New Holland Kobelco E40.2SR E50.2SR Operation & Maintenance Instruction Manual 6042147501 - PDF

Operation and Maintenance Instruction Manual

E40.2SR E50.2SR Operation and Maintenance Instruction Manual

E40.2SR-E50.2SR

Print No. 604.21.475.01 English - Printed in Italy

PROVEN PERFORMANCE

PROVEN PERFORMANCE

E40.2SR - E50.2SR OPERATION AND MAINTENANCE INSTRUCTION MANUAL ENGLISH Print No. 604.21.475.01

Edition 11/2005 English - Printed in Italy Printed by Studio ti - 62605

TABLE OF CONTENTS

FOREWORD GENERAL ......................................................................................................................... 0-1 PERIODIC INSPECTIONS ............................................................................................... 0-1 NOTICE............................................................................................................................. 0-1 FOR ORDERING .............................................................................................................. 0-2

1. SAFETY PRECAUTIONS 1.1 GENERAL SAFETY INFORMATION ....................................................................... 1-3 1.2 SAFETY PRECAUTIONS......................................................................................... 1-4 1.3 PRE-START SAFETY .............................................................................................. 1-6 1.4 SAFETY DURING OPERATION .............................................................................. 1-12 1.5 INSPECTION & MAINTENANCE SAFETY .............................................................. 1-20 1.6 BATTERY SAFETY .................................................................................................. 1-28 1.7 WARNING LABELS & DECALS............................................................................... 1-30 1.7.1

NOTICE FOR WARNING LABELS & DECALS................................................. 1-30

1.7.2

LOCATION OF WARNING LABELS & DECALS............................................... 1-30

1.8 PROHIBITED MACHINE OPERATION.................................................................... 1-37 1.9 END OF WORK SHIFT SAFETY ............................................................................. 1-40 1.10 TRANSPORTATION ................................................................................................ 1-41 1.11 TOWING THE MACHINE ......................................................................................... 1-43

2. MACHINE FAMILIARIZATION 2.1 FAMILIARIZATION................................................................................................... 2-3 2.2 GENERAL MACHINE NOMENCLATURE................................................................ 2-3 2.3 OPERATOR’S CAB NOMENCLATURE................................................................... 2-4 2.4 COMPONENT & CONTROLS NOMENCLATURE................................................... 2-6 2.4.1

MONITOR PANEL (GAUGE CLUSTER)........................................................... 2-6

2.4.2

SWITCHES........................................................................................................ 2-9

2.4.3

LEVERS AND PEDALS..................................................................................... 2-11

2.4.4

SEAT BELT ....................................................................................................... 2-16

2.4.5

CAB (OPTION) .................................................................................................. 2-17

2.4.6

GUARD WITH LOCKING DEVICE & COVERS ................................................ 2-19

2.4.7

SEAT ADJUSTMENT ........................................................................................ 2-20

2.4.8

ELECTRICAL EQUIPMENT .............................................................................. 2-20

2.4.9

STORAGE & OTHERS...................................................................................... 2-22

3. MACHINE OPERATION 3.1 BASIC MACHINE OPERATION ............................................................................... 3-3 3.1.1

PRE-START INSPECTION ............................................................................... 3-3 1

TABLE OF CONTENTS 3.1.2

INSPECTION BEFORE OPERATION............................................................... 3-4

3.1.3

CHECK BEFORE STARTING MACHINE ENGINE........................................... 3-9

3.1.4

STARTING AND STOPPING MACHINE ENGINE............................................ 3-10

3.1.5

STOPPING MACHINE ENGINE........................................................................ 3-14

3.1.6

INSPECTION AFTER STARTING MACHINE ENGINE .................................... 3-14

3.1.7

MACHINE WARM-UP ....................................................................................... 3-17

3.1.8

MACHINE OPERATION.................................................................................... 3-18

3.1.9

PRACTICES TO IMPROVE EFFICIENCY ........................................................ 3-25

3.1.10 MACHINE PARKING......................................................................................... 3-29 3.1.11 CHECKING & VERIFICATION AFTER WORK ................................................. 3-30 3.1.12 PRECAUTIONS AFTER OPERATION.............................................................. 3-30 3.1.13 MEASURES AFTER EMERGENCY STOP....................................................... 3-30 3.1.14 LOCKING UP WITH KEY .................................................................................. 3-32 3.1.15 EMERGENCY MEASURES AGAINST SUDDEN FAILURE OF MACHINE ..... 3-32 3.1.16 CAUTION ON USING RUBBER TRACKS ........................................................ 3-38 3.1.17 MACHINE OPERATION IN ADVERSE WEATHER CONDITIONS .................. 3-42 3.1.18 PRECAUTIONS WHEN STORING THE MACHINE FOR A LONG PERIOD ... 3-44

4. MAINTENANCE 4.1 GENERAL INFORMATION ...................................................................................... 4-3 4.2 GENERAL SAFETY & PRECAUTIONS .................................................................. 4-4 4.3 LUBRICANT, FUEL & COOLANT SPECIFICATIONS ............................................. 4-10 4.4 FAST MOVING PARTS............................................................................................ 4-11 4.5 ACCESSORY TOOLS.............................................................................................. 4-12 4.6 TORQUE SPECIFICATIONS FOR CAPSCREWS & NUTS ................................... 4-13 4.7 TORQUE SPECIFICATIONS FOR JOINTS & HYDRAULIC HOSES...................... 4-14 4.8 INSTALLING HYDRAULIC HOSE AND PIPE JOINTS ........................................... 4-15 4.9 RELEASING INTERNAL PRESSURE FROM THE HYDRAULIC SYSTEM............ 4-17 4.10 BLEEDING AIR IN FUEL SYSTEM ......................................................................... 4-19 4.11 REPLACEMENT OF RUBBER TRACK .................................................................. 4-20 4.11.1 REMOVAL OF RUBBER TRACK...................................................................... 4-20 4.11.2 INSTALLING RUBBER TRACKS ...................................................................... 4-21 4.11.3 CHECK AND ADJUSTMENT OF TENSION ON RUBBER TRACK.................. 4-22 4.12 INSPECTION & MAINTENANCE CHART .............................................................. 4-26 4.13 WHEN REQUIRED ................................................................................................. 4-29 4.14 PRE-START (EVERY 8 HOURS) INSPECTION & MAINTENANCE....................... 4-39 4.15 50-HOUR (WEEKLY) INSPECTION AND MAINTENANCE .................................... 4-41 4.16 250-HOUR (3–MONTH) INSPECTION AND MAINTENANCE ................................ 4-46 4.17 500-HOUR (6-MONTH) INSPECTION AND MAINTENANCE ................................. 4-53 2

TABLE OF CONTENTS 4.18 1000-HOUR (12-MONTH) INSPECTION AND MAINTENANCE ............................. 4-54 4.19 2000-HOUR INSPECTION AND MAINTENANCE ................................................... 4-59 4.20 INSPECTION MAINTENANCE CHECK LIST .......................................................... 4-68

5. TRANSPORTATION 5.1 WHEN PREPARING TRANSPORTATION PLANS ................................................. 5-3 5.2 LIFTING PROCEDURES FOR THE MACHINE COMPLETE (E40.2SR) ................ 5-5 5.3 LIFTING PROCEDURES FOR THE MACHINE COMPLETE (E50.2SR) ................ 5-6 5.4 LOAD SPECIFICATIONS......................................................................................... 5-7

6. SPECIFICATIONS 6.1 GENERAL SPECIFICATIONS (E40.2SR)................................................................ 6-3 6.1.1

