE IN SLEWING RING GREASE BATH 1. Drain water by removing drain plate located in lower frame cavity. See Figure 4.122.

CAUTION If the slewing ring ever becomes submerged in water, it is mandatory that the sump bath grease be changed.

SUMP BATH DRAIN PLATE

2. To replace the slewing bath grease it is necessary to remove the upper frame. Contact the Dealer to do it. See Figure 4.123.

FIGURE 4.122

CLEAN & FILL WITH MoS2 GREASE

SUMP BATH GREASE QUANTITIES CHART GREASE TYPE

E335

N.L.G.I.LITHIUM BASE W/MoS2

15,7 kg (34.6 lb)

FIGURE 4.123

4 — 49

Section IV – MAINTENANCE 4.11MISCELLANEOUS A . FUSES Follow the procedures below to replace “blown” or faulty fuses.

1. Move seat and seat base completely forward.

2. Remove fuse box cover from fuse box. See Figure 4.124.

3. Locate and remove faulty fuse. Replace fuse with same amperage fuse as removed.

FUSE BOX

FIGURE 4.124

WARNING NEVER REPLACE A FAULTY FUSE WITH A HIGHER AMP FUSE. NEVER USE A “JUMPER” IN PLACE OF A FUSE. NEVER SPLICE ACCESSORIES DIRECTLY INTO FUSE TERMINALS.

1

2

3

4

5

6

7

8

9

10

4. Refer to fuse box cover or Figure 4.125 for fuse amperage and their functions.

NOTE When ordering replacement fuses, order the following amperages: 10 and 20 AMP.

11 12 13 14 15 16 17 No. AMPS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

20A 10A 10A 10A 10A NONE 10A 20A 10A 20A 10A 20A 10A 20A 10A 20A 20A 20A 10A 20A

FUNCTION Mechatro Controller (CPU) Wiper, Washer Relay Engine Controller Engine Controller Cigar Lighter Horn None Fuel Supply Pump Dome Lamp, Converter (Back up) Starter Switch DC-DC Converter Swing Flasher Gauge Cluster Wiper, Washer Solenoid Valve (Safety Lock Lever) Working Light (Front) Cab Light (OPT) Air Conditioner Controller (A/C) Spare 24V FIGURE 4.125

4 — 50

18 19 20

Section IV – MAINTENANCE B . PERIODICAL INSPECTION ITEMS Since there is no definite time table for the replacement of hydraulic lines, tubes and hoses, inspect the following periodically for tightness and signs of damage. Replace all damaged lines, tubes and hoses with new parts. Refer to the parts manual for correct part numbers when ordering.

HEATER HOSES

WARNING DO NOT BEND, STRIKE OR DAMAGE HIGH PRESSURE LINES. DO NOT INSTALL BENT OR DAMAGED LINES, TUBES OR HOSES. REPLACE ALL DAMAGED LINES, TUBES AND HOSES IMMEDIATELY. TIGHTEN ALL LOOSE FITTINGS AND CONNECTIONS TO THE PROPER TORQUE VALUE. CLEAN UP ALL FUEL AND OIL SPILLS IMMEDIATELY TO HELP PREVENT FIRES. NEVER USE HANDS TO CHECK FOR LEAKS CAREFULLY INSPECT ALL LINES, TUBES AND HOSES FOR: 1. FITTINGS & CONNECTIONS DAMAGED OR LEAKING. 2. OUTER COVERING OF HOSES WORN, CUT OR DAMAGED EXPOSING WIRE REINFORCEMENT. 3. HOSE SWELLING OR “BALLOONING”.

4. EVIDENCE OF HOSE BEING KINKED OR COLLAPSED. 5. STEEL PROTECTIVE COVERING WORN OR DAMAGED. 6. LOOSE FITTINGS AND CONNECTIONS. MAKE CERTAIN ALL CLAMPS, GUARDS AND HEAT SHIELDS ARE IN PLACE AND SECURE. THIS WILL HELP PREVENT VIBRATION, EXCESSIVE WEAR OF COMPONENTS AND EXCESSIVE HEAT DURING OPERATION.

FIGURE 4.126

BOOM HOSES AND TUBES

FIGURE 4.127

ARM HOSES AND TUBES

1. Heater Hoses Inspect the heater hoses between heater and engine for signs of damage and wear. See Figure 4.126.

2. Boom Hoses & Tubes Inspect boom head and rod hoses and tubes for damage, wear and loose connections. See Figure 4.127.

3. Arm Hoses & Tubes Inspect arm head and rod hoses and tubes for damage, wear and loose connections. See Figure 4.128.

4 — 51

FIGURE 4.128

Section IV – MAINTENANCE 4. Bucket Hoses & Tubes Inspect bucket head and rod hoses and tubes for damage, wear and loose connections. See Figure 4.129.

5. Fuel Lines and Hoses Inspect fuel lines and hoses for damage, wear and loose connections. Repair or replace fuel lines and hoses before operating the machine.

BUCKET HOSES AND LINES

FIGURE 4.129 6. Hydraulic Suction Tubes & Hoses Inspect all hydraulic tubes and hoses for damage, wear and loose connections. See Figure 4.130.

USE CARDBOARD TO CHECK FOR PRESSURE LEAKS

FIGURE 4.130 7. Radiator Hoses & Cap Inspect the radiator hoses for signs of damage or deterioration. Replace hoses if found to be in bad condition. Inspect the radiator cap seal for signs of damage and deterioration and replace with new part if found to be in bad condition. See Figure 4.131.

RADIATOR HOSES AND LINES

FIGURE 4.131 8. Foam Seals Inspect the foam rubber seals around the radiator, oil cooler and on the engine cover. Make certain they are in place and secure to prevent overheating of the engine. See Figure 4.132.

FOAM SEALS

FIGURE 4.132

4 — 52

Section IV – MAINTENANCE 9. Fuel Filler Strainer Inspect the fuel filler strainer beneath fuel filler cap for damage, dirt and debris. Make certain the strainer is clean and in place before fueling the machine. See Figure 4.133. If the strainer is damaged, replace with a new part.

FUEL FILLER STRAINER

NOTE Do not remove this filter to refuel machine. To do so may allow dirt and debris to enter fuel tank.

FIGURE 4.133 CHECK FUEL LINES

10.Fuel Lines and Hoses Inspect fuel lines and hoses for damage, wear and loose connections. Repair or replace fuel lines and hoses before operating the machine. See Figure 4.133A.

FIGURE 4.133A

11. Rear View Mirrors Inspect the rear view mirrors. Make certain both sides rear view mirrors are in place, properly adjusted, clean, and in good condition. Secure them tight to prevent them from breaking. See Figure 4.133B.

MAKE SURE REAR VIEW MIRRORS ARE CLEAN AND IN GOOD CONDITION

FIGURE 4.133B

4 — 53

Section IV – MAINTENANCE C . MACHINE STORAGE Perform the following procedure to prepare the machine for long term storage.

3. Completely fill fuel tank with fresh, clean fuel to aid in preventing condensation of moisture inside the fuel tank.

4. Move machine to an indoor location for storage.

5. Operate bucket and arm completely “IN” extending cylinders. Then lower boom until attachment is resting on the floor. See Figure 4.134.

6. Coat cylinder rods with a heavy coat of grease to prevent corrosion during storage.

7. Remove batteries and store in a well ventilated, warm area.

1. Perform all inspection and maintenance procedures as previously described in this section.

2. Thoroughly clean the machine, inspect for damaged or worn parts and components and replace or repair all damaged or worn parts.

CAUTION Protect CPU and all electrical components from water and steam when cleaning the machine.

POSITION MACHINE AS SHOWN INSIDE A STORAGE BUILDING

HEAVILY GREASE ALL CYLINDER RODS TO PREVENT CORROSION

FIGURE 4.134

D . CARE DURING STORAGE Every 30 days during storage, it will be necessary to start and run the machine to circulate the fluids through the systems. Before starting clean cylinder rods and after running re-grease cylinder rods.

NOTE Run and operate machine for approximately 1 hour to allow all fluids to circulate well and reach normal operating temperatures.

E . REMOVING MACHINE FROM STORAGE 1. Perform all Inspection and maintenance procedures as described in this section before bringing machine out of storage for normal operation.

2. Remove drain plugs from travel motor and swing gear reduction units to drain off any moisture which may have accumulated during storage.

3. Carefully and closely inspect all hydraulic hoses after long periods of storage for signs of deterioration. Replace all hoses showing these signs.

4 — 54

Section V – TRANSPORTATION Table of Contents 5.1 GROUND TRANSPORTATION ............................................................................................................................... 5-1 5.2 LIFTING MACHINE ................................................................................................................................................ 5-3 5.3 LIFTING MACHINE (WITHOUT ATTACHMENT) .................................................................................................... 5-5 5.4 SHIPPING DIMENSIONS ...................................................................................................................................... 5-7

WARNING READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS AND PROCEDURES FOUND IN THIS MANUAL BEFORE ATTEMPTING ANY OPERATION, INSPECTION OR MAINTENANCE OF THIS MACHINE, ATTACHMENT OR SYSTEMS.

5—0

Section V – TRANSPORTATION 5.1 GROUND TRANSPORTATION

3. Obtain any permits required from proper government agencies for transport of machine.

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

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

A . MACHINE PREPARATION 1. Know the total weight, length, width and height of the machine being transported. See Figure 5.1.

2. Know route to be traveled. Investigate bridges, overpasses, trusses and traffic flow on route.

100 mm (3.9")

3,460 mm (11' - 4")

2,190 mm (7' - 2")

660 mm

700 mm (2' - 4")

Dimensions and weights are with 3,3 m arm, 1,40 m3 bucket and 6,5 m boom.

MACHINE MODEL E335 E335LC E335NLC

WEIGHT 600 mm SHOE 24,900 kg (54,900 lb) 25,500 kg (56,200 lb) 25,400 kg (56,000 lb)

FIGURE 5.1

THROTTLE CONTROL

WARNING

HI

LO

B . LOADING THE MACHINE

NEVER ATTEMPT TO LOAD OR UNLOAD MACHINE WITHOUT RAMPS. NEVER USE ATTACHMENT AS AN AID IN LOADING OR UNLOADING THE MACHINE. 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 in 1st ( ) speed position and move throttle control to the “LO” idle position. See Figure 5.2.

FIGURE 5.2

5—1

(2' - 2") 4,120 mm (13' - 6")

11,000 mm (36' - 1")

Section V – TRANSPORTATION 4. Slowly travel machine up trailer ramps and over rear axles of trailer. When tracks are over trailer axles, stop travel. See Figure 5.3.

WARNING TO PREVENT THE ARM AND BUCKET CYLINDER (S) FROM ANY DAMAGE, YOU ARE ADVISED TO FOLLOW THE FOLLOWING INSTRUCTIONS. DO NOT HAVE THE ARM AND/OR BUCKET CYLINDER FULLY EXTENDED TO A "RAMP OVER CENTER" SITUATION. THIS ALLOWS SUDDEN AND ABRUPT CONTACT OF THE ARM OR BUCKET TO A TRAILER DECK, RAMP OR THE GROUND. THIS CAN RESULT IN INTERNAL MECHANICAL CONTACT, WHICH CAN STRETCH THE CYLINDER ROD(S).

15° or less

FIGURE 5.3

SAFETY LOCK LEVER IN LOCKED (UP) POSITION

5. Slowly swing machine 180° until attachment is toward rear of trailer.

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

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

8. Place safety lock lever in the up “LOCKED (UP)” position. See Figure 5.4.

9. Turn machine “OFF”, remove key and lock all doors, filler caps and access panels. parts to trailer or transporting platform.

FIGURE 5.4

CAUTION SECURE FRONT & REAR OF EACH TRACK

Place a cover over the exhaust pipe of the machine and secure to avoid water entering the engine.

C. SECURING MACHINE TO TRAILER 1. Using cable or wire rope of sufficient capacity, secure front and rear of each track to trailer. See Figure 5.5 2. Secure attachment to trailer as shown in Figure 5.5 3. Secure all loose components to trailer.

SECURE ATTACHMENT

FIGURE 5.5

5—2

Section V – TRANSPORTATION 5.2 LIFTING MACHINE The following procedures are for lifting the machine, as built by the Manufacturer. These procedure do not take into account modifications made to the machine that affect machine weight or center of gravity.

1. Locate lifting locations at the front and rear of each crawler frame. See Figure 5.6 to 5.8.

2. Attach cables or wire rope with a capacity rating sufficient to lift the machine, at lifting locations.

WARNING ALWAYS USE PROPER LIFTING EQUIPMENT AND DEVICES. USE OF IMPROPER LIFTING EQUIPMENT COULD ALLOW THE LOAD TO SHIFT OR FALL CAUSING SEVERE DAMAGE, SERIOUS INJURY OR DEATH.

CAUTION

WARNING

Place a hardwood or steel block between cables and crawler frame to prevent damage to the tracks from cables during lifting. See Figure 5.6 to 5.8.

DO NOT USE COUNTERWEIGHT LIFTING EYES TO LIFT WHOLE MACHINE. LIFTING EYES CAN FALL UNDER THIS LOAD RESULTING IN PERSONAL INJURY. REFER TO OPERATOR’S MANUAL FOR PROPER WAY OF LIFTING MACHINE.

3. Bring loose ends of cables together at machine center of gravity and attach to an overhead lifting device with a rated lifting capacity sufficient to lift the machine. See Figure 5.6 to 5.8.

TOOLS ITEM CABLE (A) CABLE (B) SPREADER BARS (C)

NOTE It may be necessary to place reinforced spreader bars between lifting cables to prevent damage to the machine during lifting. See Figure 5.6 to 5.8.

SIZE Ø 45.0 X 15.7 m Ø 45.0 X 15.6 m 4.0 m

4. Slowly lift and move machine to desired location.

33,300 kg (73,400 lb) 3.3 m (10’ - 10”) 600 mm (23.6”) E335

(A) (14

)

° (10

°)

(C) (45

5°)

°) (4 4,000mm (13' - 1")

3,600mm (11' - 10"),

CENTER OF GRAVITY

(B) 2,000mm (6' - 7")

WEIGHT: ARM: SHOE: MODEL:

WARNING WARNING

740mm (29.1")

NOTE : Lifting machine with wider track shoes will tend to shift the center of gravity slightly forward, toward the center of the slewing ring.

210mm (8.3")

740mm (29.1")

PLACE BLOCK BETWEEN EACH CABLE AND FRAME

FIGURE 5.6

5—3

WARNING DO NOT USE THE COUNTERWEIGHT LIFTING EYES TO LIFT MACHINE

Q’TY 1 1 2

Section V – TRANSPORTATION TOOLS ITEM CABLE (A) CABLE (B) SPREADER BARS (C)

(B)

(1

4°

)

2,000mm (6' - 7")

(A)

33,900 kg (74,700 lb) 3.3 m (10’ - 10”) 600 mm (23.6”) CENTER OF GRAVITY E335LC

)

° 13

(

(45

°) (45°) 4,000mm (13' - 1")

(C)

3,600mm (11' - 10")

WEIGHT: ARM: SHOE: MODEL:

Q’TY 1 1 2

SIZE Ø 45.0 X 15.7 m Ø 45.0 X 15.7 m 4.0 m

780mm (30.7")

205mm (8.1")

755mm (29.7")

WARNING

WARNING

NOTE : Lifting machine with wider track shoes will tend to shift the center of gravity slightly forward, toward the center of the slewing ring.

PLACE BLOCK BETWEEN EACH CABLE AND FRAME

DO NOT USE THE COUNTERWEIGHT LIFTING EYES TO LIFT MACHINE

FIGURE 5.7 TOOLS ITEM CABLE (A) CABLE (B) SPREADER BARS (C)

(A) (1

5° )

(B) 2,000mm (6' - 7")

33,800 kg (74,510 lb) 3.3 m (10’ - 10”) 600 mm (23.6”) CENTER OF GRAVITY E335NLC

Q’TY 1 1 2

°)

1 (1

°) (45 ° ) (45 4,000mm (13' - 1")

(C)

3,600mm (11' - 10")

WEIGHT: ARM: SHOE: MODEL:

SIZE Ø 45.0 X 15.7 m Ø 45.0 X 15.5 m 4.0 m

780mm (30.7") NOTE : Lifting machine with wider track shoes will tend to shift the center of gravity slightly forward, toward the center of the slewing ring.

WARNING

205mm (8.1")

PLACE BLOCK BETWEEN EACH CABLE AND FRAME

FIGURE 5.8

5—4

755mm (29.7")

WARNING DO NOT USE THE COUNTERWEIGHT LIFTING EYES TO LIFT MACHINE

Section V – TRANSPORTATION TOOLS ITEM CABLE (A) CABLE (B) SPREADER BARS (C)

5.3 LIFTING MACHINE (WITHOUT ATTACHMENT) Lift up machine without attachment is the procedure described below. See Figure 5.9 to 5.11.

27,300 kg (60,190 lb) 600 mm (23.6”) E335

(A)

(B)

(2

2 °)

°

(1 )

(45 ° ) (45 4,000mm (13' - 1") °)

3,600mm (11' - 10")

CENTER OF GRAVITY

Q’TY 1 1 2

(C)

2,000mm (6' - 7")

WEIGHT: SHOE: MODEL:

SIZE Ø 45.0 X 16.4 m Ø 45.0 X 15.2 m 4.0 m

740mm (29.1")

WARNING DO NOT USE THE COUNTERWEIGHT LIFTING EYES TO LIFT MACHINE

990 mm (40.0")

740mm (29.1") NOTE : Lifting machine with wider track shoes will tend to shift the center of gravity slightly forward, toward the center of the slewing ring.

PLACE BLOCK BETWEEN EACH CABLE AND FRAME

FIGURE 5.9 TOOLS ITEM CABLE (A) CABLE (B) SPREADER BARS (C) (A)

27,900 kg (61,500 lb) 600 mm (23.6”) E335LC

(B)

(2

3° )

2,000 mm (6' - 7")

WEIGHT: SHOE: MODEL:

SIZE Ø 45.0 X 16.4 m Ø 45.0 X 15.2 m 4.0 m

°)

(3

(C)

3,600 mm (11' - 10")

CENTER OF GRAVITY

°) (45 ° ) (45 4,000 mm (13' - 1")

780mm (29.1")

WARNING DO NOT USE THE COUNTERWEIGHT LIFTING EYES TO LIFT MACHINE

1085 mm (40.0")

755mm (29.1")

PLACE BLOCK BETWEEN EACH CABLE AND FRAME

FIGURE 5.10

5—5

NOTE : Lifting machine with wider track shoes will tend to shift the center of gravity slightly forward, toward the center of the slewing ring.

Q’TY 1 1 2

Section V – TRANSPORTATION TOOLS ITEM CABLE (A) CABLE (B) SPREADER BARS (C)

(A)

27,800 kg (61,300 lb) 600 mm (23.6”) E335NLC

(2

4° )

(B) 2,000 mm (6' - 7")

WEIGHT: SHOE: MODEL:

SIZE Ø 45.0 X 16.4 m Ø 45.0 X 15.2 m 4.0 m

°)

(2

(C)

3,600 mm (11' - 10")

CENTER OF GRAVITY

°) (45 ° ) (45 4,000 mm (13' - 1")

780mm (30.7")

WARNING DO NOT USE THE COUNTERWEIGHT LIFTING EYES TO LIFT MACHINE

1,085 mm (42.7")

755mm (29.7")

PLACE BLOCK BETWEEN EACH CABLE AND FRAME

FIGURE 5.11

5—6

NOTE : Lifting machine with wider track shoes will tend to shift the center of gravity slightly forward, toward the center of the slewing ring.