MACHINE DIMENSIONS (E40.2SR)................................................................. 6-3

6.1.2

GENERAL SPECIFICATIONS (E40.2SR)......................................................... 6-4

6.1.3

CRAWLER SHOE TYPE (E40.2SR) ................................................................. 6-5

6.1.4

BUCKET TYPE (E40.2SR) ................................................................................ 6-5

6.1.5

ATTACHMENT WORKING RANGES (E40.2SR).............................................. 6-6

6.1.6

MACHINE & COMPONENTS WEIGHT (E40.2SR)........................................... 6-8

6.2 GENERAL SPECIFICATIONS (E50.2SR)................................................................ 6-9 6.2.1

MACHINE DIMENSIONS (E50.2SR)................................................................. 6-9

6.2.2

GENERAL SPECIFICATIONS (E50.2SR)......................................................... 6-10

6.2.3

CRAWLER SHOE TYPE (E50.2SR) ................................................................. 6-11

6.2.4

BUCKET TYPE (E50.2SR) ............................................................................... 6-11

6.2.5

ATTACHMENT WORKING RANGES (E50.2SR)............................................. 6-12

6.2.6

MACHINE & COMPONENTS WEIGHT (E50.2SR)........................................... 6-14

7. OPTIONAL EQUIPMENT 7.1 OPERATION OF HYDRAULIC HAMMER AND SHEARS ....................................... 7-3 7.1.1

SELECTION OF HYDRAULIC HAMMER AND SHEARS ................................. 7-3

7.1.2

BEFORE OPERATING HAMMER OR SHEARS............................................... 7-3

7.1.3

HYDRAULIC OIL LEVEL CHECK AND CONTAMINATION PREVENTION ..... 7-3

7.1.4

BASIC OPERATION.......................................................................................... 7-3

7.1.5

SETTING SELECTOR VALVE .......................................................................... 7-5

7.1.6

SETTING STOP VALVE.................................................................................... 7-6

7.2 SAFETY PRECAUTIONS......................................................................................... 7-7 7.3 PERIODIC INSPECTION AND MAINTENANCE INTERVAL................................... 7-11

8. TROUBLESHOOTING 8.1 GENERAL TROUBLESHOOTING ........................................................................... 8-3

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TABLE OF CONTENTS

4

FOREWORD

FOREWORD 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 MANUFACTURER IS USED, YOU MUST SATISFY YOURSELF THAT IT IS SAFE FOR YOU AND OTHERS. YOU SHOULD ALSO ENSURE THAT THE PRODUCT WILL NOT BE DAMAGED OR MADE UNSAFE BY THE OPERATION, LUBRICATION, MAINTENANCE AND/OR REPAIR PROCEDURES YOU CHOOSE.

GENERAL •

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

•

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

•

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

•

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

•

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

•

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

•

It is expressly noted that this manual is written on the presupposition that the genuine manufacturer’s parts are to be used, not including cases where parts locally procured were used and/or the machine was arbitrarily modified by the user locally.

•

Materials and specifications are subject to change without notice.

PERIODIC INSPECTIONS •

After delivery of a machine, the approved Dealer will make periodic service inspections. Contact an approved 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 approved 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 to any of the manufacturer’s products without any obligation on the part of the Manufacturer.

0-1

FOREWORD

FOR ORDERING For ordering parts and service, inform an approved Dealer of your machine’s Serial Number and Engine Serial Number stamped in the locations below, and Hour Meter reading, shown in the illustrations below. For future reference, record these Serial Numbers in the spaces provided below: MACHINE No. ENGINE No.

• MACHINE No.

MADE IN JAPAN

• ENGINE No.

• HOUR METER

0-2

1. SAFETY PRECAUTIONS

1-1

1. SAFETY PRECAUTIONS

1-2

1. SAFETY PRECAUTIONS

1.1

GENERAL SAFETY INFORMATION

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 PROPERLY STORED WHEN NOT IN USE. IF PARTS ARE MISSING OR DAMAGED, PLACE AN ORDER WITH AN APPROVED DEALER FOR A REPLACEMENT. IF YOU HAVE ANY QUESTIONS, PLEASE CONSULT AN APPROVED DEALER. 1. Most accidents, which occur during operation, are due to neglect of precautionary measures and safety rules.

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

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

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

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

WARNING c. 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.

CAUTION 4. It is very difficult to foresee 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 us.

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

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

1-3

1. SAFETY PRECAUTIONS

1.2

SAFETY PRECAUTIONS

WARNING THE PROPER AND SAFE LUBRICATION AND MAINTENANCE FOR THIS MACHINE, RECOMMENDED BY THE MANUFACTURER, ARE OUTLINED IN THIS 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 THIS OPERATOR’S MANUAL BEFORE PERFORMING ANY LUBRICATION OR MAINTENANCE. The serviceman or mechanic may be unfamiliar with many of the systems on this machine. This makes it important to use caution when performing service work. Sound knowledge of the system and or components is important before the removal or disassembly of any component.

Because of the size of some of the machine components, the serviceman or mechanic should check the weights noted in this manual. Use proper lifting procedures when removing any components. Weight of components is shown in "MACHINE & COMPONENTS WEIGHT", 6-8.

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

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

2. Always wear protective glasses and protective shoes when working around machines.

In particular, wear protective glasses when using hammers, punches or drifts on any part of the machine or attachments. Use welders gloves, hood/goggles, apron and the protective clothing appropriate to the welding job being performed. Do not wear loose fitting or torn clothing. Remove all rings from fingers, loose jewelry, confine long hair and loose clothing before working on this machinery.

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

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

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

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

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

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

Refer to item "MOUNTING & DISMOUNTING MACHINE", 1-8.

9. To avoid back injury, use a hoist when lifting components which weigh 20 kg (45 lb) or more. Make sure all chains, hooks, slings, etc., are in good condition and have 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 to the presence of hot parts on machines which have just been stopped and hot fluids in lines, tubes and compartments.

1-4

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

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

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

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

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

16. Do not damage wiring during removal operations. Reinstall the wiring so it is not damaged and will not be damaged in operation of the machine by contacting sharp corners, or by rubbing against some object or hot surface.

Do not connect wiring to a line containing fluid.

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

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

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

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

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

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.

1-5

1. SAFETY PRECAUTIONS

1.3

PRE-START SAFETY

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

OBSERVE SAFETY PRECAUTIONS GER

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.

DAN

F RO LEA A C P E KEE ING AR SW

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 ing a bu cket ne ar

WARNING

OPE MAN RATOR ’S UAL

PREVENT BATTERY EXPLOSION Batteries give off hydrogen gasses that can 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 when charging.

YN20T01001P1

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

WARNING DO NOT WEAR WORKING CLOTHES CONTAMINATED WITH OIL, SINCE IT IS WILL EASILY CATCH FIRE. WEAR PROTECTIVE CLOTHING READ AND UNDERSTAND THE OPERATOR’S MANUAL Before operating the machine, read and understand this OPERATOR’S MANUAL thoroughly in order to use the machine effectively and safely.

KEEP OPERATOR’S MANUAL IN STORAGE Keep this MANUAL in the specified storage for quick reference. Should the OPERATOR’S MANUAL become lost or damaged, contact an approved Dealer to order the OPERATOR’S MANUAL.

READ MANUAL/KEEP IN STORAGE

1-6

1. SAFETY PRECAUTIONS DO NOT OPERATE MACHINE WHEN OVER TIRED OR UNDER THE INFLUENCE OF DRUGS Your poor physical condition causes improper reactions. Voluntarily refrain from operating the machine when feeling excessively tired, and never operate the machine under the influence of drugs.

REFRAIN POOR PHYSICAL CONDITION 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 beforehand the communication means to be used in case of any emergency, and take note of telephone numbers for emergency contact.

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

WORK SITE SAFETY-KNOW THE AREA ENGAGE SAFETY LOCK LEVER BEFORE LEAVING MACHINE

1

Before leaving the operator’s seat, move the safety lock lever (1) to the "LOCKED" (Up) position. This will prevent operation of any hydraulic controls should they be accidentally moved. If the lever is not set to the "LOCKED" position (1) 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, (1) stop the engine and remove the starter switch key.