Q’TY 1 1 2

Section V – TRANSPORTATION 5.4 SHIPPING DIMENSIONS A . MACHINE WITH STANDARD ATTACHMENTS Refer to Figure 5.12 for reference in regards to the machine basic dimensions, as manufactured by the Manufacturer, with standard attachments: a. 1. Standard boom .................. 6.5 m (21’ - 4”) a. 2. Standard arm .................... 3.3 m (10’ - 10”) a. 3. Bucket ...................... 1.40 m3 (1.83 cu yd)

11,200mm (36' - 9")

(19.7")

500 mm

3,120mm (10' - 3")

3,360mm (11' - 0")

*1,200mm (3' - 11")

3,500mm (11' - 6")

4,650mm (15' - 3") / 4,980mm (16' - 4") -LC·NLC

600mm (23.6")

5,830mm (19' - 2") / 5,990mm (19' - 8") -LC·NLC

3,200mm (10' - 6") -STD,LC 3,000mm (9' - 10") -NLC

* Marked dimensions do not include height of shoe lug.

FIGURE 5.12

5—7

Section V – TRANSPORTATION B . BOOM WITH ARM CYLINDER – FIGURE 5.13

Boom

mm (ft-in)

6,500 (21'-4")

LXHXW

mm (ft-in)

6,750 X 1,820 X 910 (22'-2" X 6'-0" X 3'-0")

Weight w/ Arm Cylinder

kg (lb)

H

3,240 (7,140)

L FIGURE 5.13 C . ARM WITH BUCKET CYLINDER AND BUCKET – FIGURE 5.14 Combination LXHXW

mm (ft-in)

5,390 X 1,110 X 1,610 (17'-8" X 3'-8" X 5'-3")

6,080 X 1,070 X 1,430 (19'-11" X 3'-6" X 4'-8")

6,940 X 1,070 X 1,240 (22'-9" X 3'-6" X 4'-1")

2,780 (6,130)

2,810 (6,190)

3,000 (6,610)

2.6 m (8'-6")

3.3 m (10'-10")

4.15 m (13'-7")

3,790 X 1,090 X 650 (12'-5" X 3'-7" X 2'-2")

4,490 X 980 X 650 (14'-9" X 3'-3" X 2'-2")

5,350 X 1,030 X 650 (17'-7" X 3'-5" X 2'-2")

1,650 (3,640)

1,770 (3,900)

2,070 (4,560)

H

Weight w/ kg (lb) Bucket Cylinder

Arm 2.6 m (8'-6") Arm 3.3 m (10'-10") Arm 4.15 m (13'-7") Bucket 1.60 m3 (2.09 cu yd) Bucket 1.40 m3 (1.83 cu yd) Bucket 1.20 m3 (1.57 cu yd)

L

FIGURE 5.14

Arm LXHXW

mm (ft-in)

Weight w/ kg (lb) Bucket Cylinder

H

D . ARM WITH BUCKET CYLINDER – FIGURE 5.15

L

FIGURE 5.15

5—8

Section V – TRANSPORTATION E . BUCKET – FIGURE 5.16

(B)

Standard bucket is 1.40 m3 (1.83 cu yd) (A) Length is 1,640 mm (5’ - 5”) (B) Height is 1,460 mm (4’ - 9”) (C) Width without side cutters is 1,300 mm (4’ - 3”)

(A)

(C) (D)

(D) Width with side cutter is 1,430 mm (4’ - 8”) FIGURE 5.16

(E) Bucket weight is 1,040 kg (2,290 lb)

5—9

Section V – TRANSPORTATION NOTES

5 — 10

Section VI – SPECIFICATIONS Table of Contents 6.1 GENERAL SPECIFICATIONS ................................................................................................................................ 6-1 6.2 OPTIONAL ATTACHMENTS SPECIFICATIONS .................................................................................................. 6-14 6.3 TORQUE SPECIFICATIONS ................................................................................................................................ 6-15 6.4 MISCELLANEOUS INFORMATION ..................................................................................................................... 6-18

WARNING READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS AND PROCEDURES FOUND IN THIS MANUAL BEFORE ATTEMPTING ANY OPERATION, INSPECTION OR MAINTENANCE OF THIS MACHINE, ATTACHMENT OR SYSTEMS.

6—0

Section VI – SPECIFICATIONS 6.1 GENERAL SPECIFICATIONS

A . MACHINE DIMENSIONS – FIGURE 6.1 These dimensions consider the following: a. Standard boom ............... 6.5 m (21’ - 4”) b. Standard arm ................ 3.3 m (10’ - 10”) c. Bucket .................... 1.40 m3 (1.83 cu yd) d. Standard shoe ............... 600 mm (23.6”)

The specifications found in this section are given on the standard hydraulic excavator as manufactured by the Manufacturer. No modifications or options are taken into consideration in regard to these specifications.

11,200mm (36'- 9")

500 mm (19.7")

3,120mm (10'-3")

3,360mm (11'- 0")

*1,200mm (3'-11")

3,500mm (11'- 6")

600mm (23.6")

4,650mm (15'-3") / 4,980mm (16'-4")-LC·NLC 5,830mm (19'-2") / 5,990mm (19'-8")-LC·NLC

3,200mm (10'-6")-STD,LC 3,000mm (9'-10")-NLC

* Marked dimensions do not include height of shoe lug.

FIGURE 6.1

A B

mm

SAE

A

Maximum digging reach

11,220

36'- 10"

B

Maximum digging reach at ground

11,030

36'- 2"

C

Maximum digging depth

7,490

24'- 7"

D

Maximum digging height

10,490

34'- 5"

E

Maximum dumping clearance

7,290

23'- 11"

F

Minimum dumping clearance

2,620

8'- 7"

G

Max. vertical wall digging depth

6,570

21'- 7"

H

Minimum swing radius

4,290

14'- 1"

E F

FUNCTION

C G

ITEM

D

B . WORKING RANGES – FIGURE 6.2 Standard attachment working ranges : a. BOOM ...................................... 6.5 m (21’ - 4”) b. ARM ....................................... 3.3 m (10’ - 10”) c. BUCKET SAE heaped ............................ 1.40 m3 (1.83 cu yd) Struck ...................................... 1.00 m3 (1.31 cu yd) Width with side cutters ............ 1,430 mm (4’ - 8”) Width w/o side cutters ............. 1,300 mm (4’ - 3”) Weight ..................................... 1,040 kg (2,290 lb)

FIGURE 6.2

6—1

H

Section VI – SPECIFICATIONS C

C . BOOM – FIGURE 6.3 Standard boom is 6.5 m (21’ - 4”) A: Length is 6.5 m (21’ - 4”) Center line to center line of pins.

B: Height is 1,135 mm (3’ - 9”) From center line of boom end to center line of arm cylinder boss.

C: Width is 830 mm (32.7”) From edge to edge of boom foot.

Weight: Approximately 2,410 kg (5,310 lb)

B

ARM CYLINDER BOSS

GROUND LEVEL

A FIGURE 6.3

B

D . ARM – FIGURE 6.4 Standard arm is 3.3 m (10’ - 10”) A: Length is 3.3 m (10’ - 10”) Center line to center line of pins.

B: Width is 380 mm (15.0”) From edge to edge of arm end.

Weight: Approximately 1,090 kg (2,400 lb)

A

FIGURE 6.4 E . BUCKET – FIGURE 6.5 Standard bucket is 1.40 m3 (1.83 cu yd) A:Length is 1.64 m (5’ - 5”)

B

B:Height is 1.46 m (4’ - 9”) C:Width without side cutters is 1,300 mm (4’ - 3”) D:Width with side cutters is 1,430 mm (4’ - 8”) E:Bucket weight is 1,040 kg (2,290 lb)

A

C D FIGURE 6.5

F . SHOES – FIGURE 6.6 1. Standard shoes are 600 mm (23.6”) triple grouser.

2. Quantity of shoes; E335 ............................................ 45 per track E335LC, E335NLC ................................ 48 per track

TRIPLE GROUSER SHOE

FIGURE 6.6

6—2

Section VI – SPECIFICATIONS H . MACHINE AND COMPONENT WEIGHTS The following weight specifications are based on the standard machine with standard attachment.

1. Component weights Unit: kg (lb)

G. PERFORMANCE SPECIFICATIONS The following performance specifications are based on the standard machine with standard attachment.

1. Travel speed, swing speed & gradeability DESCRIPTION

SPECIFICATION 5.7 km per hr (3.5 mph) in mode.

TRAVEL SPEED 3.3 km per hr (2.2 mph) in mode.

-1 SWING SPEED 8.6 min IN M-Mode / "HI" idle.

GRADEABILITY 70 % (35°) SWING TORQUE 111.6 kN

COMPONENT

UPPER FRAME ASSEMBLY Counterweight Cab Boom Cylinder*

Mitsubishi (MMC)

6D16-TLU2D 4-cycle, water cooled, direct injection Type with intercooler turbocharger, diesel Number of cylinders-Bore X Stroke 6-118 mm X 115 mm (4.65" X 4.53") Compression ratio Output rating

184 kW / 2,200 rpm

Maximum torque

824 N·m / 1,800 rpm

Ignition order Injection timing

8° Before Top Dead Point

Intake valve clearance Cold

0.4 mm (0.0157")

Exhaust valve clearance Cold

0.4 mm (0. 0157") D.C. 24V

Electrical system Starting motor

24 V - 5 kW

Alternator

24 V - 35 A

Batteries

2 - 12 V - (136 Ah)

Engine dry weight* Thermostat Cooling fan drive method Air cleaner

Hydraulic Pumps Swing Motor Travel Motor Control Valves Cylinders (all) Return Filter Oil Cooler

260 (570) 270 (600) X 2 170 (370)

Pump Assembly

126 (280)

126 (280)

Control valve

170 (370)

170 (370)

Fuel Tank*

204 (450)

204 (450)

Hydraulic Tank*

172 (380)

172 (380)

510 (1,120) -NLC 11,400 10,900 (24,030) 11,530 (25,130) (25,410) 510 (1,120)

585 (1,290)

585 (1,290)

Travel Motor & Reductin Unit

360 (790) X 2

360 (790) X 2

Idler Assembly

170 (370) X 2

170 (370) X 2

Lower Roller Assembly (EU)

58 (130) X 14

58 (130) X 18

Upper Roller Assembly

30 (66) X 4

30 (66) X 4

Track Tension Assembly

190 (420) X 2

190 (420) X 2

Sprocket

88 (190) X 2

88 (190) X 2

30 (66)

30 (66)

Swivel Joint

Track Link w/600mm (23.6") Shoes 1,870 (4,120) X 2 1,995 (4,400) X 2 840 (1,850) X 2 900 (1,980) X 2 Track Link

580 kg (1,280 lb) Wax type thermostat (bottom by-pass type) Ø620 (Ø24.4") suction type, belt drive, pulley ratio: 0.9 Dry type with safety elements

6,000 (13,200)

6,000 (13,200)

Bucket Assembly [1.40m3 (1.83cu yd)]

1,040 (2,290)

1,040 (2,290)

Arm Assembly [3.3m (10'-10")]

1,770 (3,900)

1,770 (3,900)

1,160 (2,560)

1,160 (2,560)

Bucket cylinder*

260 (570)

260 (570)

Idler link

27 (60) X 2

27 (60) X 2

Bucket link

130 (290)

130 (290)

Pin (2pcs for mtg bucket cyl. & bucket)

115 (250)

115 (250)

3,180 (7,010)

3,180 (7,010)

2,580 (5,690)

2,580 (5,690)

500 (1,100)

500 (1,100)

ATTACHMENT (STANDARD)

Arm [3.3m (10'-10")]

3. Hydraulic components COMPONENT

260 (570) 270 (600) X 2

580 (1,280)

Slewing ring

1 - 5 - 3 - 6 - 2 - 4 clockwise rotation

8,420 (18,600)

170 (370)

LOWER FRAME ASSEMBLY (EU)

17.5 : 1

16,300 (35,930)

8,420 (18,600)

580 (1,280)

Swing Motor & Reduction Unit

7,545 liter (460 cu in.)

16,300 (35,930)

Radiator & Oil Cooler

Engine*

Model

Displacement

E335(N)LC

33,800 (74,510)-NLC COMPLETE MACHINE (STANDARD) 33,300 (73,410) 33,900 (74,700)

2. Engine Major engine specifications Engine maker

E335

TYPE Tandem, variable displacement, axial piston with pilot gear pump.

Axial piston Axial piston 6 spool multiple control Double acting Safety valve containing filter type Air cooled

Boom Assembly Boom Arm cylinder*

47 (100)

47 (100)

830 (1,830)

830 (1,830)

Hyd Oil

304 (670)

304 (670)

Eng Oil

25 (55)

25 (55)

466 (1,030)

466 (1,030)

35 (77)

35 (77)

Pin (mounting the arm) FLUIDS

Fuel Water

* Dry weight 4. Digging force Arm Length

3.3 m (10'-10")

Bucket Digging Force

221 / *242 kN

Arm Crowding Force

165 / *181 kN

WARNING USE ONLY LIFTING DEVICES AND EQUIPMENT WITH RATED CAPACITIES SUFFICIENT TO LIFT THE SPECIFIC COMPONENT(S) BEING REMOVED OR INSTALLED.

* Power boost engaged

6—3

Section VI – SPECIFICATIONS I . LIFTING CAPACITIES

RATED OBJECT HANDLING CAPACITIES TABLE

E335LC

HEIGHT (m)

SHOE WIDTH 600mm

LIFT POINT (AXIS) AXIS

10

ARM (See the following table)

9 8

BOOM (See the following table)

7

LD

COUNTERWEIGHT 8,420 kg

6

Z2

5 4

WORKING CONDITIONS: - with no tool (bucket, clamshell..).

If object handling is performed with tool installed, the weight of the tool shall be deducted from the values of this table.

3 2 1 0 Z1 1

- with extended bucket cylinder.

WORKING CIRCUIT PRESSURE 34,300 kPa - on a compact or horizontal, level HOLDING CIRCUIT ground.

PRESSURE 34,300 kPa

2 3 4 5 Z3

- in complete swing of the upper structure

6

AXIS OF ROTATION 0

1

2

3

4

5

6

7

8

7 9 10 11

OUTREACH (m) THESE LOADS ARE VALID FOR THE HEIGHT OF THE CONSIDERED ZONE (Z.) FOR THE INTENDED OUTREACH BOOM LENGTH 6.50 m ARM LENGTH (m) OUTREACH (m) Z2 2.60 LD=3.03 Z1 Z3 Z2 3.30 LD=3.73 Z1 Z3 Z2 4.15 LD=4.57 Z1 Z3

OUTREACH IN m LOADS IN kg 3 4.5 6 8270 16350 10600 7880 14600 7960 7480 7110 8810 7870 17380 7860 11640 10190 7760 15540 7650

(BOOM FOOT HEIGHT)

7.5 6550 5690 5580 5650 5660 5740 5550 5470

9 4470 4850 4370 4750 4190 4180

LD:BOOM POINT TO HOOK POINT DISTANCE

6—4

MAX REACH Ð 4500 (9.02m) 4070 (9.63m) 3240 (10.40m) -

Section VI – SPECIFICATIONS

RATED OBJECT HANDLING CAPACITIES TABLE (HEAVY LIFT)

E335LC

HEIGHT (m)

SHOE WIDTH 600mm

LIFT POINT (AXIS) AXIS

10

ARM (See the following table)

9 8

BOOM (See the following table)

7

LD

COUNTERWEIGHT 8,420 kg

6

Z2

5 4

WORKING CONDITIONS: - with no tool (bucket, clamshell..).

If object handling is performed with tool installed, the weight of the tool shall be deducted from the values of this table.

3 2 1 0 Z1 1

- with extended bucket cylinder.

WORKING CIRCUIT PRESSURE 37,730 kPa - on a compact or horizontal, level HOLDING CIRCUIT ground.

PRESSURE 37,730 kPa

2 3 4 5 Z3

- in complete swing of the upper structure

6

AXIS OF ROTATION 0

1

2

3

4

5

6

7

8

7 9 10 11

OUTREACH (m) THESE LOADS ARE VALID FOR THE HEIGHT OF THE CONSIDERED ZONE (Z.) FOR THE INTENDED OUTREACH BOOM LENGTH 6.50 m ARM LENGTH (m) OUTREACH (m) Z2 2.60 LD=3.03 Z1 Z3 Z2 3.30 LD=3.73 Z1 Z3 Z2 4.15 LD=4.57 Z1 Z3

OUTREACH IN m LOADS IN kg 3 4.5 6 9400 18100 11990 7880 16720 7960 8510 7950 10170 7870 19830 7860 12930 11560 7760 17810 7650

(BOOM FOOT HEIGHT)

7.5 6550 5690 6270 5650 5660 6580 5550 5470

9 4470 4850 4370 4940 4190 4180

LD:BOOM POINT TO HOOK POINT DISTANCE

6—5

MAX REACH 4500 (9.02m) 4070 (9.63m) 3240 (10.40m) -

Section VI – SPECIFICATIONS

RATED OBJECT HANDLING CAPACITIES TABLE

E335LC

HEIGHT (m)

SHOE WIDTH 800mm

LIFT POINT (AXIS) AXIS

10

ARM (See the following table)

9 8

BOOM (See the following table)

7

LD

COUNTERWEIGHT 8,420 kg

6

Z2

5 4

WORKING CONDITIONS: - with no tool (bucket, clamshell..).

If object handling is performed with tool installed, the weight of the tool shall be deducted from the values of this table.

3 2 1 0 Z1 1

- with extended bucket cylinder.

WORKING CIRCUIT PRESSURE 34,300 kPa - on a compact or horizontal, level HOLDING CIRCUIT ground.

PRESSURE 34,300 kPa

2 3 4 5 Z3

- in complete swing of the upper structure

6

AXIS OF ROTATION 0

1

2

3

4

5

6

7

8

7 9 10 11

OUTREACH (m) THESE LOADS ARE VALID FOR THE HEIGHT OF THE CONSIDERED ZONE (Z.) FOR THE INTENDED OUTREACH BOOM LENGTH 6.50 m ARM LENGTH (m) OUTREACH (m) Z2 2.60 LD=3.03 Z1 Z3 Z2 3.30 LD=3.73 Z1 Z3 Z2 4.15 LD=4.57 Z1 Z3

OUTREACH IN m LOADS IN kg 3 4.5 6 8270 16350 10600 8170 8220 14600 7480 7110 8810 8150 17380 8140 11640 10190 7790 15540 7930

(BOOM FOOT HEIGHT)

7.5 6630 5900 5580 5870 5870 5740 5770 5690

9 4640 5020 4540 4750 4360 4350

LD:BOOM POINT TO HOOK POINT DISTANCE

6—6

MAX REACH 4870 ( 9.02m) 4220 ( 9.63m) 3240 (10.40m) -

Section VI – SPECIFICATIONS

RATED OBJECT HANDLING CAPACITIES TABLE (HEAVY LIFT)

E335LC

HEIGHT (m)

SHOE WIDTH 800mm

LIFT POINT (AXIS) AXIS

10

ARM (See the following table)

9 8

BOOM (See the following table)

7

LD

COUNTERWEIGHT 8,420 kg

6

Z2

5 4

WORKING CONDITIONS: - with no tool (bucket, clamshell..).

If object handling is performed with tool installed, the weight of the tool shall be deducted from the values of this table.

3 2 1 0 Z1 1

- with extended bucket cylinder.

WORKING CIRCUIT PRESSURE 37,730 kPa - on a compact or horizontal, level HOLDING CIRCUIT ground.

PRESSURE 37,730 kPa

2 3 4 5 Z3

- in complete swing of the upper structure

6

AXIS OF ROTATION 0

1

2

3

4

5

6

7

8

7 9 10 11

OUTREACH (m) THESE LOADS ARE VALID FOR THE HEIGHT OF THE CONSIDERED ZONE (Z.) FOR THE INTENDED OUTREACH BOOM LENGTH 6.50 m ARM LENGTH (m) OUTREACH (m) Z2 2.60 LD=3.03 Z1 Z3 Z2 3.30 LD=3.73 Z1 Z3 Z2 4.15 LD=4.57 Z1 Z3

OUTREACH IN m LOADS IN kg 3 4.5 6 9400 18100 11990 8170 8250 16720 8510 7950 10170 8150 19830 8140 12930 11560 8050 17810 7930

(BOOM FOOT HEIGHT)

7.5 6760 5900 6270 5870 5870 6580 5770 5690

9 4640 5020 4540 5110 4360 4350

LD:BOOM POINT TO HOOK POINT DISTANCE

6—7

MAX REACH 4870 (9.02m) 4220 (9.63m) 3670 (10.40m) -

Section VI – SPECIFICATIONS

RATED OBJECT HANDLING CAPACITIES TABLE

E335LC

HEIGHT (m)

SHOE WIDTH 900mm

LIFT POINT (AXIS) AXIS

10

ARM (See the following table)

9 8

BOOM (See the following table)

7

LD

COUNTERWEIGHT 8,420 kg

6

Z2

5 4

WORKING CONDITIONS: - with no tool (bucket, clamshell..).

If object handling is performed with tool installed, the weight of the tool shall be deducted from the values of this table.

3 2 1 0 Z1 1

- with extended bucket cylinder.

WORKING CIRCUIT PRESSURE 34,300 kPa - on a compact or horizontal, level HOLDING CIRCUIT ground.

PRESSURE 34,300 kPa

2 3 4 5 Z3

- in complete swing of the upper structure

6

AXIS OF ROTATION 0

1

2

3

4

5

6

7

8

7 9 10 11

OUTREACH (m) THESE LOADS ARE VALID FOR THE HEIGHT OF THE CONSIDERED ZONE (Z.) FOR THE INTENDED OUTREACH BOOM LENGTH 6.50 m ARM LENGTH (m) OUTREACH (m) Z2 2.60 LD=3.03 Z1 Z3 Z2 3.30 LD=3.73 Z1 Z3 Z2 4.15 LD=4.57 Z1 Z3

OUTREACH IN m LOADS IN kg 3 4.5 6 8270 16350 10600 8280 14600 8220 7480 7110 8810 8250 17380 8240 11640 10190 7790 15540 8030

(BOOM FOOT HEIGHT)

7.5 6630 5970 5580 5940 5940 5740 5840 5760

9 4700 5080 4600 4750 4420 4410

LD:BOOM POINT TO HOOK POINT DISTANCE

6—8

MAX REACH 4730 (9.02m) 4280 (9.63m) 3240 (10.40m) -

Section VI – SPECIFICATIONS

E330LC

RATED OBJECT HANDLING CAPACITIES TABLE (HEAVY LIFT)

HEIGHT (m)

SHOE WIDTH 900mm

LIFT POINT (AXIS) AXIS

10

ARM (See the following table)

9 8

BOOM (See the following table)

7

LD

COUNTERWEIGHT 8,420 kg

6

Z2

5 4

WORKING CONDITIONS: - with no tool (bucket, clamshell..).

If object handling is performed with tool installed, the weight of the tool shall be deducted from the values of this table.

3 2 1 0 Z1 1

- with extended bucket cylinder.

WORKING CIRCUIT PRESSURE 37,730 kPa - on a compact or horizontal, level HOLDING CIRCUIT ground.

PRESSURE 37,730 kPa

2 3 4 5 Z3

- in complete swing of the upper structure

6

AXIS OF ROTATION 0

1

2

3

4

5

6

7

8

7 9 10 11

OUTREACH (m) THESE LOADS ARE VALID FOR THE HEIGHT OF THE CONSIDERED ZONE (Z.) FOR THE INTENDED OUTREACH BOOM LENGTH 6.50 m ARM LENGTH (m) OUTREACH (m) Z2 2.60 LD=3.03 Z1 Z3 Z2 3.30 LD=3.73 Z1 Z3 Z2 4.15 LD=4.57 Z1 Z3

OUTREACH IN m LOADS IN kg 3 4.5 6 9400 18100 11990 8260 16720 8340 8510 7950 10170 8250 19830 8240 12930 11560 8140 17810 8030

(BOOM FOOT HEIGHT)

7.5 6830 5970 6270 5940 5940 6580 5840 5760

9 4700 5080 4600 5170 4420 4410

LD:BOOM POINT TO HOOK POINT DISTANCE

6—9

MAX REACH 4730 (9.02m) 4280 (9.63m) 3710 (10.40m) -

Section VI – SPECIFICATIONS

RATED OBJECT HANDLING CAPACITIES TABLE

E335NLC

HEIGHT (m)

SHOE WIDTH 600mm

LIFT POINT (AXIS) AXIS

10

ARM (See the following table)

9 8

BOOM (See the following table)

7

LD

COUNTERWEIGHT 8,420 kg

6

Z2

5 4

WORKING CONDITIONS: - with no tool (bucket, clamshell..).

If object handling is performed with tool installed, the weight of the tool shall be deducted from the values of this table.

3 2 1 0 Z1 1

- with extended bucket cylinder.

WORKING CIRCUIT PRESSURE 34,300 kPa - on a compact or horizontal, level HOLDING CIRCUIT ground.

PRESSURE 34,300 kPa

2 3 4 5 Z3

- in complete swing of the upper structure

6

AXIS OF ROTATION 0

1

2

3

4

5

6

7

8

7 9 10 11

OUTREACH (m) THESE LOADS ARE VALID FOR THE HEIGHT OF THE CONSIDERED ZONE (Z.) FOR THE INTENDED OUTREACH BOOM LENGTH 6.50 m ARM LENGTH (m) OUTREACH (m) Z2 2.60 LD=3.03 Z1 Z3 Z2 3.30 LD=3.73 Z1 Z3 Z2 4.15 LD=4.57 Z1 Z3

OUTREACH IN m LOADS IN kg 3 4.5 6 8270 16350 10600 7160 14600 7230 7480 7110 8810 7140 17380 7130 11640 10190 7040 15540 6920

(BOOM FOOT HEIGHT)

7.5 6020 5180 5580 5140 5140 5740 5040 4960

9 4070 4440 3970 4530 3800 3780

LD:BOOM POINT TO HOOK POINT DISTANCE

6 — 10

MAX REACH 4100 (9.02m) 3700 (9.63m) 3190 (10.40m) -

Section VI – SPECIFICATIONS

RATED OBJECT HANDLING CAPACITIES TABLE (HEAVY LIFT)

E335NLC

HEIGHT (m)

SHOE WIDTH 800mm

LIFT POINT (AXIS) AXIS

10

ARM (See the following table)

9 8

BOOM (See the following table)

7

LD

COUNTERWEIGHT 8,420 kg

6

Z2

5 4

WORKING CONDITIONS: - with no tool (bucket, clamshell..).

If object handling is performed with tool installed, the weight of the tool shall be deducted from the values of this table.

3 2 1 0 Z1 1

- with extended bucket cylinder.

WORKING CIRCUIT PRESSURE 37,730 kPa - on a compact or horizontal, level HOLDING CIRCUIT ground.

PRESSURE 37,730 kPa

2 3 4 5 Z3

- in complete swing of the upper structure

6

AXIS OF ROTATION 0

1

2

3

4

5

6

7

8

7 9 10 11

OUTREACH (m) THESE LOADS ARE VALID FOR THE HEIGHT OF THE CONSIDERED ZONE (Z.) FOR THE INTENDED OUTREACH BOOM LENGTH 6.50 m ARM LENGTH (m) OUTREACH (m) Z2 2.60 LD=3.03 Z1 Z3 Z2 3.30 LD=3.73 Z1 Z3 Z2 4.15 LD=4.57 Z1 Z3

OUTREACH IN m LOADS IN kg 3 4.5 6 8670 18100 11060 7160 16720 7230 8510 7950 10170 7140 19830 7130 12930 10760 7040 17810 6920

(BOOM FOOT HEIGHT)

7.5 6020 5180 6170 5140 5140 6320 5040 4960

9 4070 4440 3970 4530 3800 3780

LD:BOOM POINT TO HOOK POINT DISTANCE

6 — 11

MAX REACH 4100 (9.02m) 3700 (9.63m) 3190 (10.40m) -

Section VI – SPECIFICATIONS

RATED OBJECT HANDLING CAPACITIES TABLE

E335NLC

HEIGHT (m)

SHOE WIDTH 800mm

LIFT POINT (AXIS) AXIS

10

ARM (See the following table)

9 8

BOOM (See the following table)

7

LD

COUNTERWEIGHT 8,420 kg

6

Z2

5 4

WORKING CONDITIONS: - with no tool (bucket, clamshell..).

If object handling is performed with tool installed, the weight of the tool shall be deducted from the values of this table.

3 2 1 0 Z1 1

- with extended bucket cylinder.

WORKING CIRCUIT PRESSURE 34,300 kPa - on a compact or horizontal, level HOLDING CIRCUIT ground.

PRESSURE 34,300 kPa

2 3 4 5 Z3

- in complete swing of the upper structure

6

AXIS OF ROTATION 0

1

2

3

4

5

6

7

8

7 9 10 11

OUTREACH (m) THESE LOADS ARE VALID FOR THE HEIGHT OF THE CONSIDERED ZONE (Z.) FOR THE INTENDED OUTREACH BOOM LENGTH 6.50 m ARM LENGTH (m) OUTREACH (m) Z2 2.60 LD=3.03 Z1 Z3 Z2 3.30 LD=3.73 Z1 Z3 Z2 4.15 LD=4.57 Z1 Z3

OUTREACH IN m LOADS IN kg 3 4.5 6 8270 16350 10600 7420 14600 7490 7480 7110 8810 7400 17380 7390 11640 10190 7290 15540 7180

(BOOM FOOT HEIGHT)

7.5 6210 5370 5580 5330 5340 5740 5230 5150

9 4230 4800 4130 4690 3950 3940

LD:BOOM POINT TO HOOK POINT DISTANCE

6 — 12

MAX REACH Ð 4260 ( 9.02m) Ð Ð 3850 ( 9.63m) 3240 (10.40m) -

Section VI – SPECIFICATIONS

RATED OBJECT HANDLING CAPACITIES TABLE (HEAVY LIFT)

E335NLC

HEIGHT (m)

SHOE WIDTH 800mm

LIFT POINT (AXIS) AXIS

10

ARM (See the following table)

9 8

BOOM (See the following table)

7

LD

COUNTERWEIGHT 8,420 kg

6

Z2

5 4

WORKING CONDITIONS: - with no tool (bucket, clamshell..).

If object handling is performed with tool installed, the weight of the tool shall be deducted from the values of this table.

3 2 1 0 Z1 1

- with extended bucket cylinder.

WORKING CIRCUIT PRESSURE 37,730 kPa - on a compact or horizontal, level HOLDING CIRCUIT ground.

PRESSURE 37,730 kPa

2 3 4 5 Z3

- in complete swing of the upper structure

6

AXIS OF ROTATION 0

1

2

3

4

5

6

7

8

7 9 10 11

OUTREACH (m) THESE LOADS ARE VALID FOR THE HEIGHT OF THE CONSIDERED ZONE (Z.) FOR THE INTENDED OUTREACH BOOM LENGTH 6.50 m ARM LENGTH (m) OUTREACH (m) Z2 2.60 LD=3.03 Z1 Z3 Z2 3.30 LD=3.73 Z1 Z3 Z2 4.15 LD=4.57 Z1 Z3

OUTREACH IN m LOADS IN kg 3 4.5 6 8930 18100 11440 7420 16720 7490 8510 7950 10170 7400 19830 7390 12930 11140 7290 17810 7180

(BOOM FOOT HEIGHT)

7.5 6210 5730 6270 5330 5340 6520 5230 5150

9 4230 4600 4130 4690 3950 3940

LD:BOOM POINT TO HOOK POINT DISTANCE

6 — 13

MAX REACH 4260 (9.02m) 3850 (9.63m) 3330 (10.40m) -

Section VI – SPECIFICATIONS A B

6.2 OPTIONAL ATTACHMENTS SPECIFICATIONS

ITEM

FUNCTION

mm

SAE

F

E C G

A . WORKING RANGES – FIGURE 6.7 1. Attachment with: a. BOOM ...................................... 6.5 m (21’ - 4”) b. ARM ....................................... 4.15 m (13’ - 7”) c. BUCKET SAE heaped .............................. 1.20 m3 (1.57 cu yd) Struck ........................................ 0.84 m3 (1.10 cu yd) Width with side cutters .............. 1,240 mm (4’ - 1”) Width w/o side cutters ............... 1,110 mm (3’ - 8”) Weight ....................................... 930 kg (2,050 lb)

D

The following working ranges specifications are based on the standard machine with optional attachments.

A

Maximum digging reach

11,980

39'- 4"

B

Maximum digging reach at ground

11,800

38'- 9"

C

Maximum digging depth

8,340

27'- 4"

D

Maximum digging height

10,750

35'- 3"

E

Maximum dumping clearance

7,570

24'- 10"

F

Minimum dumping clearance

1,770

5'- 10"

G

Max. vertical wall digging depth

7,290

23'- 11"

H

Minimum swing radius

4,370

14'- 4"

2. Attachment with: a. BOOM ............................ 6.5 m (21’ - 4”) b. ARM ........................................... 2.6 m (8’ - 6”) c. BUCKET SAE heaped .............................. 1.60 m3 (2.09 cu yd) Struck ........................................ 1.20 m3 (1.57 cu yd) Width with side cutters .............. 1,610 mm (5’ - 3”) Width w/o side cutters ............... 1,480 mm (4’ - 10”) Weight ....................................... 1,130 kg (2,490 lb)

ITEM

FUNCTION

mm

SAE

A

Maximum digging reach

10,640

34'- 11"

B

Maximum digging reach at ground

10,430

34'- 3"

C

Maximum digging depth

6,790

22'- 3"

D

Maximum digging height

10,330

33'- 11"

E

Maximum dumping clearance

7,120

23'- 4"

F

Minimum dumping clearance

3,320

10'- 11"

G

Max. vertical wall digging depth

5,940

19'- 6"

H

Minimum swing radius

4,380

14'- 4"

6 — 14

FIGURE 6.7

H

Section VI – SPECIFICATIONS B. BUCKET AND ARM COMBINATIONS

BUCKET m3 (cu yd) SAE (JIS) (HEAPED)

ARM

JIS, SAE (STRUCK)

1.20 (1.57)

0.84 (1.10)

1.40 (1.83)

1.00 (1.30)

1.60 (2.09)

1.20 (1.57)

1.80 (2.35)

1.40 (1.83)

2.6 m (8'-6")

3.3 m 4.15 m (10'-10") (13'-7")

• • • • Normal

working

• • • • Standard • • • • Light • • • • Do

duty only not use this combination

6.3 TORQUE SPECIFICATIONS The following torque specifications are provided for use when actual torque value of a fastener is not known.

A. CAPSCREWS AND NUTS 1. Metric coarse thread standard tightening torque values. Make certain to tighten all capscrews & nuts to proper torque values.

Torque value unit - kgf·m (lbf·ft) Classification

4.8 T

7T

10.9 T

NOMINAL SIZE NO LUBRICATION OIL LUBRICATION NO LUBRICATION OIL LUBRICATION NO LUBRICATION OIL LUBRICATION 0.45 ± 0.05 (3.2 ± 0.4) 0.38 ± 0.04 (2.7 ± 0.3) 0.98 ± 0.1 (7.1 ± 0.7) 0.83 ± 0.08 (6.0 ± 0.6) 1.77 ± 0.18 (12.8 ± 1.3) 1.5 ± 0.15 (10.8 ± 1.1)

M6

P=1

M8

P=1.25 1.09 ± 0.11 (7.9 ± 0.8) 0.92 ± 0.09 (6.6 ± 0.7) 2.4 ± 0.2 (17.3 ± 1.4)

2.0 ± 0.2 (14.4 ± 1.4)

4.3 ± 0.4 (31.0 ± 2.9)

3.6 ± 0.4 (26.0 ± 2.9)

2.2 ± 0.2 (15.9 ± 1.4) 1.83 ± 0.18 (13.2 ± 1.3) 4.7 ± 0.5 (33.9 ± 3.6)

4.0 ± 0.4 (28.9 ± 2.9)

8.5 ± 0.9 (61.3 ± 6.5)

7.2 ± 0.7 (52.0 ± 5.1)

M10 P=1.5

M12 P=1.75 3.7 ± 0.4 (26.7 ± 2.9)

3.2 ± 0.3 (23.1 ± 2.2)

8.1 ± 0.8 (58.5 ± 5.8)

6.8 ± 0.7 (49.1 ± 5.1) 14.6 ± 1.5 (105 ± 10.8) 12.3 ± 1.2 (88.8 ± 8.7)

M14 P=2

5.9 ± 0.6 (42.6 ± 4.3)

5.0 ± 0.5 (36.1 ± 3.6) 12.8 ± 1.3 (92.5 ± 9.4) 10.8 ± 1.1 (78.0 ± 7.9)

23 ± 2 (166 ± 14)

19.5 ± 1.9 (140 ± 14)

M16 P=2

9.0 ± 0.9 (64.9 ± 6.5)

7.6 ± 0.7 (54.8 ± 5.1) 19.5 ± 2.0 (140 ± 14.4) 16.4 ± 1.6 (118 ± 11.5)

35 ± 4 (252 ± 28.9)

29 ± 3 (209 ± 21.6)

M18 P=2.5

12.4 ± 1.2 (89.6 ± 8.7) 10.5 ± 1.0 (75.8 ± 7.2)

27 ± 3 (195 ± 22)

23 ± 2 (166 ± 14)

49 ± 5 (354 ± 36)

41 ± 4 (296 ± 29)

M20 P=2.5

17.5 ± 1.7 (126 ± 12.3) 14.7 ± 1.4 (106 ± 10.1)

38 ± 4 (274 ± 29)

32 ± 3 (231 ± 22)

68 ± 7 (491 ± 51)

57 ± 6 (412 ± 43)

M22 P=2.5

23 ± 2 (166 ± 14)

19.6 ± 2.0 (142 ± 14)

51 ± 5 (368 ± 36)

43 ± 4 (310 ± 29)

92 ± 9 (663 ± 65)

77 ± 7 (555 ± 58)

M24 P=3

30 ± 3 (217 ± 22)

24 ± 3 (173 ± 22)

65 ± 7 (469 ± 51)

53 ± 5 (383 ± 36)

118 ± 12 (852 ± 87)

96 ± 10 (693 ± 72)

M27 P=3

44 ± 4 (318 ± 29)

36 ± 3 (260 ± 22)

96 ± 10 (693 ± 72)

78 ± 8 (563 ± 58)

173 ± 17 (1250 ± 120) 140 ± 14 (1010 ± 100)

M30 P=3.5

60 ± 6 (433 ± 43)

50 ± 5 (361 ± 36)

131 ± 13 (946 ± 94)

110 ± 11 (794 ± 79)

235 ± 24 (1700 ± 170) 198 ± 20 (1430 ± 140)

M33 P=3.5

81 ± 8 (585 ± 58)

68 ± 7 (491 ± 51)

176 ± 18 (1270 ± 130) 148 ± 15 (1070 ± 110) 317 ± 32 (2290 ± 200) 266 ± 27 (1920 ± 200)

105 ± 10 (758 ± 72)

88 ± 9 (636 ± 65)

227 ± 23 (1640 ± 170) 190 ± 19 (1370 ± 140) 409 ± 41 (2960 ± 300) 343 ± 34 (2480 ± 250)

M36 P=4

F18238gb

2. Metric fine thread standard tightening torque values. Make certain to tighten all capscrews & nuts to proper torque values.