SAFETY LOCK LEVER

1-7

1. SAFETY PRECAUTIONS 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.

SIGNS, SIGNALS & FLAGMEN KEEP FIRE AWAY FROM FUEL AND OIL Oil, antifreeze, and especially fuel are highly flammable. Never allow 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 AND OIL SURELY INSTALL SAFEGUARD Confirm that all guards and covers are securely and properly installed. If damaged, immediately restore them to the proper conditions.

Do not operate the machine without guards or covers.

Be sure to maintain them in normal condition.

SURELY INSTALL SAFEGUARD 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 operator’s seat parallel to the tracks before stopping the engine for dismounting.

MOUNTING & DISMOUNTING MACHINE

1-8

1. SAFETY PRECAUTIONS PAY ATTENTION TO WORKING MACHINES Do not approach a working machine. Make sure to make visual contact with the operator before approaching a working machine.

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

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

PREVENT FIRES-CLEAN UP SPILLAGE CHECK OPERATING LEVER PATTERNS Check the operating patterns before working on the machine.

The figure shows the standard operating system, specified in ISO.

YN20T01089P1

CONFIRM OPERATING PATTERNS

1-9

1. SAFETY PRECAUTIONS KEEP CLEAN CAB FLOOR AND DRIVER’S SEAT Do not place any parts and tools in the driver’s cabin to prevent injury due to slippage and stumbling. Remove any debris from the cab floor, control levers, handrail, etc. Make sure to keep all operating controls clean at all times.

KEEP CLEAN AROUND DRIVER’S SEAT HOW TO HANDLE THE SAFETY HAMMER-CAB only A life hammer is provided on the right side of cab. In case of emergency, take the safety hammer (1), break the cab glass, and escape from the cab. In addition, the safety hammer (1) is equipped with a cutter (2) on the handle side to cut the seat belt, etc.

2 1

HOW TO HANDLE LIFE HAMMER-CAB ONLY PERFORM PRE-START INSPECTION Walk around the machine before starting the machine, perform a PRESTART inspection of the machine and make note of any abnormality. 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.

PERFORM PRE-START INSPECTION TAG OUT MACHINE DURING MAINTENANCE Before performing any inspection or maintenance procedures to the machine, post to the operator’s controls a "DO NOT OPERATE" tag to warn persons not to start the machine.

Be sure to inform the supervisor and all operator that the machine is under inspection or maintenance and they will be informed when the machine is ready for normal operation.

"TAG-OUT" MACHINE

1-10

1. SAFETY PRECAUTIONS USE CAUTION NEAR NOISE If noise is high during operation, loss of 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 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.

AVOID HOT SURFACES & AREAS

1-11

1. SAFETY PRECAUTIONS

1.4

SAFETY DURING OPERATION

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

NO PASSENGERS STARTING THE ENGINE Start engine from the operator’s seat. Do not short circuit the starter circuit or battery to start the engine. This may cause serious injury or cause damage to the electrical system.

DO NOT SHORT CIRCUIT HORN BEFORE STARTING THE ENGINE Sound the horn before starting the engine to warn people the machine is being started. Make sure no one is near the machine.

CAUTION Do not start the engine if the "DO NOT OPERATE" tag has been tagged out.

SOUND HORN BEFORE STARTING CHECK AFTER STARTING THE ENGINE Be sure to check machine the for proper functioning after starting the engine. Slowly cycle attachments, swing, and travel functions in an area with sufficient space, without obstacles, and personnel. Failure to do so could result in injury or machine damage. Make note of any abnormalities and repair as needed.

CHECK AFTER STARTING THE ENGINE

1-12

1. SAFETY PRECAUTIONS WARM UP MACHINE BEFORE OPERATION Take sufficient time to warm up the machine, especially in the cold season, otherwise the response of machine to the operation of operating levers is delayed which may cause injury and/or machine damage.

1

2

3

1. BLUE 2. WHITE 3. RED

WARMING UP OPERATION VERIFY THE OPERATING CONTROL PATTERN Slowly operate the control levers to confirm the operating patterns in advance. Make sure the operation control pattern is according to the indication plate.

CONFIRM OPERATING PATTERN VERIFY TRAVEL DIRECTION Make certain of the location of the travel motors before operating travel.

Pay attention in the case where the travel motors (1) are in the front side, the travel function is reversed (2).

Sound horn before moving the machine to inform any personnel around the machine that the machine is now in operation.

2 1

KNOW TRAVEL MOTOR POSITION DO NOT HIT THE CAB WITH THE ATTACHMENT Check clearance between bucket and cab before operation. Slowly operate bucket, check for interference with arm and cab, particularly if a lifting eye is welded on bucket bottom. Exercise care when operating the bucket near the cab.

DO NOT HIT CAB

1-13

1. SAFETY PRECAUTIONS SWINGING FUNCTION 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.

SLEW/SWING/TRAVEL SAFETY TRAVELLING ON SLOPES Use extreme caution when travelling on slopes, the machine could turn over or slide causing injury or machine damage.

Keep the bucket at a height of 30~40 cm (12~16 inch) above ground level, and wear the seat belt at all times.

Never make a change of direction on the slope or cross the slope.

PAY ATTENTION ON SLOPE FROZEN & SNOW COVERED WORK SITES Use extreme caution when operating the machine on frozen or snow covered work sites. Operate all controls slowly and cautiously to prevent sudden movements such as start/stop/turning, 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, the machine may unexpectedly move. Snow on shoulders or snow drifts can be much deeper than expected.

The machine can easily become buried under such conditions. Use extreme caution while operating the machine around or in snow.

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

USE EXTREME CAUTION ON FROZEN OR SNOW

TRAVEL Position the attachment as shown in illustration before beginning travel. On rough terrain move the machine at slow speeds, and do not turn suddenly. Avoid travelling over obstacles. Should it become necessary to travel over an obstacle, keep the attachment close to the ground and travel at extremely slow speed.

30cm~40cm

TRAVEL POSITION

1-14

1. SAFETY PRECAUTIONS FILLED OR UNSTABLE GROUND Be certain the condition of the work site is stable and capable of supporting the machine weight 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 crawler at right angles to the shoulder and the travel motors to the rear of the machine, allowing for quick reversal, should the work area become unstable.

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

USE PROPER LIFTING DEVICES 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. Prepare 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.

BUILD BANKING FOR SLOPE OPERATION

1-15

1. SAFETY PRECAUTIONS WORKING AROUND ELECTRIC POWER LINES If it is suspected that utility lines such as telephone or electrical power lines are in the work area, contact the local utility authority for line location BEFORE beginning work in the area. Use extreme caution around electrical power lines. Keep a sufficient distance away from electrical lines during operation. See chart below for minimum distances.

LINE VOLTAGE

Minimun Distance-M(FEET)

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

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

KEEP A SAFE DISTANCE FROM UTILITIES

WORKING AROUND UTILITY LINES UNDERGROUND When working in the presumed area of power, water or gas lines under the ground, ask the organization concerned for the actual location, carry out trial digging and proceed to work with care after confirmation for nonexistence of them or location of them.

CHECK LOCATION OF UTILITIES PARKING THE MACHINE Always park the machine on a firm, level surface.

If no firm level surface is available, block (1) the crawler and lower bucket (2) and dozer blade (3) 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 give safe warning to motorists. Refer to local code and regulations regarding the posting of work area warnings and markers.

2 3 1

PARKING SAFETY

1-16

1. SAFETY PRECAUTIONS 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 at a safe distance to prevent personal injury and/or equipment or structure damage.

Use a flagman to guide the operator.

USE EXTREME CAUTION AT RESTRICTED AREA DO NOT WORK UNDER PRECIPICES Don’t dig under a precipice. It causes falling rocks or loosening of the precipice resulting in injury and/or machine damage.

DO NOT DIG UNDER PRECIPICES WORK WITH SUFFICIENT LIGHTING When working in dark places, turn on the working light.