Torque value unit - kgf·m (lbf·ft) Classification

4.8 T

7T

10.9 T

NOMINAL SIZE NO LUBRICATION OIL LUBRICATION NO LUBRICATION OIL LUBRICATION NO LUBRICATION OIL LUBRICATION 2.5 ± 0.2 (18.0 ± 1.4)

2.1 ± 0.2 (15.2 ± 1.4)

4.5 ± 0.4 (32.5 ± 2.9)

3.8 ± 0.4 (27.4 ± 2.9)

M10 P=1.25 2.3 ± 0.2 (16.6 ± 1.4) 1.91 ± 0.19 (13.8 ± 1.4) 4.9 ± 0.5 (35.4 ± 3.6)

4.2 ± 0.4 (30.3 ± 2.9)

8.9 ± 0.9 (64.2 ± 6.5)

7.5 ± 0.7 (54.2 ± 5.1)

M12 P=1.25 4.0 ± 0.4 (28.9 ± 2.9)

3.4 ± 0.3 (24.5 ± 2.2)

8.7 ± 0.9 (62.8 ± 6.5)

7.3 ± 0.7 (52.7 ± 5.1)

15.7 ± 1.6 (113 ± 13) 13.2 ± 1.3 (95.3 ± 9.4)

M16 P=1.5

9.4 ± 0.9 (67.9 ± 6.5)

7.9 ± 0.8 (57.0 ± 5.8)

20 ± 2 (144 ± 14)

17.2 ± 1.7 (124 ± 12)

37 ± 4 (267 ± 29)

M20 P=1.5

19 ± 9 (137 ± 14)

15.8 ± 1.6 (114 ± 14)

41 ± 4 (296 ± 29)

34 ± 3 (246 ± 22)

74 ± 7 (535 ± 51)

62 ± 6 (448 ± 43)

M24 P=2

32 ± 3 (231 ± 22)

27 ± 3 (195 ± 22)

70 ± 7 (506 ± 51)

58 ± 6 (419 ± 43)

126 ± 12 (910 ± 87)

105 ± 10 (758 ± 72)

M30 P=2

65 ± 6 (469 ± 43)

54 ± 5 (390 ± 36)

142 ± 14 (1030 ± 100)

118 ± 12 (852 ± 87)

M36 P=3

109 ± 11 (787 ± 79)

91 ± 9 (657 ± 65)

238 ± 23 (1720 ± 170) 198 ± 20 (1430 ± 140) 428 ± 43 (3090 ± 310) 357 ± 36 (2580 ± 260)

M8

P=1.0

1.15 ± 0.11 (8.3 ± 0.8) 0.97 ± 0.1 (7.0 ± 0.7)

31 ± 3 (224 ± 22)

255 ± 26 (1840 ± 190) 212 ± 21 (1530 ± 150) F18239gb

6 — 15

Section VI – SPECIFICATIONS B . NUTS AND SLEEVES

B

NUT

SLEEVE

O.D. (Ø)

O.D. (Ø)

WORKING PRESSURE kgf/cm2 (psi)

350 (4,980) Travel line only

350 (4,980) Travel line only

TUBE SIZE O.D. X THICKNESS mm (in) 10 X 1.5 (0.394 X 0.059) 15 X 2.0 (0.591 X 0.079) 18 X 2.5 (0.709 X 0.098) 22 X 3.0 (0.866 X 0.118) 28 X 4.0 (1.10 X 0.157)

OPPOSING FLATS mm Dimension B 19 27 32 36 41

35 X 5.0 (1.38 X 0.20)

55

TORQUE VALUE kgf·m (lbf·ft) 4.5 ± 0.5 (33 ± 4) 15 ± 2 (108 ± 14) 18 ± 2 (130 ± 14) 22 ± 2 (159 ± 14) 28 ± 3 (203 ± 22) 35 ± 4.5 (253 ± 33) F18502gb

C . FLARE TYPE FITTING JOINTS Overtightening of flare type (Union nut type) metal joints may cause damage to nuts, seat surfaces and prevent optimum sealing resulting in oil leaks.

1. Pipe Threads Unit : kgf·m (lbf·ft) NOMINAL SIZE

TORQUE VALUE

1 / 4˝

2.5 ± 0.3 (18.1 ± 1.8)

3 / 8˝

5 ± 0.5 (36.2 ± 3.6)

1 / 2˝

6 ± 0.6 (43.4 ± 4.3)

3 / 4˝

12 ± 1.2 (86.8 ± 8.7)

1˝

14 ± 1.4 (101 ± 10)

1-1 / 4˝

17 ± 1.7 (123 ± 12)

1-1 / 2˝

21 ± 2.1 (152 ± 15)

2˝

42 ± 4.2 (304 ± 30)

D . N2 (NYLON) TUBE FITTING JOINTS 1. Clean tube and make certain tube end is trimmed smooth.

2. Insert tube into fitting until tube end is securely seated in fitting body.

3. Tighten the nut by hand.

4. Use a spanner wrench, securely tighten nut by turning 1-1/4 turns.

PLASTIC SLEEVE

F18503gb

BODY

E . ORS JOINTS (O-RING SEALING TYPE)

Hose mouth ring and coupling

NOMINAL SIZE

OPPOSING FLATS mm

TORQUE VALUE kgf·m (lbf·ft)

1-14 UNS

30 • 32

14 ± 1.4 (101 ± 10)

1-3/16 12 UN

36 • 41

18 ± 1.8 (130 ± 13)

1-7/16 12 UN

41 • 46

21 ± 2.1 (152 ± 15)

NYLON TUBE

NUT

WORKING PRESSURE kgf/cm2 (psi) 350 (4,980) F18501gb

O-RING

CONNECTOR

NIPPLE

NUT

6 — 16

Section VI – SPECIFICATIONS F . TORQUE VALUES FOR MOST COMMON BOLTS Follow the table below and tighten or retighten every capscrew and nut. Check for any loose or missing capscrews or nuts before daily operation and during periodical inspections. Retighten or supply new parts for missing ones as required.

Size

Q'ty

M5

5

• Sending unit mounting (fuel tank)

• 0.2 ± 0.02 (1.4 ± 0.1)

M6

6

• A/C Condenser mounting

• 0.45 ± 0.1 (3.2 ± 0.7)

M8

4 4 4

• Muffler mounting (Nut-Upper) • Muffler mounting (Nut-Lower) • A/C compressor mounting

• 1.1 ± 0.1 (7.9 ± 0.7) • 0.9 ± 0.09 (6.5 ± 0.7) • 2.7 ± 0.3 (20 ± 2.2)

M10

6 2 16 4 12 12 2

• Swivel joint dust cover mounting • Slewing grease bath inspection cover mounting • Floor plate rubber mouting • Air cleaner mounting • Power take-up bracket mounting • Hydraulic oil tank cover mounting • Lower frame grease cover mounting

• 1.5 ± 0.2 • 3.0 ± 0.3 • 4.7 ± 0.5 • 4.0 ± 0.4 • 4.0 ± 0.4 • 4.7 ± 0.5 • 1.1 ± 0.1

(10.8 ± 1.4) (21.7 ± 2.2) (34 ± 3.6) (29 ± 2.9) Apply Loctite #262 (30 ± 2.9) Apply Loctite #262 (34 ± 4.0) (7.9 ± 0.7)

M12

3 8 8 4 14

• Swivel joint mounting • Cab mounting • Engine mounting (Rear side) • Engine mounting (Front side) • Travel motor cover mounting

• 11 ± 1.0 • 11 ± 1.5 • 7.5 ± 0.8 • 10 ± 1.0 • 8.5 ± 0.5

(80 ± 7) (80 ± 11) (54 ± 5.8) (72 ± 7) (62 ± 4)

M16

6 4

• Fuel tank mounting • Floor plate rubber mounting nut

• 22 ± 2.0 • 19 ± 2.0

(159 ± 14) Apply Loctite #262 (137 ± 14)

M18

4 8

• Engine mounting • Power take-up coupling mounting

• 39 ± 4.0 • 33 ± 3.0

(282 ± 29) Apply Loctite #271 (238 ± 22)

M20

4 4 4 4 4 52

• Hydraulic pump mounting • Idler and idler adjuster connection • Radiator mounting • Hydraulic tank mounting • Upper roller mounting • Sprocket mounting

• 44 ± 4.0 • 55 ± 5.5 • 57 ± 6.0 • 55 ± 6.0 • 55 ± 5.5 • 55 ± 5.5

(318 ± 29) (398 ± 40) (412 ± 43) (398 ± 43) (398 ± 40) (398 ± 40)

Apply Loctite #262 Apply Loctite #262 Apply Loctite #262 Apply Loctite #262 Apply Loctite #262 Apply Loctite #262

• 75 ± 7.5

(542 ± 54)

Apply Loctite #262

Location

Tightening torque kgf¥m (lbfáft)

56 • Lower roller mounting (72-LC,NLC) M22 180 • Shoe bolt mounting (192-LC,NLC)

Apply Loctite #262 Apply Loctite #262 Apply Loctite #262

• 120 ± 12 (868 ± 87)

Apply SAE30 CD

Apply Loctite #262 Apply Loctite #262 Apply Loctite #262 Apply Loctite #262 Apply Loctite #262

M24

10 35 36 14 36 8

• Side cutter mounting (GD) • Slewing bearing outer race mounting • Slewing bearing inner race mounting • Swing reduction unit mounting • Travel motor mounting • Track guide mounting

• 105 ± 5 • 95 ± 9.5 • 95 ± 9.5 • 95 ± 9.5 • 95 ± 9.5 • 95 ± 9.5

M27

10

• Side cutter mounting (HD)

• 160 ± 16 (1157 ± 115)

M36 5/8-18 UNF

4

• Counterweight mounting

• 300 ± 30 (2170 ± 217) Apply Loctite #262

2

• Idler adjuster grease nipple mounting

•6±1

6 — 17

(759 ± 36) (687 ± 69) (687 ± 69) (687 ± 69) (687 ± 69) (687 ± 69)

(43 ± 7)

Section VI – SPECIFICATIONS 6.4 MISCELLANEOUS INFORMATION

D . CAPS AND PLUGS FOR TUBES AND HOSE FITTINGS

A . TEMPERATURE TABLE °C

°F

-10 14 -5 23 0 32 5 41 10 50 15 59 20 68 25 77 30 86 35 95 40 104 45 113 50 122

°C

°F

°C

°F

°C

°F

°C

°F

°C

°F

55 60 65 70 75 80 85 90 95 100 105 110 115

131 140 149 158 167 176 185 194 203 212 221 230 239

120 125 130 135 140 145 150 155 160 165 170 175 180

248 257 266 275 284 293 302 311 320 329 338 347 356

185 190 195 200 205 210 215 220 225 230 235 240 245

365 374 383 392 401 410 419 428 437 446 455 464 473

250 255 260 265 270 275 280 285 290 295 300 305 310

482 491 500 509 518 527 536 245 554 563 572 581 590

315 320 325 330 335 340 345 350 355 360 365 370 375

599 608 617 626 635 644 653 662 671 680 689 698 707

B A

TUBE DIA.

Example of how to convert 45°C to °F: °F = 1.8 X °C + 32 °F = 1.8 X 45 + 32 = 81 + 32 = 113˚F ° Example of how to convert 122˚F to C ° ° ° ° C = 0.56 ( F - 32) C = 0.56 (122 - 32) = 0.56 X 90 = 50 C

F18505gb

"A" INTERNAL (For hose end)

"B" NUT (Use with "A")

"C" EXTERNAL (For tube end)

10 mm 15 mm 18 mm 22 mm

B . SPECIAL PIPE WRENCHES A

C

Tube & Hose Plugs

28 mm

B

35 mm C

G

Male PF Plugs F TUBE DIA.

"D"

D

E

"C" "B"

A

B

C

D

E

F

G

15 27 70 22 8 12.7 40 16 (0.591) (1.06) (2.76) (0.87) (0.50) (0.32) (1.57) (0.63)

"A" Dia. (ø)

32 70 22 12.7 42 11 18 19 (0.709) (1.26) (2.76) (0.87) (0.50) (0.43) (1.65) (0.75) 36 70 22 12.7 11.5 48 23 22 (0.866) (1.42) (2.76) (0.87) (0.50) (0.44) (1.89) (0.91) 41 109 22 12.7 14.5 60 28 29 (1.10) (1.614) (4.29) (0.87) (0.50) (0.57) (2.36) (1.14)

60°

55 90 45 20.5 81 35 20 41 (1.38) (2.17) (3.54) (1.77) (0.79) (0.81) (3.19) (1.61) F18507gb

C . WEIGHT OF MATERIALS TABLE lb/yd3 700 750 950 1170 1600 1780 2100 2100 2250 2400 2500 2550 2600 2700 2800 2800 2850 2900 3100 3400

kg/m3 420 440 560 690 950 1050 1250 1250 1330 1420 1480 1510 1540 1600 1660 1660 1690 1720 1840 2020

Material (loose weight) Wood chips Peat, dry Cinders Peat, wet Topsoil Coal Caliches Earth, loam Shale Sand, dry Clay, dry Earth, dry Limestone, broken or crushed Earth, wet Clay, wet Rock, granite, blasted & broken Sand, moist Sand and gravel, dry Sand, wet Sand and gravel, wet

PLUG SIZE

"A" O.D. (Ø)

"B" LENGTH

"C" LENGTH

"D" FLATS

PF 1/4

13.5

16.5

24.5

14

PF 3/8

16.6

17.5

25.5

17

PF 1/2

20.6

20.0

31.0

22

PF 3/4

26.2

21.5

34.0

27

PF 1

33.3

23.5

36.0

36 F18509gb

Female PF caps SIZE PF 1/4 PF 3/8 Thread Screw

PF 1/2 PF 3/4 PF 1 PF 11/4

F18508gb

6 — 18

Section VII – TROUBLESHOOTING Table of Contents 7.1 GENERAL TROUBLESHOOTING .......................................................................................................................... 7-1

WARNING READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS AND PROCEDURES FOUND IN THIS MANUAL BEFORE ATTEMPTING ANY OPERATION, INSPECTION OR MAINTENANCE OF THIS MACHINE, ATTACHMENT OR SYSTEMS.

7—0

Section VII – TROUBLESHOOTING 7.1 GENERAL TROUBLESHOOTING This troubleshooting information covers the components and systems as described in this MANUAL. Should in depth troubleshooting, repair or replacement of components or adjustment of valves be required, contact your Dealer for assistance.

OPERATING Problem

Probable cause

Possible remedy

All operating speeds are slow or power is lost.

Low hydraulic oil level.

Fill oil to specified level.

Air leaking into the suction pipe.

Tighten suction pipe hose clamp or replace hose.

Hydraulic pump is damaged.

Repair or replace.

Pilot gear pump is damaged.

Repair or replace.

Main relief valve is not adjusted correctly.

Adjust or replace.

Pilot relief valve is not adjusted correctly.

Adjust or replace.

Cylinder seal is damaged.

Repair or replace.

Control valve or overload valve functions incorrectly or there are signs of air in the cylinder.

Repair or replace/Bleed air from cylinder.

Pilot valve is damaged.

Repair or replace.

Pilot valve piping is loose.

Retighten.

Cylinder seal is scored.

Repair or replace.

Control valve or overload valve is damaged.

Repair or replace.

Overload valve is not operating.

Repair or replace.

Pilot valve is damaged.

Repair or replace.

Brake valve is not working.

Repair or replace.

Hydraulic motor (swing) is not working or slewing gear is damaged.

Repair or replace.

A specific cylinder functions improperly or loses power.

The cylinder position will not hold with operating lever in neutral.

Machine does not swing.

Swing bearing is damaged.

Repair or replace.

Pilot valve is not working.

Repair or replace.

Swing reduction unit is damaged.

Repair or replace.

7—1

Section VII – TROUBLESHOOTING OPERATING Problem

Probable cause

Possible remedy

Swing speed is slow.

Brake valve is not working.

Repair or replace.

Control valve is not working.

Repair or replace.

Hydraulic motor (swing) is not working.

Repair or replace.

Hydraulic pump is not working.

Repair or replace.

Insufficient lubrication of slewing gear and bearings.

Grease.

Low oil level in the swing reduction unit.

Refill with proper oil.

Brake valve malfunctions.

Repair or replace.

Set pressure of brake valve is incorrect.

Adjust or replace.

Brake lining is worn.

Repair or replace.

Abnormal sound occurs when swing.

With swing stopped, the machine drifts and is hard to control.

7—2

Section VII – TROUBLESHOOTING TRACKS Problem

Probable cause

Possible remedy

Machine does not travel smoothly.

Too much track tension.

Adjuster track tension.

Dirty track links and shoes.

Clean tracks.

Brake valve is not working.

Repair or replace.

Travel reduction unit is damaged.

Repair or replace.

Hydraulic pump is damaged.

Repair or replace.

Poor engine performance.

Repair or replace.

Main relief valve pressure is set incorrectly.

Adjust or replace.

Low hydraulic oil level.

Fill to proper level.

Hydraulic motor (travel) is not working.

Repair or replace.

Brake valve is not working.

Repair or replace.

Seal in swivel joint is scored or oil is leaking.

Repair or replace.

Unequal tensions on tracks.

Adjust tension.

Set pressures of main relief valves unbalanced.

Adjust.

Performances of hydraulic travel motor has deteriorated.

Repair or replace.

Traveling power is insufficient.

Machine does not travel in a straight line.

7—3

Section VII – TROUBLESHOOTING HYDRAULIC Problem

Probable cause

Possible remedy

Temperature rise in the hydraulic oil temp.

Oil cooler core clogged.

Clean.

Engine fan belt slipping.

Adjust or replace.

Low hydraulic oil level.

Refill to specified level.

Wrong type hydraulic oil used.

Replace with correct, new oil.

Hydraulic pump is not working.

Repair or replace.

GAUGE CLUSTER DISPLAY Problem

Probable cause

Possible remedy

Engine oil pressure is too low.

(Buzzer sounds and icon displays).

Engine oil level low.

Fill to specified level.

Oil leaking.

Repair and fill to proper level.

Wrong oil viscosity.

Replace with proper oil.

Low coolant.

Fill to proper level.

Coolant leaking.

Repair and fill to proper level.

Loose radiator cap.

Tighten.

Radiator core clogged.

Clean cooling system.

V-belt loose or damaged.

Tighten to proper tension.

Rust or scale in coolant.

Flush system/fill to level.

Faulty thermostat.

Replace.

Clogged air cleaner.

Replace elements.

Hoses from air cleaner to turbo clogged.

Clean, repair or replace.

Abnormal rise in the coolant temperature.

(Buzzer sounds and icon displays).

Air cleaner clogged.

7—4

Section VII – TROUBLESHOOTING ENGINE Problem

Probable cause

Possible remedy

Starter does not turn or turns slowly which does not start the engine.

Battery disconnected.

Connect.

Battery discharged.

Charge.

Battery terminals disconnected, loose, or corroded

Clean and connect.

Ground cable disconnected.

Connect.

Engine oil viscosity too thick (Cold Weather)

Change to proper oil.

Insufficient fuel.

Refuel.

Improper starting procedure.

Refer to section “BASIC MACHINE OPERATION”.

Air in fuel line.

Bleed.

Clogged fuel filter.

Replace element.

Clogged air cleaner.

Replace elements.

Air heater circuit malfunctioning.

Check circuit.

Low idling RPM.

Contact authorized workshop/Dealer.

Fuel filter clogged.

Replace element.

Air cleaner clogged.

Replace elements.

Improper valve clearance.

Contact authorized workshop/Dealer.

Fuel filter clogged.

Replace element.

Air cleaner clogged.

Replace element.

Improper valve clearance.

Contact authorized workshop/Dealer.

Loose clamps on the air inlet hose (with turbo charger).

Tighten clamps.

Cracked air inlet hose (with turbo charger).

Replace hose.

Insufficient coolant

Refill coolant.

Clogged radiator.

Clean cooling components.

V-belt to loose or damaged.

Adjust or replace belt.

Faulty thermostat.

Replace.

Air cleaner clogged.

Replace elements.

Improper valve clearance.

Contact authorized workshop/Dealer.

Starter turns but engine does not start.

Engine tends to stop at low speed.

No power.

Engine overheats.

Engine exhaust is black.

7—5

Section VII – TROUBLESHOOTING ENGINE Problem

Probable cause

Possible remedy

Poor fuel consumption.

Fuel leak.

Contact authorized workshop/Dealer.

Air cleaner clogged.

Replace elements.

Loose clamps on suction hose (with turbo charger).

Tighten clamps.

Cracked suction hose (with turbo charger).

Replace w/new hose.

Improper oil.

Replace with correct oil.

Oil leak.

Contact authorized workshop/Dealer.

Improper oil replacement intervals.

Change at correct interval.

Improper warming-up operation.

Refer to paragraph 3.5 - Section III.