And if required, provide additional lighting facilities to ensure visibility.

Stop working when it is impossible to ensure visibility due to fog, snow or rain.

WORK WITH SUFFICIENT LIGHTING SET LIMITS TO WORKING AREAS Set limits around the working area to avoid collision or personal injury. Make sure to check for obstacles and personnel while swinging. Use a flagman to guide the operator whenever necessary.

OFF LIMITS TO WORKING AREA

1-17

1. SAFETY PRECAUTIONS CAUTION FOR WORK IN URBAN AREAS It is dangerous to allow other personnel to enter into the working area.

Make the working area off-limits to other people by providing caution signs.

Make sure to provide a flagman in working areas with heavy traffic to avoid accident.

USE A FLAGMAN WHEN NECESSARY DO NOT USE A NON-SERVICED MACHINE The use of non-serviced machine may cause an unexpected accident or breakdown.

Stop operation of a faulty machine. Make sure to repair any abnormalities before resuming operation.

DO NOT USE NON-SERVICED MACHINE SLIPPERY GROUND SURFACE Use caution when operating machine on boards or steel plates. Boards and steel plates become very slippery when wet.

Pay special attention when working on inclined areas.

Provide a device to prevent skidding and proceed to work with extra care. Piled up tree leaves or branches also may cause skidding.

PAY ATTENTION TO SLIPPERY SLOPES REINFORCE SOFT GROUND When working on a soft ground or marshy area, the machine may sink.

Provide logs or lumber to pave horizontally to prevent the machine from sinking.

Frozen ground becomes soft along with the increase of ambient temperature.

STRENGTHEN SOFT GROUND

1-18

1. SAFETY PRECAUTIONS LOOSENED GROUND AFTER RAIN After rain, there is a possibility of the machine being exposed to the danger of tumbling down or falling down of the machine under the vibration and weight of the machine, due to the loosened shoulder of the road.

Pay attention to loosened precipices or shoulders of roads, and do not access such places without care.

PAY ATTENTION TO LOOSENED GROUND LOOSENED GROUND AFTER EARTHQUAKE OR DYNAMITING Pay attention to loosened precipices or shoulders of roads, and falling rocks. Also pay attention to the unexploded dynamite.

PAY ATTENTION TO LOOSENED GROUND BOOM, ARM & ATTACHMENTS Give the work you are doing your undivided attention.

Make certain the attachment being used is suited for the job on 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. SLEW/SWING SAFETY STABILIZE ATTACHMENTS Stabilize all attachments removed from the machine to prevent the attachment falling over.

STABILIZE ATTACHMENTS

1-19

1. SAFETY PRECAUTIONS

1.5

INSPECTION & MAINTENANCE SAFETY

UNDERSTAND INSPECTION/MAINTENANCE PROCEDURES Incorrect maintenance may cause not only damages on the machine, but also injury.

Be sure to read and fully understand the maintenance procedures and safety precautions described in this manual before performing any maintenance in this machine.

UNDERSTAND PROCEDURES MEETING PRIOR TO WORK To prevent any accidents or injury due to errors, have a meeting before start working. When a flagman is provided, make sure that all signals are understood accordingly.

MEETING PRIOR TO WORK ORGANIZE AND CLEAN UP WORKING AREA Organize and clean up the working area. Remove any obstacles and also remove any grease, oil, paint, broken pieces, etc., from the working area to avoid injury.

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

"TAG-OUT" MACHINE

1-20

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

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

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

1

2

HYDRAULIC OIL LEVEL CHECK POSITION

1. BUCKET 2. DOZER BLADE 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.

KEEP MACHINE CLEAN STOP THE ENGINE BE CERTAIN TO TURN THE 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.

STOP ENGINE/ENGAGE SAFETY LOCK LEVER

1-21

1. SAFETY PRECAUTIONS REFUELLING Move the machine to a well ventilated area for refuelling. Use only specified fuel as described in the MAINTENANCE section of this MANUAL. Immediately clean up all spilled fuel and dispose of waste properly. After refuelling is complete, securely tighten fuel cap.

Never use the fuel for cleaning.

REFUELING 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 (1) or blocks (2), with a sufficient capacity rating to support the machine, under the track/ frame. NEVER INSPECT OR PERFORM MAINTENANCE PROCEDURES UNDER A RAISED MACHINE THAT IS NOT SUFFICIENTLY SUPPORTED.

1 2

SUPPORT THE MACHINE 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. Seek for immediate medical assistance if injury occurs.

CHECKING FOR HIGH PRESSURE LEAKS 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 CAREFUL OF HOT FLUIDS AND GASES FROM SYSTEMS ON MACHINES THAT HAVE JUST BEEN STOPPED. ALLOW SUFFICIENT TIME FOR SYSTEMS TO COOL BEFORE PERFORMING ANY INSPECTION OR MAINTENANCE PROCEDURES.

RELEASE HYDRAULIC TANK PRESSURE

1-22

1. SAFETY PRECAUTIONS CARE ABOUT VENTILATION Maintenance for the machine indoors or in a place with poor ventilation may cause poisoning by gas.

Pay special attention to ventilate any exhaust gas, fuel, cleaning oil, paint or similar articles.

Ensure proper ventilation in the working area when the machine is operated indoors. Provide a ventilating fan, if required.

CARE ABOUT VENTILATION PREVENTIVE MEASURE AGAINST FIRE It is unavoidable to handle flammable materials such as battery, fuel, lubricating oil, etc. in a maintenance area; therefore, follow the general guidelines to prevent fire: •

Use a nonflammable cleaning oil to clean the parts, etc.

•

Extinguish any naked lights capable of causing fires.

•

Provide appropriate fire fighting equipment such as a fire extinguisher.

•

Refrain from smoking during maintenance work.

•

Put away any flammable materials during grinding work or welding work.

PREVENTIVE MEASURE AGAINST FIRE

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

USE APPROVED WORK LIGHTS DO NOT HEAT HYDRAULIC EQUIPMENT OR PIPING Never apply heat to hydraulic equipment or piping, such as when welding, soldering, heating with torch, etc.

Heating of hydraulic components or piping will cause gas expansion, which can easily catch fire and/or explode.

DO NOT HEAT HYDRAULIC PIPING

1-23

1. SAFETY PRECAUTIONS WORKING ABOVE GROUND There exists danger of falling when working on areas above ground. Be careful not to approach edges.

•

Make sure to use the appropriate equipment, such as ladders or a man lift when working above ground. In addition, strap yourself to the proper equipment accordingly.

•

Avoid spillage of any oil or grease.

•

Do not leave any tools around the working area.

•

Use extreme caution to avoid slipping while walking.

•

Never jump into or from climbing equipment. Use a step-ladder or handrail and securely maintain a three point contact while mounting or dismounting at all times.

•

Make sure to read the manlift equipment operator’s manual before using.

•

Comply with climbing equipment weight ratings.

TAKE CARE AT ELEVATED SPOT

DO NOT DROP TOOLS AND PARTS Dropping of any tools and parts in the working area may cause injury or faulty machine operation.

Do not leave any tools or articles in the working area or component compartment. Be sure to store all tools properly when the work is completed.

DO NOT DROP TOOLS AND PARTS ELECTRICAL SYSTEM Before performing any inspection work or maintenance on the electrical system, or performing any welding procedures, disconnect the negative (–) cables from the battery terminals. Failure to disconnect the negative (–) cable could cause extensive damage to the electrical system.

ELECTRICAL SYSTEM PRECAUTIONS

1-24

1. SAFETY PRECAUTIONS CAUTION WITH MODIFICATIONS We will not be liable for any injury or damages due to equipment modification without approval.

When any modification is intended, consult with an approved Dealer in advance.

CAUTION WITH MODIFICATIONS AFTER COMPLETION OF MAINTENANCE WORK Always, be sure to check the machine for proper functioning when any maintenance work is completed: •

After any maintenance work is completed, operate the engine at low idle, and check for leakages and abnormalities.

•

Slowly operate each machine function to confirm proper operation.

•

Increase the engine speed gradually, and again check for leakages and abnormalities.

•

Operate each operating lever normally to confirm smooth operation.

CHECK FOR SMOOTH OPERATION

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.

DISPOSE OF WASTE PROPERLY

1-25

1. SAFETY PRECAUTIONS GENERAL GUIDELINES FOR WELDING Welding work must be performed by a certified welder with sufficient experience. In addition, safety practices must be followed by any personnel involved in such work. Identify all cracks to be repaired or areas to be welded by thoroughly cleaning the suspected surface, remove paint, and check with dye penetrant or magnetic particle testing. The life expectancy of the welded area depends on the work quality and the attention given to details during welding.

•

•

Avoid welding structures with surface temperatures below 16 C (60 F). If needed, preheat surface with a hand torch. In cases where the machine components are extremely cold, it is recommended that the components be brought inside and allowed to warm to 16 ~ 20 C (60 ~ 70 F) for at least 12 hours prior to welding.

PAY ATTENTION TO WELDING WORK

Remove paint from any surface to be heated or welded. Painted surfaces produce unhealthy gases when heated or welded. Use mask and proper skin protection when removing paint from any surface.

When removing paint sanding, do not breath the generated dust. Be sure to use plenty of soap and water to rinse the surface to be welded, since chemicals will generate unhealthy gases when heated and/or welded.

WARNING •

HAVE A FIRE EXTINGUISHER ON HAND AT ALL TIMES WHILE GRINDING, HEATING, OR WELDING.

•

BE SURE TO CLEAN OIL AND/OR FLAMMABLE MATERIALS FROM ANY SURFACE TO BE CUT.

•

PROTECT ALL FLAMMABLE PARTS AND SURFACES FROM SPARKS AND/OR FLAMES

•

BE SURE TO PERFORM WORK IN A WELL VENTILATED AREA.

•

KEEP SPARKS AND FLAMES AWAY FROM PAINT AND/OR SOLVENT.

•

KEEP SPARKS AND FLAMES FROM CYLINDER RODS, SEALS, ELECTRICAL WIRES, AND/OR HYDRAULIC HOSES.

1-26

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

Refer to 4-22 for the procedures to adjust the tension on the track.

USE CAUTION WHEN ADJUSTING CRAWLER PAYING ATTENTION TO BROKEN PIECES WHEN HAMMERING Flying particles may cause injury when hammering hard metal parts, such as pin, edge, tooth, bearing, etc.

Wear protective clothes such as protective glasses, safety hat, etc. during maintenance.

USE CAUTION WHEN HAMMERING

1-27

1. SAFETY PRECAUTIONS

1.6

BATTERY SAFETY

WEAR PROPER PROTECTIVE CLOTHING Wear a long sleeve shirt, gloves and approved safety glasses or face protection 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 the effected clothing, flush area with clean water for 15 minutes and get prompt medical attention.

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

KEEP AWAY FROM FIRE OR FLAMES CHARGING BATTERY Make sure the battery is charged in a well ventilated area. When charging battery, remove cell caps to allow gases to escape. Avoid breathing gases from battery.

1-28

1. SAFETY PRECAUTIONS USING BOOSTER CABLES •

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.

C A

B

D

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 DISABLED MACHINE. 3. START ENGINE AND REMOVE BOOSTER CABLES IN REVERSE ORDER. OTHER PRECAUTIONS •

Pay attention to danger of sparks triggered off by erroneous connection between the positive (+) terminal of battery and the machine body with a tool, etc.

•

Make certain of tightening the battery caps.

•

Securely tighten up the battery terminals.

•

Leave the waste battery to a specialist for disposal.

1-29

E

(A) Normal Battery (B) Discharged Battery (C) Red Cable (D) Black Cable (E) To the upper frame of the troubled machine Cable connecting order: 1>2>3>4 Cable disconnecting order: 4>3>2>1

1. SAFETY PRECAUTIONS

1.7

WARNING LABELS & DECALS

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

1.7.1

NOTICE FOR WARNING LABELS & DECALS

•

Do not take away the attached warning labels and decals.

•

Check whether labels can be easily read.

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

•

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

•

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

Contact your Dealer for new labels.

1.7.2

LOCATION OF WARNING LABELS & DECALS

A 5

A 8 6

B 4

C

B C 7

D

D

F

10

1-30

1. SAFETY PRECAUTIONS 3

1

12

2

E F

E

10

9 13

DD 11

1-31

1. SAFETY PRECAUTIONS 15

H

G

G

14

H

9

17 HH DD 16 GG

1-32

1. SAFETY PRECAUTIONS 1. BOOM AND DIPPER MOVEMENT WARNING PLATE Located on seat stand cover.

It shows the danger represented by the bucket hitting the cab.

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

2. HYDRAULIC OIL BLEEDING PLATE Located on top of radiator duct.

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

Danger of pump seizure.

3. ELECTRICAL LINE SAFETY DECAL; SAFETY CONTROLS Located on seat stand cover.

It warns about danger in the case of work near electrical lines.

It is imperative for the operator when leaving the cab with engine running, even for a very short time, to move the safety lever to LOCKED position. Controls are thereby disconnected and any accidental equipment movement is impossible.

PV20T01005P1

4. HOT SURFACE DECAL Located on hood hinge.

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 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.

1-33

1. SAFETY PRECAUTIONS 5. PRESSURIZED FLUIDS & LUBRICANTS DECAL Located on radiator duct.

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 gases from systems on machines that have just been stopped, allow sufficient time for systems to cool before performing any inspection or maintenance procedures.

6. ENGINE STOP DECAL Located on hood support.

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.

7. DECAL, COUNTERWEIGHT SAFE OPERATING AREA Located on radiator cover.

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

8. ENGINE STOP DECAL 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.

1-34

1. SAFETY PRECAUTIONS 9. BOOSTER CABLE DECAL Located on battery box cover.

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

10. TRACK ADJUSTER DECAL Located on crawler frame.

It shows that it is obligatory to consult the Operator’s Manual prior to acting on the track adjust valve.

Danger of severe injuries.

11. KEEP CLEAR WORKING AREA Located on both sides of the dipper.

Make certain area is clear of obstacles and persons before beginning the operation of the machine. Always look around before you start the swing operation. Be sure that everyone is cleared in your worksite. Sound horn before beginning swing operation.

12. DOZER BLADE DECAL Located on seat stand cover.

It indicates to consult the Operator’s Manual before operating the dozer controlling lever.

1-35

1. SAFETY PRECAUTIONS 13. BATTERY DECAL Located on battery box cover.

Flammable gas (hydrogen gas) is generated in the battery. Do not produce sparks near the battery, and do not expose it to naked lights, to prevent the battery from catching fire and explosion.

14. DECAL FOR WINDOW LOCK Located inside of front window.

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

15. FALLING FRONT WINDOW Located on front window.

Falling front window can cause injury.

Always lock securely in place with lock lever on both sides.

When operating the window, use handles and keep the lock lever in release position.

16. CAB DOOR DECAL Located inside cab door.

It indicates the danger of possible injury from incorrect securing of cab door in open position.

17. REMOVING CAB Located inside cab R.H.

1-36

1. SAFETY PRECAUTIONS

1.8

PROHIBITED MACHINE OPERATION

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

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

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

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

DO NOT HAMMER WITH ATTACHMENT DO NOT USE THIS MACHINE FOR ANYTHING OTHER THAN ITS INTENDED PURPOSE. This machine is designed and manufactured for digging, loading and ground levelling operations only. Any other use can exert excessive force on 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

1-37

1. SAFETY PRECAUTIONS DO NOT OPERATE BUCKET AND DIPPER CYLINDERS TO STROKE END REPEATEDLY.

A

Extending the bucket and dipper 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.