Low oil volume.

Fill to specified level.

Oil leak.

Contact authorized workshop/Dealer.

Improper oil viscosity.

Replace with proper oil.

Battery teminals disconnected loose, or corroded.

Clean and tighten terminals.

Low battery electrolyte.

Fill cells w/distilled water.

V-belt loose or damaged.

Adjust or replace belt.

Defective battery.

Replace battery.

Excessive oil consumption.

Engine oil pressure does not rise.

Battery dies often.

7—6

Section VIII – OPTIONAL EQUIPMENT Table of Contents 8.1 HYDRAULIC BREAKER ....................................................................................................... 8-1 8.2 SAFETY PRECAUTIONS ...................................................................................................... 8-5 8.3 MAINTENANCE FOR NIBBLER/BREAKER ........................................................................ 8-7 8.4 REINFORCEMENT OF ATTACHMENT ................................................................................ 8-7 8.5 EXTRA (GRAPPLE, CLAMSHELL, ETC) AND NIBBLER & BREAKER ............................. 8-8 8.6 3-PIECE DEMOLITION ATTACHMENT ................................................................................. 8-9

WARNING READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS AND PROCEDURES FOUND IN THIS MANUAL BEFORE ATTEMPTING ANY OPERATION, INSPECTION OR MAINTENANCE OF THIS MACHINE, ATTACHMENT OR SYSTEMS.

8—0

Section VIII – OPTIONAL EQUIPMENT 8.1 HYDRAULIC BREAKER A. SELECTION OF THE HYDRAULIC BREAKER When mounting the breaker on the hydraulic excavator, it is necessary to match stability, hydraulic pressure, and the oil level for each breaker. To select hydraulic breakers, contact your Dealer.

B. BEFORE OPERATING THE HYDRAULIC BREAKER Consult your Dealer for the piping or enforcement of the arm when installing the hydraulic breaker.

REPLACE THE HYDRAULIC RETURN FILTER ACCORDING TO THE REPLACEMENT SCHEDULE TABLE LISTED ON PAGE 8-7.

Thoroughly read the hydraulic breaker operation manual and SAFETY PRECAUTIONS from this section, as well as the safety precaution’s section on this manual to avoid damaging the machine or hydraulic breaker during operation.

SELECT THE APPROPRIATE HYDRAULIC FLOW FOR THE BREAKER BY FOLLOWING THE INSTRUCTIONS DETAILED IN PAGE 8-2.

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

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

D. BASIC OPERATION

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

SAFETY LOCK LEVER IN UNLOCKED (DOWN) POSITION

1. Start machine and place the safety lock lever in the “UNLOCKED” (Down) position. See Figure 8.1.

2. Move throttle control to the “HI” idle position.

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

4. Release control pedal lock rod. See Figure 8.2.

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

6. Place right foot on pedal and depress with toe to activate breaker or nibbler. See Figure 8.2.

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

FIGURE 8.1

PUSH LOCK ROD FORWARD TO RELEASE

PULL LOCK ROD BACKWARD TO LOCK PEDAL DEPRESS PEDAL WITH TOE TO ACTIVATE

WARNING OPERATION OF BREAKER OR NIBBLER LONGER THAN ONE MINUTE INTERVALS COULD CAUSE PREMATURE WEAR OR DAMAGE TO THE ATTACHMENT AND THE MACHINE. IF MATERIAL IS NOT BREAKING, REPOSITION BREAKER OR NIBBLER AND REPEAT OPERATION IN ONE MINUTE INTERVALS.

FIGURE 8.2

WARNING NEVER LEAVE THE OPERATOR CAB WITH ENGINE RUNNING.

8—1

Section VIII – OPTIONAL EQUIPMENT E. BREAKER AND NIBBLER SELECTOR SWITCH This machine is provided with breaker or nibbler single circuit and nibbler and breaker Bi direction flow circuit.

To use breaker or nibbler, select circuit appropriate to the specification through switch on the side of driver’s seat. See Figure 8.3.

1. Switch Position Specification

Switch Position

Breaker

Circuit Single flow

Nibbler Nibbler flow

Bi direction

CAUTION Never turn switch on (Bi direction flow) to operate breaker.

It may cause damage of machine.

FIGURE 8.3

F. SELECTION OF B (BREAKER) MODE – SEE FIGURE 8.4 AND 8.5 In case the attachments in option like breaker, etc. are used, the flow rate can be altered to optimum value automatically.

Adjust the max. flow rate by the following procedure.

Each time the work mode is pressed, the work mode indicator lamp is switched to · or in order.

1. Adjusting Max. Flow Rate Turn the screen change switch of gauge cluster ON within 3 to 10 seconds after turning the starter switch ON (E/G does not start) and the mode switch to B (breaker) mode, and the mode is switched to adjust mode.

FIGURE 8.4

KPSS WORK MODE LAMP

2. Flow Rate Display The last stored flow rate is indicated on the display, but the max. flow rate is initially displayed as a reference. Each time the mode switch is pressed the displayed value of flow rate increases, and each time the buzzer stop switch is pressed the displayed value decreases. Since the increasing and decreasing action starts in 2 seconds after pressing either of switches and is indicated by graduation of 10 L/min, release the hand immediately after the desired value of flow rate is displayed.

The flow rate can be adjusted within the range of max. flow rate and min. flow rate.

Turn the screen change switch ON again, and the maximum value of flow rate is stored and the adjust mode is canceled.

6

SCREEN CHANGE SWITCH

FIGURE 8.5

8—2

KPSS WORK MODE SWITCH

Section VIII – OPTIONAL EQUIPMENT G. CONTROL PEDAL 1. Hydraulic Breaker Single Circuit Release pedal lock on the right front side of driver’s seat to operate pedal. See Figure 8.6.

CAUTION Precaution for pedal operation.

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

Foot Pedal Depressing

Operating Condition

Section Depress toe section

Breaker starts operation

Pedal in neutral section

Breaker stops operation

PUSH LOCK ROD FORWARD TO RELEASE

2. Nibbler and Breaker Combined (Conflux) Circuit Release pedal lock on the right front side of driver’s seat to operate pedal. See Figure 8.6.

DEPRESS PEDAL WITH TOE TO ACTIVATE

PULL LOCK ROD BACKWARD TO LOCK PEDAL

Hydraulic breaker Foot Pedal Depressing

Operating Condition FIGURE 8.6

Section Depress heel section

Breaker stops operation

Pedal in neutral section

Breaker starts operation

Nibbler Foot Pedal Depressing

Operating Condition

Section Depress toe section

Nibbler close

Depress heel section

Nibbler open

WARNING NEVER LEAVE THE OPERATOR CAB WITH ENGINE RUNNING.

8—3

Section VIII – OPTIONAL EQUIPMENT H. SETTING SELECTOR VALVE – FIGURE 8.7 For machines provided in nibbler and breaker specification, the selector valve installed on the main control valve is required to be switched to the position corresponding to the specification.

(A)

NOTE • Inappropriate switching of selector valve may cause decrease of work efficiency and operating speed due to inferior operation, and also cause damage of machine.

Securely switch selector valve.

• Be sure to switch selector valve 1 or 2 times a month periodically.

FIGURE 8.7 IN SERVICE OF BREAKER

TO HYD. TANK STAMP

1. Tools Used Circuit

Tools

(A)

Main (circuit)

Spanner (24 mm)

B TO ATT.

N

Selector Valve

Allen Wrench (5 mm)

TO C/V

FIGURE 8.8 IN SERVICE OF NIBBLER

2. Setting Procedure – FIGURE 8.8 ~ 8.9 a. Use a allen wrench to loosen and remove the socket bolt. b. Use a wrench to turn the selector valve to the proper position. c. After the valve is in the proper position, tighten the socket bolt. d. Markings of the selector valve are shown below.

B: Breaker N: Bi direction flow of nibbler

TO HYD. TANK

N

B

TO ATT.

TO C/V

FIGURE 8.9 I. SETTING STOP VALVE – FIGURE 8.10 Stop valve on arm top end is used to stop hydraulic oil flowing.

Free: Hydraulic oil flows.

Stop: Hydraulic oil stops flowing.

Before removing attachment, set stop valve to “STOP” position.

(B)

1. Tools Used Stop Valve

Circuit

Tools

(B)

Main (Arm)

Spanner (24 mm) mm 20

FREE

STOP

FIGURE 8.10

8—4

Section VIII – OPTIONAL EQUIPMENT 8.2 SAFETY PRECAUTIONS The following safety precautions should be used in conjunction with all other safety precautions found in this manual.

WARNING READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS AND OPERATING PROCEDURES FOUND IN THIS MANUAL BEFORE OPERATING THE MACHINE OR ANY ATTACHMENT. FIGURE 8.11 A. USE FOR INTENDED PURPOSE – FIGURE 8.11 Use the attachment only for its intended purpose. If not used in accordance with the manufactures instructions, the excessive pressure exerted on the boom, arm and frame structure of the machine will cause premature failure of the components.

B. PASSENGERS Never allow passengers on the attachment or machine.

INSTALL GUARD AND CLOSE WINDOWS

FIGURE 8.12

C. PROTECTIVE EQUIPMENT – FIGURE 8.12 Install protective guards on the machine and close the all window to protect the operator from flying debris. Also the operator and all personnel in the vicinity of the machine should wear protective gear such as safety shoes, hard hat, gloves and face shield or goggles.

D. CYLINDERS – FIGURE 8.13 Do not operate boom, arm or bucket cylinders to stroke ends when using a breaker attachment. Doing this can cause undue stress on the cylinder rods and result in damage.

FIGURE 8.13 E. AVOID CONTINUOUS OPERATION – FIGURE 8.14 Operate the breaker or nibbler in one minute intervals.

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

Within One Minute

FIGURE 8.14

8—5

Section VIII – OPTIONAL EQUIPMENT F. HOSE SURGE – FIGURE 8.15 Should the hydraulic hoses begin to surge or vibrate abnormally during operation of a breaker or nibbler, immediately stop operation and contact a distributor for assistance. This problem often is a result in damaged accumulators and can also result in valve failure.

G. DO NOT USE DROPPING FORCE – FIGURE 8.16 Never use the dropping force of the attachment to break or drive objects. This will cause extensive damage to the attachment and machine structure.

FIGURE 8.15

H. DO NOT USE SWING FORCE – FIGURE 8.17 Never use the swing force of the machine for pushing or sliding objects. This will cause premature failure of the attachment and other machine components.

FIGURE 8.16

I. DO NOT LIFT – FIGURE 8.18 Never use an optional attachment to lift or transport objects or material. Doing so can cause extensive damage to the attachment, the machine structures and cause injury or death.

FIGURE 8.17

FIGURE 8.18

J. WORKING RANGES – FIGURE 8.19 Never operate an optional attachment over the sides of the machine. Only operate over the front or rear of the tracks.

UNACCEPTABLE WORK RANGE

ACCEPTABLE WORK RANGE

ACCEPTABLE WORK RANGE

UNACCEPTABLE WORK RANGE

FIGURE 8.19

8—6

Section VIII – OPTIONAL EQUIPMENT 8.3 MAINTENANCE BREAKER

FOR

NIBBLER/

DEPRESS RUBBER CAP TO RELEASE PRESSURE

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

HYDRAULIC TANK

FIGURE 8.20

Replacement Schedule Component

Location

1st Maintenance

2nd Maintenance

Regular Maintenance

Change Hydraulic oil

Hydraulic tank

-

-

Every 600 hours

Return filter for nibbler/

Hydraulic tank

50 hours

250 hours

Every 250 hours

Hydraulic tank

50 hours

250 hours

Every 250 hours

braker Return filter element kit for std & nibbler/breaker

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

8—7

Section VIII – OPTIONAL EQUIPMENT 8.5 EXTRA (GRAPPLE, CLAMSHELL, ETC) AND NIBBLER & BREAKER A. BASIC OPERATION

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

SAFETY LOCK LEVER IN UNLOCKED (DOWN) POSITION

FIGURE 8.22

1. Start machine and place the safety lock lever in the “UNLOCKED” (Down) position. See Figure 8.22.

2. Move throttle control to the “HI” idle position.

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

4. Place the “EXTRA” switch, located on the L.H. control console, to the “ON” position. See Figure 8.23.

5. Use the boom, arm and bucket controls to position the attachment.

6. Place right foot on pedal and depress with toe to close attachment and depress back of pedal with heel to open attachment. See Figure 8.23.

7. After operation is complete or operator is required to leave the machine, place pedal lock rod in the locked position, operate attachment in hydraulic oil check position, move throttle control to “LO” idle position.

PLACE EXTRA SWITCH IN THE “ON” POSITION

PRESS HERE FOR “OFF”

FIGURE 8.23 PUSH LOCK ROD FORWARD TO RELEASE

DEPRESS PEDAL WITH TOE TO ACTIVATE PULL LOCK ROD BACKWARD TO LOCK PEDAL

SUPPLEMENTARY EXPLANATION For machine provided in extra & breaker specification, before starting operating, unlock left control pedal. See Figure 8.24.

EXTRA SPEC.

WARNING NEVER LEAVE THE OPERATOR CAB WITH ENGINE RUNNING.

PUSH LOCK ROD FORWARD TO RELEASE

PULL LOCK ROD BACKWARD TO LOCK PEDAL

DEPRESS PEDAL WITH TOE TO ACTIVATE

BREAKER SPEC.

FIGURE 8.24

8—8

SECTION VIII - OPTIONAL EQUIPMENT

8.6 3-PIECE DEMOLITION ATTACHMENT 8.6.1 PRE-START SAFETY Many failures that occur during machine operation or servicing result from neglecting fundamental safety precautions. The following safety precautions are given to prevent such failures, but they are only a part of what you must follow. Read, understand and follow all safety precautions found in this manual and on the machine thoroughly before operating the machine.

A. CONFIRM THE WORKING MODE This machine is set for “A” mode start to obtain the best performance as a special demolition machine.

Always operate the machine with working mode “A” position.

Unsuitable control of machine may occur if operating with other working mode except “A” mode.

Read, understand and follow operating procedures found in this manual before operating this machine or any attachment.

B. DON’T PRESS THE CONTROL CARELESSLY The foot pedal for jib cylinder and the crusher specification is located on the floor plate at the foot of operator, so be careful not to press the pedal when operating, or getting on and off by mistake, and also don’t fail to lock the pedal lock when SPECIAL DEMOLITION ATTACHMENT is not operate.

A. Push lock rod forward to release B. Pull lock rod backward to lock pedal C. Depress pedal with toe to activate

8-9

SECTION VIII - OPTIONAL EQUIPMENT C. SAFETY CHECK AROUND THE MACHINE Check the safety around the machine before starting operation, and make certain there are no obstacles within the operating range around the machine.

Also, station an experienced person to signal operator to prevent strangers from coming into the vicinity of the machine and to prevent the machine from coming into contact with constructions when working in the site in towns and narrow areas.

D. PRECAUTIONS WHEN TRAVELLING When travelling position the attachment as shown in the figure, keeping the attachment in the height of 30 to 40 cm above the ground.

Run the machine at slow speed on the rough ground, and don’t change the directions suddenly.

E. THE ENGINE SHOULD BE STARTED FROM ALARM Ensure safe operation of the machine by sounding the travel alarm and horn and also paying attention to the moving range of the front attachment when starting engine, running machine and starting the swing motion.

F. START THE MACHINE TRAVELLING AFTER MAKING SURE OF THE DIRECTION Before starting the machine, make sure that the travel device is directed frontward or rearward and move the control lever gradually to run at slow speed first.

8-10

SECTION VIII - OPTIONAL EQUIPMENT G. SAFETY CHECK WHEN PARKING When parking on sloping ground is unavoidable, don’t fail to put the crusher on the ground and stop the crawler.

A. BLOCK

H. MAKE SURE THAT CRUSHER IS IN CONTACT WITH BOOM AND CRAWLER Make sure that a part of the crusher does not come into contact with boom and the top end of crawler when fully retracting the arm toward the boom.

I. PRECAUTION BEFORE LEAVING FROM OPERATOR’S SEAT Before leaving from the operator’s seat of machine, don’t forget to put the crusher on the ground, place the lever to the neutral position, raise the safety lock lever to lock, and then stop the engine. Keep the key to avoid it being operated by others without permission.

8-11

SECTION VIII - OPTIONAL EQUIPMENT 8.6.2 MACHINE OPERATIONS NOT ALLOWED Improper operation when demolishing using of long range machine specialized for demolition may cause damage of crusher, attachment and also the machine itself, or the work may become dangerous. To prevent these troubles, master the safe and correct operating skill including similar operations referring to precautions in operation which are described with concrete examples.

A. BE CAREFUL FOR MACHINE NOT TO STRIKE The working operation hitting or striking the crusher with objects may cause damage of crusher, machine, boom, arm, link, etc. by unreasonable pressure.

B. DON’T PINCH OR PULL, HOLDING THE OBJECT BY CRUSHER Don’t pinch or pull unreasonably, holding a part of building or construction by crusher.

C. NEVER OPERATE SWING MOTION, HOLDING THE OBJECT BY CRUSHER It is very dangerous to pull down the object by swinging force of the body, holding the crusher.

8-12

SECTION VIII - OPTIONAL EQUIPMENT D. THE CUTTER SHOULD BE USED ONLY FOR STEEL BARS The cutter section (A) should not to be used to break any objects other than steel bars.

E. DON’T CATCH OBJECT OBLIQUELY Place the machine selecting the machine position and breaking position in order no to catch the object to be broken against the opening of the crusher.

F. BREAK OBJECT IN RATHER SMALL SIZE Break the wall, pillar, beam, slab, etc. as small as possible in size, and be careful not to drop items on the street side.

G. DON’T TRAVEL HOLDING OBJECT BY CRUSHER Don’t pull the object through travelling force holding the top end of building or construction by crusher.

8-13

SECTION VIII - OPTIONAL EQUIPMENT H. DON’T USE CRUSHER OUT OF THE AREA FOR THE OPERATING RADIUS This machine is equipped with “Operating range limit alarm” device, which is used to prevent turning over. When the working area of crusher spreads beyond the limited range, the buzzer sounds for 2 seconds continuously and the gauge cluster displays the “CAUTION TURNING”.

It is strictly prohibited to operate in the range of danger zone because it may cause the machine to turn over.

NOTE: buzzer sounds, but the machine does not stop operating.

A. Danger zone B. Safety zone I. WORK ON THE FLAT AND HARD GROUND Select flat and hard ground to place the machine. Don’t work in the inclined machine condition where the crawler is placed on the soft ground or the broken pieces, etc. It my cause the machine to turn over.

J. BE CAREFUL NOT TO DROP THEM ON THE HEAD Don’t operate the machine in the condition where broken pieces may drop on the head.

8-14

SECTION VIII - OPTIONAL EQUIPMENT K. CYLINDER STROKE GIVING A SUFFICIENT ALLOWANCE The breaking work in the condition where the cylinder is moved to the stroke end may cause damage of the cylinder.

Don’t operate the cylinder in the bucket cylinder stroke end; it may cause damage of the cylinder, link and rod pin.

When the bucket cylinder reaches to the position of 75 mm just before the stroke end, the proximity switch (B) acts on and the buzzer in the cab sounds. Then move the bucket cylinder in the opposite direction.

A. Allowances

8-15

SECTION VIII - OPTIONAL EQUIPMENT 8.6.3 FAMILIARIZATION All operators, service mechanics and personnel responsible for operation, inspection and maintenance of the machine should become thoroughly familiar with the controls and components and their functions before working with or on this equipment.

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

GENERAL MACHINE NOMENCLATURE The nomenclature drawing below, points out locations of major components of the E335(LC) hydraulic excavator.

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

8-16

SECTION VIII - OPTIONAL EQUIPMENT 1.

2.

3.

4.

5.

6.

7.

8.

10.

11.

3.33 m main boom 2.65 m insert boom 4.485 m front boom 2.3 m inter boom 5.85 m arm Crusher (locally procured) Bucket cylinder and protector Debris redirector Water lines (opt.)

Arm cylinder

12.