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

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

DO NOT OVER EXERT THE MACHINE CAUTION WITH DOZER BLADE HITTING OBSTACLES. Pay attention that the dozer blade does not hit any obstacles such as rock lumps.

It causes damage to the dozer blade and cylinder.

DO NOT HIT ROCKS, ETC. WITH DOZER CAUTION WITH RETRACTING ATTACHMENT. When the attachment is retracted for travel or transport, pay attention that the bucket does not to hit the dozer blade.

DO NOT HIT DOZER BY BUCKET DO NOT SUPPORT MACHINE WITH DOZER BLADE AT ONE END. When the dozer blade is used as a stabilizer, do not support the machine at one end of the dozer blade, but surely at both ends.

DO NOT SUPPORT MACHINE WITH DOZER BLADE AT ONE END

1-38

1. SAFETY PRECAUTIONS CAUTION WITH DEEP EXCAVATIONS. Pay attention during deep excavation to the dozer blade in front. The boom cylinder could come in contact with the dozer blade.

Place the dozer blade at the back of the machine for deep excavations, unless the working area does not permit it.

TAKE CARE WITH DEEP EXCAVATIONS

1-39

1. SAFETY PRECAUTIONS

1.9

END OF WORK SHIFT SAFETY

Perform all of the following procedures after each shift is complete to insure the machine is 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 (CAB only).

END OF WORK SHIFT SAFETY

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

If storing the machine in cold climates, it may be necessary to remove the batteries from the machine and store them 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.

1-40

1. SAFETY PRECAUTIONS

1.10

TRANSPORTATION

Use the following general guidelines for loading or unloading the machine on a transportation vehicle: •

Loading and unloading of the machine must be carried out on firm level areas away from the road shoulder. Do not use the attachments to load or unload the machine from the trailer.

TAKE CARE ON LOADING/UNLOADING •

When needed, use a ramp capable of withstanding the machine weight. Check the ramp’s width, length and thickness to secure the loading/unloading work. And when much warp appears on the ramp structure, support them with safety blocks or alike.

•

Remove any mud, oils and grease from the ramp surface as well as from track shoes on the machine, to prevent the machine from side skidding.

•

Do not change the travel direction on the ramp.

When required, back down the machine to the ground, reposition and try again.

•

Always use low travel speed for loading or unloading from the trailer.

•

After loading the machine, shut off the engine and set the safety lock lever to "LOCKED" position.

•

Use cable or wire rope with sufficient capacity to secure front and rear of the machine to trailer. Provide blocks to the machine tracks, to avoid any movement of the machine.

•

USE RAMP FOR LOADING AND UNLOADING

A

Protect wire rope against edges with a pad.

B

2

2

1. WIRE ROPE

1

2. PAD FOR EDGE A. LOCKED (Up) POSITION B. UNLOCKED (Down) POSITION

SECURE FROM MOVEMENT

1-41

1. SAFETY PRECAUTIONS While transporting, observe legal regulations concerned, keeping safety in mind.

•

Select the routing taking overall height and length of the truck into consideration.

•

Refer to chapter 5. "TRANSPORTATION" for the details of loading, unloading and fixing procedures of the machine.

B

A

•

A. OVERALL HEIGHT B. OVERALL LENGTH

OBSERVE LEGAL REGULATIONS

1-42

1. SAFETY PRECAUTIONS

1.11

TOWING THE MACHINE

1. If the machine should become stuck in soft soil areas it may be necessary to tow the machine. Attach a wire cable or chain, with the capacity to pull the machine out, to the lower frame.

2. Attach other end to the vehicle used to pull the machine. Operate the machine’s travel lever in the proper direction while pulling with the other vehicle.

WARNING •

WHILE TOWING, DO NOT ENTER THE AREA BETWEEN THE MACHINE AND TOWING VEHICLE.

•

DO NOT APPLY A SHOCK LOAD ONTO THE TOWING ROPE.

•

DO NOT USE EYES ON MACHINE LOWER FRAME TO TOW MACHINE.

•

KEEP THE WIRE CABLE HORIZONTAL, AND PERPENDICULARLY TO THE CRAWLER FRAME.

•

TOW THE MACHINE SLOWLY AT LOW SPEED MODE.

•

FOR THE TOWING OF THE MACHINE BODY, PROVIDE PADS TO BE APPLIED TO THE CORNER OF CRAWLER FRAME TO PREVENT THE WIRE CABLE AND CRAWLER FRAME FROM ANY DAMAGE.

TOW MACHINE PROPERLY

NOTE: DO NOT PULL MACHINE UTILIZING THE BRACKETS WELDED ON THE LOWER PLATES OF THE CHASSIS. THESE BRACKETS ARE PROVIDED FOR PULLING LIGHTWEIGHT OBJECTS. SEE FIGURE FOR BETTER REFERENCE.

1-43

1. SAFETY PRECAUTIONS

1-44

2. MACHINE FAMILIARIZATION

2-1

2. MACHINE FAMILIARIZATION

2-2

2. MACHINE FAMILIARIZATION

2.1.

FAMILIARIZATION

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

2.2.

GENERAL MACHINE NOMENCLATURE

The nomenclature drawing below points out locations of major components of the hydraulic excavator. Study these areas and locate these components on the machine. Specific information regarding these components are explained on the following pages of this section.

32 30

36

33

34 15 16

17

8 18

35

19

31

12 3

37 13

5

11

4

14

1

29 28 24

27

20

25

7

2 6

26 23 22 10

No.

NAME

No.

NAME

No.

NAME

9

21

No.

NAME

1 Engine

2 Oil filter

3 Radiator

4 Reservoir tank

5 Air cleaner

6 Muffler

7 Fuel tank

8 Hydraulic reservoir

9 Hydraulic pump

10 Slewing motor

11 Swing cylinder

12 Control valve

13 Travel lever

14 Safety lock lever

15 Canopy

16 Operating lever

17 Dozer operating lever

18 Throttle lever

19 Monitor panel (gauge cluster)

20 Battery

21 Swivel joint

22 Travel motor

23 Slewing bearing

24 Idler assy

25 Lower roller

26 Upper roller

27 Rubber track

28 Dozer blade

29 Dozer cylinder

30 Boom

31 Boom cylinder

32 Dipper cylinder

33 Light

34 Arm

35 Link

36 Bucket cylinder

37 Bucket

2-3

2. MACHINE FAMILIARIZATION A. FRONT, REAR, RIGHT AND LEFT DIRECTION In this manual, the front, rear, right and left directions are based on the conditions where the travel motors are positioned at the rear and the operator is facing the direction in which the machine advances (forward).

A

1. TRAVEL MOTOR A. FRONT B. RIGHT

C

C. LEFT

B

1

2.3.

OPERATOR’S CAB NOMENCLATURE

The operator’s cab nomenclature, see Figure below, points out locations of operator controls in the hydraulic excavator operator cab. Study these areas and locate these components on the machine. Specific information regarding these components are explained on the following pages of this section.

2

8

7

5

9

4

6

1 14

3

15 13 12 10 17 18 11 16

No.

NAME

No.

NAME

No.

NAME

1 Right operating lever

2 Left operating lever

3 Safety lock lever

4 Right travel lever

5 Left travel lever

6 Boom swing operating pedal

8 Horn switch

9 Travel speed select switch

10 Monitor panel (gauge cluster)

11 Working light switch

12 Throttle lever

13 Starter switch

14 Deceleration switch

15 Dozer blade operating lever

16 Operator’s seat

17 Wiper switch (cab spec.)

18 Heater switch (option)

7

Option pedal (hydraulic hammer & shears)

2-4

2. MACHINE FAMILIARIZATION A. HOUR METER The hour meter indicates the total time the engine has run. Even if the machine is not moving, the meter continues to count as long as the engine is running, regardless of the engine speed. While the engine is running, the indicator flashes to show that the hour meter is active. Use the hour meter as reference for maintenance.