13.

14.

15.

16.

17.

18.

19.

20.

Jib cylinder Cab guard Counterweight (heavy type) Angle sensor (boom) Angle sensor (inter boom) Angle sensor (arm) Cylinder stroke end proximity switch One way call Auto greaser controller

8.6.4 OPERATOR CAB NOMENCLATURE The operator cab nomenclature, points out locations of operator controls of the E335(LC) long range machine for demolition hydraulic excavator operator cab. Study these areas and locate these components on the machine.

Specific information regarding these components are explained on the following pages of this section.

1.

2.

3.

4.

Right hand operator control lever (with switch for right rotation of crusher) Gauge cluster Right operator pedal (crusher close / open) Left operator pedal (jib cylinder extend / retract)

5.

6.

7.

8.

9.

8-17

Left hand operator control lever (with switch for left roration of crusher) Breaker and crusher selector switch L.M.N (crusher) / B.H (back hoe) selector switch Rotary light switch Sky light wiper switch

SECTION VIII - OPTIONAL EQUIPMENT 8.6.5 2-PIECE BOOM OPERATION OF HYDRAULIC CONTROLS The following instructions are aimed at providing an operator with the basic function of each hydraulic control. Use of these instructions, and practice with a machine, will allow a given operator to become more efficient in the operation of this equipment. Each operator must read, understand and follow these basic instructions along with all safety precautions found in this manual and on the machine before operating this equipment.

YYy S WARNING YYy

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

ALWAYS KNOW THE LOCATION OF TRAVEL MOTORS BEFORE OPERATING ANY HYDRAULIC CONTROLS. A. Travel motors at rear of machine A. SAFETY LOCK LEVER Unlocked Position BeforAe any hydraulic operation is possible the safety lock lever must be placed in the “UNLOCKED” (DOWN) position. Placing the safety lock lever in the UNLOCKED (DOWN) position also positions the left operator’s console in its operating position.

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

YYy S WARNING YYy Always place the safety lock lever in the “locked” (up) position before leaving cab to prevent any operation of hydraulic controls. Failure to place safety lock lever in the locked (up) position could result in serious injury or death as well as serious damage to the machine and its components.

8-18

SECTION VIII - OPTIONAL EQUIPMENT 8.6.6 OPERATION PATTERN A. LONG RANGE MACHINE SPECIALIZED FOR DEMOLITION OPERATION PATTERN The operating pattern of special demolition attachment is shown in the figure.

Understand the operating pattern thoroughly before operation.

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

A. Horn * One of 3 switches on the control lever is used to rotate the crusher.

8-19

SECTION VIII - OPTIONAL EQUIPMENT Left hand control lever

Right hand control lever

1

Right swing

5

Boom down

2

Left swing

6

Boom up

3

Arm out

7

Crusher down

4

Arm in

8

Crusher up

9

Jib cylinder retract

11

Crusher open

Left control pedal 10 Jib cylinder extend

Right control pedal 12 Crusher close

Crusher rotation switch 13 Switch ON, and it rotates right 14 Switch ON, and it rotates left

8-20

SECTION VIII - OPTIONAL EQUIPMENT

YYy S WARNING YYy

B. BACK-HOE OPERATION PATTERN The operating pattern of back-hoe is shown in the figure.

Understand the operating pattern thoroughly before operation

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

A. Transport position B. Digging position Left hand control lever

Right hand control lever

1

Right swing

5

Boom down

2

Left swing

6

Boom up

3

Arm out

7

Bucket in (digging)

4

Arm in

8

Bucket out (dumping) SUPPLEMENTARY EXPLANATION Application of 3.33 m main boom in long range special demolition attachment.

When the 3.6 m front boom, standard arm in 3.3 m and bucket are installed, they can be used as backhoe attachment.

8-21

SECTION VIII - OPTIONAL EQUIPMENT 8.6.7 COMPONENT AND CONTROLS NOMENCLATURE The following information provides a brief description and function of the components and controls of the E330(LC) long range machine for demolition.

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

A. SPECIAL DEMOLITON ATTACHMENT SWITCH POSITION 1. Sky Light Wiper Switch Switch used to move wiper on the sky light.

• Press the symbol mark, and the wiper starts moving.

• Press the lower side (no symbol mark), and the wiper stops moving.

2. Breaker and Crusher Selector Switch This machine is provided with breaker single circuit and crusher and breaker Bi direction flow circuit. To use breaker or crusher, select circuit appropriate to the specification through switch on the left side of driver’s seat.

1. Switch position Specification

Switch position

Circuit

Breaker Crusher

Single flow

Crusher

Bi direction flow

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

3. L.M.N (Crusher) / B.H (Back-hoe) Selector Switch Selector switch when being used for backhoe specification after removing the parts other than the main boom of attachment from the machine for L.M.N crusher or L.M.N rotating crusher, and attaching the front boom and arm.

8-22

Specification

Switch position

L.M.N. (Crusher)

L.M.N.

B.H (Back-hoe)

B.H

NOTE: 1. When the arm lever is set to the L.M.N (crusher) side The oil flow to the head side and rod side of the arm cylinder to meet the arm operating direction with L.M.N (crusher) operation is changed, consequently the arm lever is moved in the same operation as B.H (back-hoe) operation.

2. When the switch is set to B.H (back-hoe) side The hydraulic circuit is changed from L.M.N (crusher) work to the back-hoe work to meet the arm operating direction to B.H (back-hoe) work.

SECTION VIII - OPTIONAL EQUIPMENT 4. Rotary Light This switch is located to the rear on the left hand control console. Its basic function is to turn the rotary light “ON” and “OFF”.

• Depress this side to turn rotary light (A) “ON”.

• Depress empty side of switch to turn rotary light “OFF”.

SUPPLEMENTARY EXPLANATION If the cartridge is replaced with new one, press the “ESC” key for 5 seconds or more. When release your finger from key, figure 0 flickers 3 to 4 times on the indicator, and it shwos the reset of greasing limit frequency.

8-23

SECTION VIII - OPTIONAL EQUIPMENT B.

SETTING SELECTOR VALVE For machines provided in nibbler and breaker specification, the selector valve installed on the main control valve is required to be switched to the position corresponding to the specification.

NOTE: • Inappropriate switching of selector valve may cause decrease of work efficiency and operating speed due to inferior operation, and also cause damage of machine. Securely switch selector valve.

• Be sure to switch selector valve 1 or 2 times a month periodically.

1. Tools used Selector valve

Circuit

A

Main circuit

Tool Spanner (24 mm) Allen wrench (5 mm)

2. Setting Procedure a. Use a allen wrench to loosen and remove the socket bolt. b. Use a wrench to turn the selector valve to the proper position. c. After the valve is in the proper position, tighten the socket bolt. d. Markings of the selector valve are shown below.

1.

2.

3.

4.

B. N.

In service of breaker to hydraulic tank To attachment To control valve Socket bolt BREAKER BI DIRECTION FLOW OF CRUSHER

C. SETTING SELECTOR VALVE Stop valve on arm top end is used to stop hydraulic oil flowing.

1. Free: Hydraulic oil flows.

2. Stop: Hydraulic oil stops flowing.

Before removing attachment, set stop valve to “STOP” position.

1. Tools used Selector valve

Circuit

Tool

B

Main (arm)

Spanner (24 mm)

8-24

SECTION VIII - OPTIONAL EQUIPMENT 8.6.8 AUTO GREASE LUBRICATOR SETTING A. CONTROLLER INDICATION AND SETTING KEY

When the auto start is selected, the controller starts operating on reaching the set time of greasing interval.

When Manual operation is selected, press key of controller. One cycle operation is performed regardless of the counting. In this case, the operating interval during counting is once canceled, and the new counting starts again after the electric motor pump stops automatically.

3. Controller indicator After definite time of operation of electric pump, the set value of pressure indicator is in the pressure hold state of 24.0 MPa (245 kgf/cm2), and the indication of controller returns to “zero”.

4. The LED of indicator flickers While counting a operation interval, the LED on a table.

Represented by

key hereafter.

Represented by

key hereafter.

Represented by ▼ key hereafter.

A. Indicator B. Blade type fuse C. Led

Represented by ► key hereafter.

B. SETTING ITEMS AND SET VALUES The three items shown in Table 1 can be set through controller.

The set values are varied conforming to the size and operating condition, and the initial setting of this controller is shown in table.

Item

Set value

Contents

a

Greasing interval

1.5 hour

Greasing interval during auto operation

b

Greasing time

15 minutes

Pump operating time per greasing

150 times

Greasing frequency carried out by the time the 1000 cc cartridge grease is consumed

Greasing c frequency limit

C. OPERATING PROCEDURE AND THE DESCRIPTION 1. Starting engine Starting engine flickers indicator lamps on the lubricating controller for several seconds.

After the CPU housing a controller has restored, the LED of indicator flickers (begins counting of greasing interval) and lamps other than power lamp go out.

2. Switching operation from auto mode to manual mode There are two switching methods as shown below.

Auto start → Auto stop Manual start → Auto stop

5. Engine key off When the grease pump is operated, stop it immediately and release the pressure.

8-25

SECTION VIII - OPTIONAL EQUIPMENT D. CHECKING GREASING OPERATION OF DISTRIBUTING VALVE Press start key (Manual) of controller to start pump operating, and when greasing or the pressure release has been performed, make sure that indicator of distributing valve is actuated.

Cross sectional view of one section distributing valve.

1. Remove cap (3).

2. Check the operation of indicator through inspection door (3).

When applying grease : indicator (1) moves in A direction.

When releasing pressure: indicator moves in B direction.

• Indicator returns to the original point immediately after the pressure release is completed.

E. CARES WHEN ATTACHMENT PINS ARE PULLED OUT When pins on the grease applied part are pulled out to remove attachments, etc., grease should be applied through grease nipple (1) until the grease is come out from the boss end after attaching the pins.

F. SETTING PROCEDURE OF SET VALUE Select code No. corresponding to the setting item in Table “Setting Table” to input the set value.

1. Start engine, and turn power on.

2. Press ▼ (level) key and ► (item) key simultaneously, and the set mode is selected.

3. Setting items on the indicator of controller are changed as shown in the right diagram.

G. HOW TO SET (EXERCISE) When the set values of greasing interval, greasing time, and greasing limit frequency are 1.5 hour, 15 minutes, and 150 times.

1. Press ▼ key and ► key simultaneously.

2. Select and set the required item by pressing ► key. In case of the exercise, press ► key until a is appeared.

3. While a flickers, press ▼ key and a → → 0 → → a → → 0 flicker by turns.

Then, code No. (figure portion) is moved up for every pressing. It changes as follows. a→→0 →→a →→1 →→a →→ 2 → → → → → → → a 9.

8-26

SECTION VIII - OPTIONAL EQUIPMENT 4. For exercise, input 2 in Table “Setting Table” to set 1.5 hour.

When a → → 2 flickers, press SET key. Now 1.5 hour has been set to a and b → → 0 → → → → 0 flickers for next setting item. So, for exercise, input 6 in Table “Setting Table” to set 1.5 minutes.

When b → → 6 → → b → → 6 flickers, press SET key.

5. For the following setting, since the c → → 0 flickers, input code 6 in Table “Setting Table” when c → → 5 flickers.

When c → → 5 → → c → → 5 flickers, press SET key.

6. After setting every items for (a) (b) (c).

Press ESC key 3 second or more to switch off the set mode.

Immediately after pressing ESC key, the counting of greasing interval is started, and the flicker at a part of indication segment proves the execution of counting.

After setting, the set value is stored even if the power is off.

SETTING TABLE Greasing Code interval (Hr) No. (a)

►

►

c

► Press key Symbol

Symbol

a

Greasing interval Greasing time

c

1

1

2

25

2

1.5

3

50

3

2

5

75

4

3

7

100

5

4

10

150

6

5

15

200

7

6

20

250

8

8

25

9

b

►

Greasing limit frequency (c)

0

SUPPLEMENTARY EXPLANATION If the cartridge is replaced with new one, press the ESC key for 5 seconds or more. When release your finger from key, figure 0 flickers 3 to 4 times on the indicator, and it shwos the reset of greasing limit frequency.

a

Greasing time (min) (b)

Greasing limit frequency

REPLACING SETTING ITEMS

8-27

SECTION VIII - OPTIONAL EQUIPMENT INITIAL GREASE APPLYING PROCEDURE After completion of grease piping, apply grease as follows.

A. APPLY GREASE IN EVERY PIPING FROM THE PUMP ASSY TO THE DISTRIBUTING VALVE 1. Disconnect elbow (A) from the connector on the lower part of the pump assy.

2. Attach socket (C) and grease nipple (E) to the elbow (A).

3. Remove blank plug (PT3/8) on the top end of the arm distributing valve.

4. Apply grease through grease nipple attached with paragraph mentioned above, until dust, etc. are completely removed through the hole from which the blank plug is disconnected.

5. Apply grease in the connector of the pump assy (B) and the elbow.

D. To control valve B. APPLY GREASE FROM THE DISTRIBUTING VALVE TO EACH PIN Fill grease through respective grease nipple (1) supplementary attached on the distributing valves on the right front of the swing frame, boom and arm until dust is removed from boss and pin completely.

YYy S

YYy

CAUTION • Apply grease after connection of main pipe from the lower part of the pump assy to the arm top end.

Connect them after applying grease by respective pipe to respective distributing valve, or air leaves in the connector, causing the abnormal operation.

• Take care that dust, mud, etc. don’t enter in the piping.

8-28

SECTION VIII - OPTIONAL EQUIPMENT CHANGING THE CARTRIDGE GREASE WITH NEW ONE 1. Cartridge Changing Interval The cartridge grease capacity is 1 liter. The change of grease is not necessary for about 1.5 months (hour meter 200 Hr or equivalent).

2. Grease Change Signal When the grease change is required, the error code E O on the controller flickers alternately.

In addition, when the counter of greasing reaches to the counter just before 10 times required for the grease change, the counter will count down like 9 8 → 7... However, when the cartridge is replaced, the controller is required to be reset.

YYy S

A. Intermediate cover B. Cap Type Capacity Grease in use

YYy

CAUTION Press RESET / ESC key for 5 seconds of more just after the cartridge grease has been changed, and the greasing counter is reset and the counter returns to the set value.

3. Cartridge replacing method The recommended grease should be used.

YYy S

YYy

CAUTION When the above cartridge grease is used on electric pump, screw in it after removing the intermediate cover.

4. Air bleeding of grease tank a. Remove the air-bleed plug (G) on side of pump using 5 mm allen wrench (F). b.Press the switch marked START/SET, and start pump, then continue the running of pump till the containing air-bubbles grease is completely removed.

Confirm that the only pure grease comes out continuously from air bleeding hole. c. Stop the pump and install the air-bleed plug in original position.

NOTE: do not recycle empty cartridge refilling with new other grease, it causes failure of feeding pump.

C. D. E. F. G.

8-29

Spring Spring retainer Cartridge Allen wrench: 5 mm Air bleeding plug

MY Tank DL-2 1,000 cc See table “Lubricant specifications”

SECTION VIII - OPTIONAL EQUIPMENT SETTING OF COUNTER FOR GREASE DISCHARGE Setting the counter for the grease to be discharged.

Remove vinyl caps (H) of each distributing valve, turn the allen wrench (3 mm with opposing flats), and set the counter of the grease quantity to be discharged.

I. Adjusting screw L. Inspection door

YYy S

YYy

CAUTION The discharge of each control valve is about 0.4 cc in the initial condition where the adjusting screw is not turned.

And, the discharge quantity can be reduced about 0.1 cc by one right rotation of the adjusting screw. (1 mm stroke by one turn).

INDICATION A. NORMAL OPERATION DISPLAY LIST The condition of the lubrication system can be known by 7 segments LED of the control panel and the display contents of LED. This list is useful to judge whether the operation is normal or abnormal after the initial setting and the installation.

Normal operation under usual operation Items

Phenomenon

LED Display

7 Segments Display

1) In operation of pump (un- “DRIVE” LED lamp lights Clockwise flickered. der lubrication) up.

Under lubrication

2) Under holding of pressure “DRIVE” LED lamp is flicker(After approx. 3 minutes Flickering stops. ing (slow). from E/G start) 3) Under releasing of pres- “DRIVE” LED is flickering Counterclockwise sure (Quick). flickered.

After 0 display just after E/G starting.

Under counting (IN period of operation)

4) In normal operation

Power LED is lights up.

LED is flickering or the figure flickering.

Under setting

5) Setting mode

“SET” LED is flickering.

Following each setting mode.

* When the number of remaining lubricating times is 10 or less, the figure (9 to 0) flickers, and is counted down by completion of lubrication.

8-30

SECTION VIII - OPTIONAL EQUIPMENT 1)

Just after E/G start

4)

Under counting in normal operation Note: possible to access the mode set in this condition.

1. Flickers clockwise 2)

After 2 minutes from the starting Note: impossible to access the mode set in this condition.

4. Flickers 5)

Under setting mode

2. Flickering (slow) 3)

5. Flickering

Under releasing of pressure (Charging of piston chamber)

3. Flickers counter clockwise for several seconds

8-31

SECTION VIII - OPTIONAL EQUIPMENT B: ERROR LIST 4 kinds of the lubrication system error (see table) are shown by alarm LED, and the error contents and the display (table) are indicated by error code. However, the power LED does not light up when the fuse is blown.

Error

Phenomenon

Error code

Pump pressurizing error

The pressure does not go up within the lubricating time.

E → a Flickers alternately

Pressure releasing error

The pressure is remained after releasing the pressure.

E → b Flickers alternately

Pressure detection error

The pressure detection LS is actuated before the lubrication system is started.

E → c Flickers alternately

Tank empty

When the number of the lubrication times is 10 times or less equivalent to the limit number of times, the counting is down like 9 → 8 → 7 →.

E → 0 Flickers alternately

8-32

SECTION VIII - OPTIONAL EQUIPMENT TROUBLESHOOTING When this lubrication system fails, the corresponding error code on the controller display flickers.

Check the system for the cause of failure and take a corrective action.

YYy S

YYy

CAUTION When error occurred, the grease mark is displayed on the multidisplay in the cab.

AUTO-LUBE SYS. FAIL

Error code

E → a

E → b

E → c

E → 0

Error item

Pump pressurizing error

Pressure release error

Pressure detection error

Tank empty

Cause

Corrective action

1. Air contaminated in main pipe

1. Operate the pump to discharge the grease through the pipe end, and then release air.

2. Air entered in the pump

2. Discharge grease through air escape section on the pump and release air.

3. Insufficient screwing in of cartridge

3. Tighten the cartridge securely.

4. Grease leakage of main pipe

4. Check and tighten each connection of main pipe including hoses.

5. The cartridge of grease is empty

5. Change of cartridge grease.

1. Failure of pressure release system housed in pump.

1. Disassemble the pressure release section carefully and check for possible failure and clean it.

2. Failure of pressure detecting unit housed in pump.

2. Check the limit switch on the pressure detecting section for possible failure.

1. Failure of pressure detecting unit housed in pump.

1. Check the limit switch for possible failure.

2. Failure of pressure release system housed in pump.

2. Disassemble the pressure release section carefully and check for possible failure and clean it.

1. When the number of lubrication times reaches to the limit time.

1. Change the grease cartridge with new one.

2. Change the grease cartridge with new one under counting.

2. Press ESC key on the controller for 5 seconds or more to reset.

8-33

SECTION VIII - OPTIONAL EQUIPMENT 8.6.9 ONE WAY CALL Microphone and amplifier are installed on the right front side inside of the cab and speaker is installed on the front side of the swing frame section.

This one-way-call system enables the operator to have a connection with the outside while operating.

1.

2.

3.

4.

5.

Power lamp Power switch Volume Microphone outlet Microphone

8.6.11 GAUGE CLUSTER Press the screen change switch (1) on the switch panel, and the working reach or boom angle is dispayed on the L.C.D display (A).

When the arm top position reaches to the warning zone, is displayed on the L.C.D display to alarm the danger of fall down by the dangerous position.

21

CAUTION FALL DOWN

8-34

SECTION VIII - OPTIONAL EQUIPMENT 8.6.10 WORKING RANGE LIMIT ALARM Provide warning for the turning over due to the bad position of the attachment to ensure safety of operation.

YYy S WARNING YYy Never carry out the work in danger zone (b) because the working in danger zone may cause turning over of the machine.

YYy S

YYy

CAUTION Cautions in use of long range crusher 1. Operate it in the safety zone (a).

2. Raising and lowering work of attachment.

• Assemble the attachment in the back-and-forth directions of crawler.

• Raise the attachment from the lowest boom in order.

• Retract the attachment from the highest crusher and arm in order.

1. Install potentiometers (1,2,3) on the boom, inter boom and arm.

And the controller reads the rotating angles (A,B,C) of respective pins.

2. The controller computes the arm top pin position (P) based on the read angles to judge the stability of the machine.

3. When the attachment is operated, and the arm top pin position (P) reaches to the danger zone, the warning buzzer (alarm) sounds 2 seconds continuously.

And the “CAUTION FALL DOWN” is displayed on the multidisplay until the arm top pin position moves far away from the danger zone.

4. When abnormal signal value is input into the controller due to such as disconnection of harness connected to respective potentiometer, the “**** POTENTIO” is displayed on the multidisplay, and the warning buzzer sounds intermittently, and stops sounding in 5 seconds.

After stopping alarm sounding, but the display of respective potentio is not disappeared.

1.

2.

3.

4.

Boom potentiometer Inter boom potentiometer Arm boom potentiometer Proximity switch

5. When the starter key is turned to ON, if abnormal condition such as disconnection of harness is detected by trouble diagnosis, the “**** POTENTIO” is displayed on the multidisplay, and the warning buzzer sounds intermittently, and stops sounding in 5 seconds.

After stopping alarm sounding, but the display of respective potentio is not disappeared.

YYy S

YYy

CAUTION The warning buzzer sounds, but the machine does not stop operating.

8-35

SECTION VIII - OPTIONAL EQUIPMENT 8.6.11 BUCKET CYLINDER STROKE LIMIT For the machine specially used for demolition, the stroke of the bucket cylinder is difficult to look at due to the long boom, consequently the idler link and bucket cylinder may be damaged.

To prevent this damage, the proximity switch is attached on the idler link section.

Cut the bucket remote control just before the stroke end, and the crusher stops moving and the buzzer sounds for 1 second.

A. Idler link B. 5.85 m arm C. Proximity switch D. Bucket cylinder stroke end stopper

8-36

SECTION VIII - OPTIONAL EQUIPMENT 8.6.12 HOW TO DEMOLISH The demolishing procedure differs according to the buildings and the site conditions, so the example being seemed as an effective procedure is shown below.

A. CRUSHER USED TO DEMOLISH THE FERROCONCRETE BUILDINGS In case of high building

A. Rock pin B. Rocker beam

In case of low building

1. Pillar, etc. should be broken in traverse direction after swinging the crusher 90 degrees.

2. Beams are broken by cutting down both ends and crushing them on the ground according to the site conditions.

3. The “A” part is broken in upward direction, so be careful for the drop of the broken pieces.

4. The broken pieces dropped on the ground includes steel bars with small pieces of concrete and the size is irregular, so break them in small size and separate the steel bars.

5. Break the small-scale underground basements, and separate the steel bars from the concrete.

8-37

SECTION VIII - OPTIONAL EQUIPMENT 8.6.13 PERFORMANCE SPECIFICATIONS The following performance specifications are based on long range machine specialized for demolition.

1. Travel speed, swing speed and gradeability DESCRIPTION

SPECIFICATION

TRAVEL SPEED

5.7 km per hr (3.5 mph) in U mode 3.2 km per hr (2.2 mph) in T mode

SLEWING SPEED

*1

8.6 rpm in M-mode/ “HI” idle

GRADEABILITY

70% (35°)

*1: in case of long range machine operation, this speed is decreased.

2. Engine Major engine specifications Engine maker

Mitsubishi (MMC)

Model

6D16-TLU2D

Type

4-cycle, water cooled, direct injection with turbocharger and intercooler, diesel

Number of cylinders-Bore x Stroke

6 - 118 mm x 115 mm (4.65˝ x 4.53˝)

Displacement

7.545 liter (460 cu·in)

Compression ratio

17.5 : 1

Output rating

184 kW / 2,200 rpm

Maximum torque

834 Nm / 1,800 rpm

Ignition order

1 - 5 - 3 - 6 - 2 - 4 clockwise rotation

Injection timing

8° Before top dead point

Intake valve clearance cold

0.4 mm (0.0157˝)

Exhaust valve clearance cold

0.4 mm (0.0157˝)

Electrical system

D.C. 24 V

Starting motor

24 V - 5.0 kW

Alternator

24 V - 35 A

Batteries

2 – 12 V - (170F51)

3. Hydraulic components COMPONENTS Hydraulic pumps

TYPE Tandem, variable displacement, axial piston with pilot gear pump

Swing motor

Axial piston

Travel motor

Axial piston

Control valves

6 spools multiple control

Control valves (jib)

1 spool multiple control

Cylinders (all)

Double acting

Return Filter

Safety valve containing filter type

Oil Cooler

Air cooled

4. Operating pressures MPa kgf/cm2 Pilot system

4.9 (50)

Attachment (main)

29.4 (300)

Swing

27.4 (280)

Travel

34.3 (350)

Power boost / Heavy lift

37.7 (385)

8-38

SECTION VIII - OPTIONAL EQUIPMENT 5. Machine weight and ground pressure Working weight

39,400 kg (86,860 lb)

Ground pressure

74 kPa (0.75 kgf/cm2)

8.6.14 MACHINE DIMENSIONS A. FULL ATTACHMENT (3.33M MAIN BOOM + 2.65M INSERT BOOM + 4.485M FRONT BOOM + 2.3M INTER BOOM + 5.85M ARM + CRUSHER)

* Dimension does not include height of grouser

B. 3.33M MAIN BOOM + 4.485M FRONT BOOM + 2.3M INTER BOOM + 5.85M ARM

8-39

SECTION VIII - OPTIONAL EQUIPMENT C. BACK-HOE (3.33M MAIN BOOM + 3.6M FRONT BOOM + 3.3M ARM + 1.4M3 BUCKET)

8-40

SECTION VIII - OPTIONAL EQUIPMENT 8.6.15 WORKING RANGES A. L.M.N (CRUSHER) TYPE

Item

Function

YYy S

YYy

CAUTION Cautions in use of long range crusher 1. Operate it in the safety zone.

2. Raising and lowering work of attachment.

• Assemble the attachment in the back-and-forth directions of crawler.

• Raise the attachment from the lowest boom in order.

• Retract the attachment from the highest crusher and arm in order.

Combination of attachments (1) + (2) + (3) + (4) + (5)

(1) + (3) + (4) + (5)

Maximum working reach

18,500 (60´-8˝)

15,880 (52´-1˝)

Maximum working reach in safety

11,000 (36´-1˝)

11,500 (37´-9˝)

Maximum working height

20,040 (65´-9˝)

17,400 (57´-1˝)

C´

Reach of maximum working height

3,940 (12´-11˝)

3,750 (12´-4˝)

D

Minimum swing radius

3,250 (10´-8˝)

3,060 (10´-0˝)

Reach of minimum swing radius

12,650 (41´-6˝)

10,010 (32´-10˝)

A ** A´ * C

* E

Limit weight of crusher

2,450 kg (5,400 lb)

8-41

SECTION VIII - OPTIONAL EQUIPMENT NOTE: • The dimensions of mark * does not include the shoe lug height (37 mm).

YYy S WARNING YYy The values of mark ** shows the max. working reach on the flat and hard ground, and the operation on the area for the area larger than the values are unstable and may cause turning over.

B. BACK-HOE TYPE {3.33 m Main boom + 3.6 m Front boom + 3.3 m Arm + 1.4 m3 (1.83 cu·yd bucket)}

YYy S

YYy

CAUTION The digging work in the transport position may cause the damage of the attachment. Never carry out the digging work in transport position.

1. Transport position 2. Digging position

8-42

SECTION VIII - OPTIONAL EQUIPMENT ITEM

FUNCTION

mm

ft-in

A

Maximum digging reach

A´

Maximum digging reach at 11,190 36´ - 9˝ ground

*B

Maximum digging depth

7,610

25´ - 0˝

*C

Maximum digging height

10,530

34´- 7˝

*D

Maximum dumping clearance

7,380

24´ - 3˝

*E

Minimum dumping clearance

2,890

9´ - 6˝

*F

Maximum vertical wall digging 6,350 depth

20´-10˝

11,380 37´ - 4˝

G

Minimum swing radius

4,360

14´ - 4˝

*H

Minimum height swing height

8,900

29´ - 2˝

*I

8-feet level digging depth

7,440

24´ - 5˝

K

Horizontal digging Stroke stroke at ground Minimum level

5,850

19´ - 2˝

2,780

9´- 1˝

L

NOTA: • This attachment is adjusted into the specification for back-hoe attachment by adding the front boom to the main boom on the machine specially used for the demolishing.

The standard arm of back-hoe is used as arm.

• The dimensions of mark * does not include the shoe lug height (37 mm).

8-43

SECTION VIII - OPTIONAL EQUIPMENT 8.6.16 SHIPPING DIMENSIONS A. 3.33 m MAIN BOOM + 2.65 m INSERT BOOM Item

Shoe width A mm (in)

With main boom + insert boom + counterweight

600 (23.6˝)

Total lenght L mm (ft-in)

Total height H mm (ft-in)

Total width W mm (ft-in)

Weight kg (lb)

10,240 (33´-7˝) 3,300 (10´-10˝)

3,200 (10´-6˝)

32,460 (71,560)

B. 3.33 m MAIN BOOM + WITHOUT COUNTERWEIGHT Item With main boom Without counterweight

Shoe width A mm (in)

Total lenght L mm (ft-in)

Total height H mm (ft-in)

Total width W mm (ft-in)

Weight kg (lb)

600 (23.6˝)

7,390 (24´-3˝)

3,300 (10´-10˝)

3,200 (10´-6˝)

21,430 (47,240)

Total height H mm (ft-in)

Total width W mm (ft-in)

Weight kg (lb)

5,760 (18´-11˝) 3,310 (10´-10˝)

3,200 (10´-6˝)

19,490 (42,970)

C. WITHOUT COUNTERWEIGHT AND ATTACHMENT Item Without counterweight and attachment

Shoe width A mm (in) 600 (23.6˝)

Total lenght L mm (ft-in)

8-44

SECTION VIII - OPTIONAL EQUIPMENT D. COUNTERWEIGHT Item

Total lenght L mm (ft-in)

Total height H mm (ft-in)

Total width W mm (ft-in)

Weight kg (lb)

Counterweight

3,000 (9´-10˝)

1,000 (3´-3˝)

650 (2´-2˝)

9,700 (21,380)

E. 3.33 m MAIN BOOM Attachment

mm (ft-in)

3,330 (10´-11˝)

LxHxW

mm (ft-in)

4,240 x 1,000 x 910 (13´-11˝ x 3´-3˝ x 3´-0˝)

Weight

kg (lb)

1,950 (4,300)

F. 2.65 m INSERT BOOM Attachment

mm (ft-in)

2,650 (8´-8˝)

LxHxW

mm (ft-in)

3,570 x 920 x 780 (11´-9˝ x 3´-0˝ x 2´-7˝)

Weight

kg (lb)

1,310 (2,890)

G. 4.485 m FRONT BOOM + 2.3 m INTER BOOM + 5.85 m ARM Attachment

mm (ft-in)

4.485 m arm + 2.3 m inter boom + 5.85 m arm (14´-9˝ x 7´-7˝ x 19´-2˝)

LxHxW

mm (ft-in)

6,230 x 3,030 x 900 (20´-5˝ x 9´-11˝ x 2´-9˝)

Weight

kg (lb)

4,720 (10,410)

8-45

SECTION VIII - OPTIONAL EQUIPMENT H. 2.3 m INTER BOOM Attachment

mm (ft-in)

2,300 (7´-7˝)

LxHxW

mm (ft-in)

3,520 x 890 x 900 (11´-7˝ x 2´-11˝ x 2´-11˝)

Weight

kg (lb)

1,150 (2,540)

I. 5.85 m ARM Attachment

mm (ft-in)

5,850 (19´-2˝)

LxHxW

mm (ft-in)

6,030 x 930 x 540 (19´-9˝ x 3´-1˝ x 1´-9˝)

Weight

kg (lb)

1,590 (3,510)

J. 4.485 m FRONT BOOM Attachment

mm (ft-in)

4,485 (14´-9˝)

LxHxW

mm (ft-in)

4,720 x 1,440 x 900 (15´-6˝ x 4´-9˝ x 2´-11˝)

Weight

kg (lb)

1,980 (4,370)

K. 3.6 m FRONT BOOM (BACK-HOE) Attachment

mm (ft-in)

3,600 (11´-10˝)

LxHxW

mm (ft-in)

4,000 x 1,050 x 780 (13´-1˝ x 3´-5˝ x 2´-7˝)

Weight

kg (lb)

2,340 (5,160)

8-46

SECTION VIII - OPTIONAL EQUIPMENT

YYy S WARNING YYy

8.6.17 INSPECTION AND MAINTENANCE Follow the chart below for recommended intervals of regular inspection and maintenance procedures.

System

Maintenance to perform

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

Component location

Interval (hours on hourmeter) 8

Special demolition attachment

Check boom and arm Special demolition Attachment structure attachment

Check bolts / torque

Hydraulic

Electrical

50

120

250

500

1,000 2,000

Grease bucket pins

Arm and bucket pin

Auto greaser

Complete machine

Hydraulic oil level

Side of hydraulic tank

Check hydraulic functions

Cab

Check hoses / lines

Attachment hose

Check for oil leaks

Hydraulic system

Adjust slow return valve

Boom

L.C.D display

Gauge cluster

Check switches

Cab

Inspect all wiring

Complete machine

Check one way call

Cab

Regular inspection and maintenance required NOTE: check and maintenance the crusher and train the person concerned according to operator’s manual prepared by maker of crusher.

8-47

SECTION VIII - OPTIONAL EQUIPMENT 8.6.18 PRE-START (EVERY 8 HOURS) INSPECTION AND MAINTENANCE The following procedures are to be performed every 8 hours or daily, before the machine is started.

A. CHECK BOLTS / TORQUE Check that there is no omission and loosing of capscrew used on special demolition attachment.

B. CHECK BOOM AND ARM 1. Inspect boom and arm structures for signs of excessive wear and damage.

2. Should repair or replacement be necessary, contact the Dealer for assistance.

C. HYDRAULIC FUNCTIONS Check all hydraulic controls (A) for proper function before operating the machine.

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

8-48

YYy S WARNING YYy 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.

SECTION VIII - OPTIONAL EQUIPMENT D. HYDRAULIC OIL LEVEL 1. Place the machine in the oil check position on a firm surface.

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

YYy S WARNING YYy 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°.

A. Upper limit B. Proper level C. Low (add oil) E. HYDRAULIC OIL LEAKS AND HOSES LINES 1. Check complete hydraulic system for leaks.

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

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

2. Check all hoses (B) and lines for signs of damage.

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

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

8-49

SECTION VIII - OPTIONAL EQUIPMENT F. MACHINE ELECTRICAL 1. Check all switches for proper operation.

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

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

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

G . L.C.D DISPLAY 1. Move throttle control (1) to “LO” position.

2. Insert key into key switch (2) 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.

5. After placing the operating position while operating the boom and arm motions, press the operating radius screen change (3) and angle display, and make sure that the operating radius and the attachment angle are indicated.

8-50

SECTION VIII - OPTIONAL EQUIPMENT H. ONE WAY CALL 1. Insert key into key switch and turn to the “ON” position.

2. Press power switch (2) of one-way call amplifier.

Turn the volume dial clockwise, make sure that the communication with outside is possible by means of the microphone (5).

1.

2.

3.

4.

5.

I. AUTO GREASER 1. Insert key into key switch and turn to the “ON” position.

2. Turn the power on, and make sure that a part of indicator flickers and all lamps other than the power lamp go out after all indicator lamps light up for several seconds.

3. Check that the grease pump starts automatically and functions in the procedure of Press Greasing press holding (greasing), Depress (charge to provide for the following greasing).

NOTA: when error occurs on the power or the greasing device, contact the Dealer for assistance immeditely.

A. Power B. Indicator C. Control valve (boom) D. Control valve (arm) E. Grease cartridge F. Controller G. Wiring harness H. Grease pump I. Control valve (frame boom)

8-51

Power lamp Power switch Volume Microphone outlet Microphone

SECTION VIII - OPTIONAL EQUIPMENT 8.6.19 50 HOUR (WEEKLY) AND NEW MACHINE BREAK-IN INSPECTION AND MAINTENANCE PROCEDURES A. ATTACHMENT LUBRICATION Lubricate attachment pins every 50 hours of engine operation. Use extreme pressure multipurpose grease No.2 EP type. Lubricate all points until grease purges.

NOTA: if attachment is sunk in water, it is recommended to lubricate it every 8 hours.

1. Bucket link pins (4) (5).

2. Idler link to arm pin (2) and arm to bucket pin (3).

3. Bucket cylinder rod pin (1).

8.6.20 MISCELLANEOUS A. ADJUSTMENT OF SLOW RETURN VALVE The slow return valve is an adjustable type to improve the operability at fine working.

The valve is set as shown below at shipment.

Device circuit

Opening (Rotating number)

Boom

2·0

Jib

3 · 1/4

Arm

3 · 3/4

Bucket

3 · 1/2

The opening shows the rotating number from the complete close condition.

YYy S

YYy

CAUTION Don’t carry out adjustment in the condition where the pressure is applied.

When adjustment is necessary, contact the Dealer for assistance.

8-52

SECTION VIII - OPTIONAL EQUIPMENT 8.6.21 DISASSEMBLY OF ATTACHMENT A. PRECAUTION WHEN ASSEMBLING AND DISASSEMBLING 1. Select flat and hard ground, and also the area where the main body, boom, arm, etc. can be arranged and crane, etc. can be placed around for assembly and disassembly.

2. The disconnected hydraulic pipe and hose should be plugged without fail to prevent the entry of dust, etc.

3. The removed shim should be placed in a set, be tagged and be stored for reference to enable their assembly to the former positions.

4. Check on dust seal, O-ring etc. for possible damage when assembling and disassembling, and replace the damaged one.

YYy S •

• • •

YYy

CAUTION Decide working method and procedure, and have them well-known to person connected, and designate a chief for work and perform the work under command of chief.

When meeting pin to pinhole, don’t put fingers into pinhole, but meet them visually.

Use the slinging tools applicable to the weight of object.

Never enter in the area under the attachment hoisted by the crane to prevent being caught between them.

C. DISASSEMBLY 1. Remove Crusher a. Direct the opening part of the crusher to this side, and place the crusher on level ground stably. b.Remove crusher attaching pin and idler link attaching pin. c. Stop engine, press crusher control pedal several times, or open the crusher beam, or return it slightly in the reverse direction from the close end, and remove pressure remaining in the pipe. d.Close stop valve on the upper face of the boom, disconnect hydraulic hose, and attach plug. e. Raise boom slowly, and remove crusher.

YYy S

YYy

CAUTION Stabilize the unstable shape crusher using wood block (A) etc. to prevent it from falling over.

B. NECESSARY TOOLS 1. Pedestal Pedestal having a sufficient capacity to component parts.

2. Wire 3. Slinging wire rope 4. Wood block timber 5. Tools Accessory tools: spanner (opposing flat 95 mm) General tools: large hammer, driving pin 6. Oil pan to receive oil when removing hose 7. Cap, plug, etc. on the hose removing parts 8. Crane

8-53

SECTION VIII - OPTIONAL EQUIPMENT 2. Removing Arm a. Lower the long range demolition attachment, and receive the inter boom and boom by pedestal. b.Stop engine, release the remaining pressure in the pipe connected to bucket cylinder and arm cylinder by operating the control lever several times, and close stop valves other than that for inter boom cylinder installed on the insert boom and main boom. c. Disconnect hydraulic hoses of bucket cylinder and arm cylinder and plug the disconnected hoses. d.The rod of bucket cylinder should be fixed to arm with wire to prevent extending. e. Remove arm cylinder.