2-5

2. MACHINE FAMILIARIZATION

2.4.

COMPONENT & CONTROLS NOMENCLATURE

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

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

2.4.1.

MONITOR PANEL (GAUGE CLUSTER)

The monitor consists of the following.

A

B

1

GROUP A METERS

B WARNING LAMPS

C INDICATOR LAMP

2

3

No.

4

5

8

7

C

B

6

NAME

1

COOLANT TEMPERATURE METER

2

FUEL METER

3

ENGINE OIL PRESSURE LAMP (Red)

4

COOLANT TEMPERATURE LAMP (Red)

5

BATTERY CHARGE LAMP (Red)

6

LOW FUEL WARNING LAMP (Red)

7

AIR CLEANER RESTRICTION LAMP (Red)

8

HIGH (2nd.) TRAVEL SPEED LAMP (Yellow)

A. METERS 1. COOLANT TEMPERATURE METER

3

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 indicator enters the red range, let the engine low idle until the water cools down and the indicator moves back into the white range.

1. WHITE 2. RED 3. BLUE

2-6

1

2

2. MACHINE FAMILIARIZATION 2. FUEL METER

2

This indicates the amount of fuel. F : Full tank is about 53L (14 gal) This gauge indicates the residual volume of fuel in the fuel tank. Make sure to refuel when the indicator is approaching the "E" point. Refill the fuel tank with diesel fuel only. Normally the gauge takes time to move up to the appropriate level after turning the key switch to the ON position.

1. WHITE 2. RED

B. WARNING LAMPS

CAUTION When any warning lamp is alight, immediately stop the work. Then investigate the cause for it, and carry out appropriate inspection and maintenance referring to the Section for "INSPECTION AND MAINTENANCE".

3. ENGINE OIL PRESSURE LAMP (Red) This warning lamp will illuminate if the engine oil pressure drops abnormally while the engine is running. Stop the engine and check the quantity of engine oil. (Refer to 3-5.)

CAUTION The engine may suffer severe damage if the machine is operated with the engine oil pressure lamp illuminated.

4. COOLANT TEMPERATURE LAMP (Red) If the coolant temperature rises abnormally a warning lamp lights.

•

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

CAUTION The engine may suffer severe damage if the machine is operated with the coolant temperature lamp illuminated.

1. If the engine is overheating, stop operation immediately and let the engine run at idle speed to lower the engine temperature.

2. Once the coolant has cooled down, stop the engine.

3. Once the engine temperature lowers, inspect the coolant level, fan belt, clogging of radiator core, etc.

Refer to Chapter 4. "MAINTENANCE" for details.

2-7

1

1

2. MACHINE FAMILIARIZATION

WARNING DO NOT PERFORM ANY KIND OF MAINTENANCE ON AN ENGINE THAT HAS JUST STOPPED WORKING. FLUIDS AND SURFACES WILL BE EXTREMELY HOT. ALLOW THE ENGINE TO COOL BEFORE PROCEEDING TO INSPECTION AND/OR MAINTENANCE. 5. BATTERY CHARGE LAMP (Red) This is to warn of an abnormality in the battery charging system during engine running. This indicator with illuminate when the starter switch is turned to the "ON" position, and should go out after the engine is started.

Check the charging system if this indicator does not turn off after the engine is started. See Chapter 4.

"MAINTENANCE" for details.

6. LOW FUEL WARNING LAMP (Red) If the fuel is low, a warning lamp lights up. Stop the engine immediately and add fuel.

7. AIR CLEANER RESTRICTION LAMP (Red) This lamp comes on if the air cleaner filter is clogged. If the lamp comes on, clean or replace the element immediately.

C. INDICATOR LAMP This lamp indicates the working conditions.

8. HIGH (2ND) TRAVEL SPEED LAMP (Yellow) This indicator will be illuminated when the travel speed is switched to high (2nd.) speed. The travel speed selector switch is located on the grip of the right travel lever.

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

2-8

2. MACHINE FAMILIARIZATION 2.4.2.

SWITCHES

3

2 4

9 1

7 6 5 8

1. STARTER SWITCH

2. TRAVEL SPEED SELECT SWITCH

3. HORN SWITCH

4. DECELERATION SELECTOR SWITCH

5. WORKING LIGHT SWITCH

6. HEATER SWITCH (CANOPY'S OPT.)

7. WIPER & WASHER SWITCH (CAB SPEC.)

8. TRAVEL ALARM SELECT SWITCH (OPT.)

9. SOCKET FOR 12V POWER SOURCE 1. STARTER SWITCH This is used to start or stop the engine.

HEAT : When engine start up is difficult due to the cold climate, turn the key to this position to activate the pre-heating.

Hold the key in this position for around 15 seconds and then turn the key to the START position to start the engine. Release key after engine starts.

OFF : In this position, the electrical system is turned off and the engine is stopped.

ON : In this position, the machine's electrical circuit is energized. Maintain the key in this position while the machine is in operation.

START : Turn the key to this position to start the engine and release it after the engine starts, the key will automatically return to the "ON" position.

2-9

2. MACHINE FAMILIARIZATION 2. TRAVEL SPEED SELECT SWITCH Use this switch to select travel speed, HIGH (2nd speed) or LOW (1st speed). When the starter switch is turned to the "OFF" position, the travel speed is automatically set to LOW. Select the desired speed before starting travelling.

WARNING TRAVEL WITH THE MACHINE IN LOW SPEED ON A SLOPE AND WHEN LOADING/UNLOADING THE MACHINE ON TO A TRUCK/TRAILER. SUDDEN CHANGE OF THE MACHINE TRAVEL SPEED MAY CAUSE THE MACHINE TO ROLL OVER.

Select this speed when travelling on rough or soft terrains, slopes, in narrow places, when powerful tractive force is required, or loading or unloading from a truck/ trailer. See 6-4 for speed.

Set to HIGH when travelling on flat, hard ground. See 6-4 for speed.

3. HORN SWITCH Depress this switch provided on top of the left operating lever to sound the horn.

CAUTION Sound the horn before starting engine, travelling, slewing or operating the attachments.

4. DECELERATION SELECTOR SWITCH Press this switch during the engine rotation to shift the engine to the low speed. Press this switch again to release the deceleration function. When you are waiting for the dump truck or the next job, fuel cost and noise generation can be reduced by this release. Turn the starter switch from "ON" to "OFF" to release the deceleration function automatically.

5. WORKING LIGHT SWITCH This is used for the boom and the canopy working light.

OFF - ON

2-10

2. MACHINE FAMILIARIZATION 6. HEATER SWITCH (Option) This is used to warm up the cab interior.

OFF : Stop L : Low speed fan drive H : High speed fan drive NOTE: Engine coolant is utilized for the heater, accordingly the heater generate warm air only when coolant is hot.

7. WIPER & WASHER SWITCH (Cab spec.)

This is used for the wiper and washer fluid.

WASH (Left) : Spraying washer fluid.

OFF : Stop.

ON : Operating wiper.

WASH (Right) : Operating wiper and spraying washer fluid.

NOTE:If washer is used continuously for 20 sec. or more, or if washer is operated without washer fluid, the motor mounted on washer tank may be damaged.

8. TRAVEL ALARM SELECT SWITCH (OPT.) The travel alarm switch is located on the left side panel.

When travel is engaged the alarm sounds automatically.

9. SOCKET FOR 12V POWER SOURCE This socket is provided for use as a power source for any 12V electrical appliance (inspection light, etc).

NOTE: It can not be used for the cigarette lighter.

2.4.3.