1.

2.

3.

4.

5.

6.

7.

Bucket cylinder Potentiometer Arm attaching pin Potentiometer Stop valve Potentiometer Arm cylinder

8-54

f. Suspend arm by catching hook on the upper face of arm and crusher attaching hole with wire rope, remove nut with spanner (opposing flat 95 mm) in accessory, and pull out arm attaching pin. g.Remove proximity switch of the arm top and harness coupler for potentiometer on the inter boom top section. Loosen nut and disconnect ball joint on the potentiometer side from the rod. The rod should be fixed on the tube, etc. with cord. h.Remove arm.

NOTE Be careful not to damage harness for potentiometer.

SECTION VIII - OPTIONAL EQUIPMENT 3. Removing Inter Boom a. Remove pin on the jib cylinder rod side, retract rod, and fix it to the boom with wire. b.Close stop valve on the pipe for inter boom on the upper face of insert boom and main boom. c. Disconnect hydraulic hose of jib cylinder, and plug the disconnected hydraulic hoses. d.Suspend inter boom slightly catching hooks on the upper face of inter boom with wire rope, remove nut with spanner (opposing flat 95 mm) in accessory, and pull out the inter boom attaching pin.

1.

2.

3.

4.

e. P u l l o u t c o u p l e r o f h a r n e s s f o r potentiometer on the front boom top section. Loosen nut and disconnect ball joint on the potentiometer side from the rod.

The rod should be fixed on the tube, etc. with cord. f. Remove inter boom.

Inter boom Inter boom attaching pin Stop valve Jib cylinder

8-55

SECTION VIII - OPTIONAL EQUIPMENT 4. Removing Front and Insert Boom SUPPLEMENTARY EXPLANATION The connections of front boom, insert boom and main boom is provided with concave guide to receive respective mating pin to make positioning of each pin easier. a. Lower the boom assy, and remove front boom supporting the front boom with wood blocks as shown in the figure. b.Remove nut with spanner (opposing flat 85 mm) in accessary and pull out connecting pin. c. Move the machine backward lowering main boom and inter boom slightly. d.Remove the insert boom by the same procedure as that described above.

1.

2.

3.

4.

5.

6.

Front boom Nut Pin Guide Connecting pin Insert boom

8-56

1.

2.

3.

4.

5.

6.

Front boom Nut Pin Guide Connecting pin Insert boom

SECTION VIII - OPTIONAL EQUIPMENT 5. Removing Main Boom When the machine is transported by trailer, the removal of main boom is not required, but when transported by truck, etc. the removal of the main boom is required, so remove it in the procedure shown below. a. Put suitable pedestal to the front side of the main boom to support boom. b.Stop engine, remove the pressure remaining in the pipe, etc. to boom cylinder by operating the control lever several times, and disconnect hydraulic hose. c. Pull out harness coupler for potentiometer on the main boom foot section. For the ball joint, loosen nut and disconnect rod.

The rod should be fixed on the tube, etc. with nylon cord. d.Hook wire rope to the boom cylinder, suspend slightly by crane, remove pin on the boom side first and then head side, and remove the cylinder.

YYy S

YYy

CAUTION When lifting up the cylinder, the rope should be twisted to prevent slipping and to ensure safety. And when moving the cylinder, fix it with wire (1) to protect the rod from extending out of the cylinder. e. Put wire rope through the hook (2) on the main boom, suspend slightly, lift up slightly after removing the boom foot pin, move the machine back and separate the main boom.

8.6.22 ASSEMBLING ATTACHMENT Assemble attachment by the reverse procedure of the disassembly. After assembly, attention should be paid to the following points.

1. Check that each pin section is fully lubricated.

2. Check the level gauge of hydraulic oil tank, and make up oil loss.

3. Repeat operations of the boom, inter boom, arm and crusher at low speed of the engine, and bleed air in each cylinder and pipe.

4. Check each hydraulic pipe and hydraulic hose for oil leakage.

8-57

SECTION VIII - OPTIONAL EQUIPMENT NOTES:

8-58

Section IX – SPECIAL PROCEDURES Table of Contents 9.1 GENERAL .............................................................................................................................................................. 9-1 9.2 RELEASING TRAVEL MOTOR BRAKES ............................................................................................................... 9-1 9.3 LOWERING ATTACHMENT WHEN SUDDEN ENGINE FAILURE OCCURS ........................................................... 9-4 9.4 HYDRAULIC TANK PRESSURE ............................................................................................................................ 9-5 9.5 RELEASING SWING BRAKE ................................................................................................................................ 9-6

WARNING READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS AND PROCEDURES FOUND IN THIS MANUAL BEFORE ATTEMPTING ANY OPERATION, INSPECTION OR MAINTENANCE OF THIS MACHINE, ATTACHMENT OR SYSTEMS.

9—0

Section IX – SPECIAL PROCEDURES 9.1 GENERAL

ATTACHMENT ON GROUND

The machine incorporates automatically applied spring brake systems in the travel motors and swing motors.

These systems will automatically engage the brakes when engine is stopped making it impossible to move the machine.

This section contains the required procedures for releasing the travel motor brakes, the swing motor brake and lowering the attachment to the ground should sudden engine failure be experienced.

CHOCK BLOCKS AT FRONT AND REAR OF EACH TRACK

WARNING

WARNING

READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS AND PROCEDURES FOUND IN THIS MANUAL BEFORE ATTEMPTING ANY OPERATION, INSPECTION, MAINTENANCE OR REPAIR OF THIS MACHINE, ATTACHMENT OR ANY OF ITS SYSTEMS.

MAKE CERTAIN CHOCK BLOCKS ARE SECURE AT FRONT AND REAR OF EACH TRACK BEFORE ATTEMPTING TO RELEASE BRAKES. NEVER STAND IN THE PATH OF THE TRACKS WHEN RELEASING BRAKES.

WARNING

FIGURE 9.1

THE PROCEDURES FOUND IN THIS SECTION SHOULD BE PERFORMED BY A WELL TRAINED EXPERIENCED SERVICE TECHNICIAN WHO IS FAMILIAR WITH THE E335(LC) MACHINES.

9.2 RELEASING TRAVEL MOTOR BRAKES A. TOOLS AND EQUIPMENT REQUIRED 1. Four chock blocks.

2. One 14 mm allen wrench.

3. One 8 mm allen wrench.

4. Two 12 liter (3.2 Gal)capacity drain pans.

5. One M10-1.5 X 30 mm lifting eyes.

6. Overhead lifting device capable of lifting and holding 45 kg (100 lb).

7. Torque wrench 8 ~ 10 kgf·m (58 ~ 72 lbf·ft) capacity or better.

8. Thread sealant. (For drain and check/fill plugs) 9. Rubber or soft faced mallet.

THROTTLE IN "LO" POSITION

KEY SWITCH IN "OFF" POSITION

FIGURE 9.2

REMOVE CHECK / FILL PLUG WITH 14 mm ALLEN WRENCH

B. PROCEDURES 1. Place chock blocks at front and rear of each track to prevent machine from moving when brakes are released. See Figure 9.1.

2. Lower attachment to ground. See “9.3 Lowering attachment” for proper procedures, page 9-4.

3. Turn key switch “OFF” and remove key. See Figure 9.2.

4. Remove check/fill plug from each travel motor using the 14 mm socket head wrench. See Figure 9.3.

FIGURE 9.3

9—1

Section IX – SPECIAL PROCEDURES 5. Place a clean 12 liter (3.2 gallon) capacity drain pan under each travel motor drain plug and remove drain plug using the 14 mm socket head wrench. See Figure 9.4.

6. After all of the gear oil has drained, cover the drain pans to prevent contamination and move them to an area away from the machine.

7. Remove the fifteen plate mounting bolts from the travel motor reduction unit cover plates. See Figure 9.5.

8. Remove the two bolts from the bossed areas and install the two M10-1.5 X 30 mm lifting eyes into each of these holes. See Figure 9.6.

9. Attach the overhead lifting device to the lifting eyes and remove most of the slack from the chain or cable.

10.Using a rubber mallet, gently strike the edge of the cover plate to help release plate from housing.

REMOVE DRAIN PLUG WITH 14 mm SOCKET WRENCH

12 LITER (3.2 GAL) CAPACITY DRAIN PAN

FIGURE 9.4 REMOVE 22 MOUNTING BOLTS WITH 8 mm SOCKET WRENCH

CAUTION

FIGURE 9.5

Be careful not to damage lip of cover plate. Any damage to the lip could result in a gear oil leak.

REMOVE BOLTS FROM BOSSES WITH 8 mm SOCKET WRENCH

INSTALL M10-1.5 X 30 mm LIFTING EYE INTO EACH BOSS

11. After cover plate has release from housing, carefully move cover away from machine with lifting device.

12.Install the one M12-1.75 X20mm lifting eye into one of the pinion gear shafts. See Figure 9.7.

CAUTION When removing the following components it will be necessary to have a clean area free of dirt and grit to lay these components.

FIGURE 9.6 INSTALL M12-1.75 INSTALL M12-1.75 XX 20 20 mm mm LIFTING EYE INTO LIFTING EYE INTO PINION GEAR PINIONSHAFT GEAR SHAFT

13.Attach the overhead lifting device to the lifting eye and remove most of the slack from the cable or chain.

See Figure 9.7.

14.Carefully by hand work the planetary gear assembly free from the housing. See Figure 9.7.

CAUTION Be aware of and protect hands from pinch areas when removing and installing planetary gears or any other component which may cause personal injury.

WORKPLANETARY PLANETARY GEAR WORK GEAR ASSEMBLY FREE FROM ASSEMBLY FREE FROM HOUSINGWITH WITH LIFTING HOUSING LIFTING DEVICEAND AND HANDS DEVICE HANDS

FIGURE 9.7

9—2

Section IX – SPECIAL PROCEDURES 15.Lower the planetary gear assembly to a clean surface such as a piece of plywood with the “Sun Gear B” facing up. See Figure 9.8.

REMOVE / INSTALL “SUN GEAR B” AND LAY ON A CLEAN SURFACE

16.Carefully remove “Sun gear B” from the planetary gear assembly by hand and lay aside. See Figure 9.8.

17.Carefully remove the “drive gear” from the planetary gear assembly and lay aside. See Figure 9.9.

18.Install “sun gear B” back into the planetary gear assembly. See Figure 9.8.

19.Remove splined coupling from center of second planetary gear assembly in travel reduction housing. See Figure 9.10.

FIGURE 9.8

REMOVE “DRIVE GEAR” AND LAY ON A CLEAN SURFACE

20.Using lifting device, install planetary gear assembly back into housing.

21.Install cover plate onto housing and tighten all bolts securely.

22.Install drain plug into cover plate and replace gear oil into travel reduction unit through fill / check port to proper level.

23.After steps 4 through 22 have been performed on both travel reduction units, the machine may be towed to an area where repairs can be made.

FIGURE 9.9 24.After repairs are made reinstall the “drive gear” in reverse order. Use the following torque specifications for bolts and plugs.

REMOVE “SPLINED COUPLING” AND LAY ON A CLEAN SURFACE

TORQUE SPECIFICATIONS COVER BOLTS .............. 5,5 ~ 6,5 kgf·m (40 ~ 47 lbf·ft) PLUGS ........................... 5 ~ 6,5 kgf·m (36 ~ 47 lbf·ft) (Use thread sealant on plugs)

FIGURE 9.10

9—3

Section IX – SPECIAL PROCEDURES 9.3 LOWERING ATTACHMENT WHEN SUDDEN ENGINE FAILURE OCCURS A.

HOW TO LOWER ATTACHMENT – FIGURE 9.11 The port relief valve is used to return the oil remaining in the cylinder to the hydraulic tank to protect the piping when the pressure inside of piping rises higher than the set pressure owing to the external load exerted on the cylinder, and also may be used as a measures to lower attachment when the engine stops owing to trouble, etc.

After loosening lock nut of port relief valve as adjuster screw is loosened the set pressure gradually falls. When the set pressure decreases lower than the hold pressure of cylinder currently holding attach-

NOTE Before loosening adjuster screw, mark those positions, and after bringing down attachment to the ground, tighten adjuster screw to the marked positions.

LOCK NUT

POPPET

PISTON

ment, the above hold pressure opens the poppet, the plunger moves rightward and the continuity from P to R is made. And the oil remaining in the cylinder returns to the tank.

With this, attachment can be brought down to the ground while engine stops.

P

P R

R SEAT

PLUNGER

SPRING

TO TANK BOOM CONFLUENCE

BOOM SLEWING

CUT & ARM CONFLUENCE ARM BOOM SPOOL

Drc

BOOM CYLINDER

R

R

H

H

(Ab)

TRAVEL LEFT TRAVEL RIGHT

ARM REGENERATION & CUT

PBb PLc1

BUCKET

Bb

FIGURE 9.11

9—4

TRAVEL STRAIGHT

Section IX – SPECIAL PROCEDURES B. HOW TO LOWER ATTACHMENT – FIGURE 9.12 When engine stops because of troubles, the relief valve incorporated in the holding valve mounted on the boom cylinder head side is available to lower attachment.

As shown in the figure, after loosening lock nut of stop valve as setscrew is loosened, the poppet is opened and then the oil remaining in the boom cylinder head side returns to the tank through T port enabling attachment to be lowered.

HOLDING VALVE

RELIEF VALVE

NOTE After lowering attachment, tighten the above setscrew to the specified torque without fail.

CAUTION Be careful when lowering attachment. Do not stand under boom.

LOCK NUT

FIGURE 9.12

9.4 HYDRAULIC TANK PRESSURE – FIGURE 9.13

DEPRESS RUBBER CAP TO RELEASE PRESSURE

How to release air pressure remaining in the hydraulic tank.

After engine stops, the air pressure remaining in the hydraulic tank.

Can be released by pushing valve on the air breather rubber cap several times (5 ~ 7 times). Air breather mounted on the upper part of hydraulic tank.

FIGURE 9.13

9—5

Section IX – SPECIAL PROCEDURES 9.5 RELEASING SWING BRAKE

WARNING MAKE CERTAIN THAT THE ATTACHMENT IS ON THE GROUND TO HELP PREVENT SUDDEN ROTATION OF THE UPPER STRUCTURE BEFORE ATTEMPTING TO RELEASE THE SWING BRAKE. REFER TO PAGE 105 FOR ATTACHMENT LOWERING PROCEDURES. The Manufacturer highly recommends the use of a hydraulic hand pump to release the swing brake manually when the engines fails to start. Refer the Figure 9.15 to use the proper fitting connector on PG port.

Remove the hose and install the proper connector on PG port. Install the hydraulic hand pump and apply hydraulic pressure as follows: 29 kgf/cm2 (413 psi)

REMOVE HOSES, TUBES AND FITTINGS FROM COVER

FIGURE 9.14

TOP VIEW

SWING MOTOR

IP

CAUTION

DB

In highly contaminated environments it is recommended to remove the whole swing motor assembly, if a hydraulic hand pump is not available. Refer to the shop manual for special instructions or contact your Dealer for assistance. When the swing motor is removed, make sure to use caps and plugs on hoses, tubes and fittings to protect the hydraulic system from any contamination. Also, a cover must be used to protect the swing reduction unit.

If this approach is taken, and the swing reduction unit becomes contaminated, make sure to flush and clean the swing reduction unit. Refer to page 4-8 and 4-9 for proper oil and component capacity.

B

PB

IP

PG A PA

SIDE VIEW SWING SHOCKLESS VALVE

M

PB

PA

L M

DB

2-M12 DEPTH 18 LIFTING CAPACITY 220 kg/2 bolts

A,B

If a hydraulic hand pump is not available, and the contamination can be controlled easily, then proceed to the next page for specific instructions on a different alternative to release the swing parking brake.

PG

IP

CAUTION Use safety protection such as: hard hat, working gloves, safety shoes and safety glasses when needed to perform this job.

Code

Name

Size

A,B M DB PA, PB PG L IP

Main port Make-up port Drain port Gauge port Brake release port Gear oil level port Gear oil filling port

2-PF3/4 PF1 PF1/2 PF1/4 PF1/4 PT1/2 PT3/4

Torque N·m {kgf·m} 167 216 108 36 36 65 98

FIGURE 9.15

9—6

{17} {22} {11} {3.7} {3.7} {6.6} {10}

Remarks

Section IX – SPECIAL PROCEDURES A. TOOLS & EQUIPMENT REQUIRED 1. Handtools required for removal of hydraulic tubes, hoses and fittings.

2. Plugs and caps for tubes, hoses and fittings.

3. 10 mm allen wrench.

4. 5 mm allen wrench.

5. Two M12-1.75 X 18 mm lifting eye.

6. Overhead lifting device capable of lifting and holding 100 kg (220 lb).

7. Plenty of clean, dry shop rags and/or paper towels.

8. 17 mm allen wrench.

9. 45 kgf·m (325 lbf·ft) torque wrench.

INSTALL PROPER CAPS AND PLUGS ON HOSES, TUBES AND FITTINGS TO HELP PREVENT CONTAMINATION ENTERING THE SYSTEM

FIGURE 9.16

B. PROCEDURES 1. Lower attachment to ground. Refer to previous page for proper procedures in lowering the attachment.

2. Remove all hoses and tubes from the swing motor top plate and swing valve to gain access to the top plate mounting bolts.

3. Install the proper plugs and caps onto hoses, tubes and fittings to avoid the possibility of contamination entering the hydraulic system. See Figure 9.16.

REMOVE THE TWO PLUGS AND INSTALL LIFTING EYES (M12-1.75 X 23 mm)

TOP COVER

FIGURE 9.17

CAUTION SWING SHOCKLESS VALVE

Use only plugs and caps designed to properly seal the specific hose, tube or fitting they are to be installed on.

4. Remove two plugs, as indicated in Fig. 9.17, and install 2 X M12-1.75 X 14 mm eye bolts.

LOOSEN (4) COVER MOUNTING BOLTS

NOTE Place a large quantity of clean, dry shop rags around the swing motor to help catch any overflow of hydraulic oil from the removal of the top plate.

FIGURE 9.18

5. Loosen the four top plate mounting bolts with the 17 mm allen wrench. See Figure 9.18.

9—7

Section IX – SPECIAL PROCEDURES 6. Remove two top plate mounting bolts from corners opposite of each other. See Figure 9.19.

7. Attach overhead lifting device to the lifting eyes and remove most of the slack from the cable or chain.

8. Carefully remove the remaining two bolts from the top mounting plate.

REMOVE TWO BOLTS, OPPOSITE CORNERS OF EACH OTHER

NOTE The top plate will raise from spring pressure as the last two bolts are removed. Some movement of the upper frame may be experienced as the spring tension is released.

FIGURE 9.19

9. Using the overhead lifting device, carefully lift the swing motor top cover with swing shockless valve assembly and away from the swing motor.

REMOVE ALL SPRINGS

CAUTION Do not allow any dirt or debris to enter the swing motor or settle on the top plate.

10.Carefully remove all brake springs and place in a container filled with fresh, clean hydraulic oil. Then, seal the container to prevent contamination. See Figure 9.20.

11.Align the holes of the distributor plate in the swing motor until they are located toward the front and back of the swing motor housing. See Figure 9.21.

12.Carefully place the top plate over the swing motor and align the dowel pins of the top plate with the holes in the distributor plate. See Figure 9.22.

13.Carefully and slowly lower the top plate into position on the swing motor and install, by hand, the four top plate mounting bolts.

FIGURE 9.20

ALIGN DISTRIBUTOR PLATE HOLES TOWARDS FRONT AND REAR OF HOUSING

CAUTION

FIGURE 9.21

Make certain the top plate dowel pins and the distributor plate holes mesh together.

DOWEL PINS

FIGURE 9.22

9—8