LEVERS AND PEDALS

1. SAFETY LOCK LEVERS

2

2. RIGHT/LEFT OPERATING LEVERS

7

3

6

2

3. TRAVEL LEVERS

1

4. THROTTLE LEVERS 5. DOZER OPERATING LEVER

5

6. BOOM SWING OPERATING PEDAL 7. (OPTION PEDAL) HYDRAULIC HAMMER AND SHEARS

4

2-11

2. MACHINE FAMILIARIZATION 1. SAFETY LOCK LEVER The safety lock lever is provided to prevent any unexpected operation due to accidental movement of the operator's control levers.

WARNING ALWAYS PLACE THE SAFETY LOCK LEVER IN THE LOCKED (UP) POSITION BEFORE LEAVING THE OPERATOR SEAT. NEVER LEAVE THE MACHINE UNATTENDED WITH ENGINE RUNNING OR LEVER IN THE DOWN POSITION. NOTE THAT EVEN WHEN THE SAFETY LOCK LEVER IS SET IN THE LOCKED (UP) POSITION, THE FUNCTIONS FOR DOZER AND BOOM SWING ARE STILL ENABLED.

A

LOCKING HYDRAULIC SYSTEM (A) When the safety lock lever is set in "LOCKED (UP) Position" the hydraulic system is shut down, except the boom swing functions NOTE: • When the safety lock lever is set to "LOCKED" (UP) position, each attachment and swing motor is locked simultaneously even though each lever can be moved, because they are part of a hydraulic locking system. However, the travel levers are separately locked with their mechanical locking to prevent the movement of the levers themselves.

•

B

LOCKED (UP) POSITION

The safety lock lever is fitted only on the left side.

A UNLOCKING HYDRAULIC SYSTEM (B) When the safety lock lever is set in "UNLOCKED (DOWN) Position" all hydraulic functions are enabled.

B

UNLOCKED (DOWN) POSITION

2-12

2. MACHINE FAMILIARIZATION 2. OPERATING LEVERS(ISO OPERATING PATTERN)

E

These two levers activate each function as illustrated in the right.

A

G

H

WARNING •

IF LABELS DO NOT MATCH THE OPERATOR'S CONTROL PATTERN, REPLACE THEM IMMEDIATELY TO AVOID ACCIDENTS AND/OR INJURY.

4 1

G

H

B

E

F 2 C

NOTE:The operator's control levers return to the neutral position when released, and the operation of attachment is stopped.

All functions can be activated simultaneously.

D B

F

CONFIRM FOR SAFETY AROUND THE WORKING AREA. ALSO ENSURE THAT EACH LEVER OPERATION IS IN ACCORDANCE WITH THE OPERATING PATTERN INDICATED ON THE LABELS.

•

C

D

A 3

ISO OPERATING PATTERN LH OPERATING LEVER RH OPERATING LEVER 2 4

E DIPPER OUT F DIPPER IN G SLEWING LEFT H SLEWING RIGHT

1 3

A BOOM DOWN B BOOM UP C BUCKET IN D BUCKET OUT

2-13

2. MACHINE FAMILIARIZATION 3. TRAVEL CONTROL LEVERS

A

The travel levers are located in front of operator's seat.

They are used to move the left or right track of the machine either forward or backward. These controls have 2 basic operational functions:

N

A

B B

NOTE: In EU case, the travel lever has the pedal for travel.

WARNING USE CAUTION TO AVOID COMING IN CONTACT WITH OTHER MACHINES WHILE TRAVELLING. BE SURE TO KNOW THE LOCATION OF THE TRAVEL MOTORS BEFORE OPERATING THE TRAVEL FUNCTION.

A

The travel alarm sounds to exclude workers from the machine vicinity, whenever the travel lever is operated.

2

CAUTION

1

If the travel alarm does not sound after the travel lever is operated, stop the engine immediately and contact the nearest approved Dealer for repair.

Operation with a travel alarm failure may cause severe accidents resulting in injury or death.

NOTE:The travel functions described below are with the travel motors located behind the operator's cab.

A: Push both levers forward to travel forward.

B: Pull both levers back to travel in reverse.

C: Neutral (Release levers in the centre position to stop the travel function.)

1. TRAVEL MOTOR 2. DOZER BLADE NOTE: Refer to 3-18 for changing travel direction.

NOTE: Travel alarm function is standard in Oceania and China but an option in EU area.

2-14

B

2. MACHINE FAMILIARIZATION 4. THROTTLE LEVER A

The throttle control lever is located to the right side of the operator’s seat and it is used to control the engine speed.

B

A : LO (Low Idling) Push the lever fully forward to set the engine in low idle.

B : HI (High Idling) Pull the lever fully backward to set the engine in high idle.

5. DOZER OPERATING LEVER This lever is to control the dozer (1) up or down functions.

D

C

WARNING EVEN THOUGH THE SAFETY LOCK LEVER IS SET AT LOCKED POSITION, THIS DOZER LEVER IS NOT LOCKED. C : Dozer up (Pull the lever back)

1

C

D : Dozer down (Push the lever forward)

D

DOZER OPERATION 6. BOOM SWING OPERATING PEDAL This pedal is to operate the swing motion of boom.

B

WARNING LOCK THE OPTIONAL PEDAL WHILE THIS FUNCTION IS NOT BEING USED, FAILURE TO DO SO MAY CAUSE SERIOUS ACCIDENTS. A : Right Swing (Right pushing down) B : Left Swing (Left pushing down) NOTE:The pedal lock becomes available by means of dropping the cover (1) of pedal down toward yourself.

2-15

A

B

A 1

2. MACHINE FAMILIARIZATION 7. OPTION PEDAL (Hydraulic hammer and shears) When an optional attachment other than the standard one is used, this pedal is used for operation.

WARNING LOCK THE PEDAL WHILE OUT OF USE. CARELESS OPERATION OF THE UNLOCKED PEDAL MAY CAUSE SERIOUS ACCIDENTS. Refer to Chapter 7. "OPTIONAL EQUIPMENT" for the operation of hydraulic hammers and shears.

Pedal lock device This is the lock device for the hammer and shear optional operating pedal. The lock is released if the lock pin of the pedal is pushed forward.

1

A

1. PEDAL LOCK PIN A. LOCKED POSITION B. UNLOCKED POSITION (PEDAL IS AVAILABLE)

2.4.4.

B

SEAT BELT

Fastening/Unfastening 1. Check there is no twisting in the seat belt, fully insert the other side into the buckle until engaging is heard (1).

1

2. Adjust the belt length so that there is no slackness (2).

2 3. Push down the red button on the buckle to unfasten the seat belt.

WARNING INSPECT SEAT BELTS DAILY. REPLACE SEAT BELT IF IT SHOWS SIGNS OF DEFORMATION OR DAMAGE. ALWAYS ENSURE THE SEAT BELT SUPPORT CAPSCREWS ARE PROPERLY TIGHTENED.

2-16

2. MACHINE FAMILIARIZATION 2.4.5.

CAB (OPTION)

The following equipment are provided for the cab to ventilate or to facilitate operation.

WARNING WHEN USING THE EQUIPMENT IN THE CAB, SET THE SAFETY LOCK LEVER TO THE LOCKED POSITION TO AVOID UNEXPECTED MACHINE MOVEMENT IF A WORK LEVER IS ACCIDENTALLY ACTUATED WHICH COULD CAUSE PERSONAL INJURY. A. LOCKING CAB DOOR To lock the door in the open position, slide the door fully open until it locks on the catch located on the rear of the cab.

1. CATCH

1

2

2. HANDLE 3. KEY

3

B. UNLOCKING DOOR FROM INSIDE To unlock the door, pull the lever (1) backward.

1

C. HOUSING (UPPER) FRONT WINDSHIELD The upper front windshield is able to slide into the ceiling for storage.

1

CAUTION Be sure to move the machine to level ground when opening/closing the front windshield, and lock it. Especially, unlocking windshield in forward-inclined position of the machine causes the front windshield to fall down.

1. Move the machine to the level ground, set the safety lock lever in lock position, then stop the engine.

2. Push down the lock levers (1) provided on the left/ right sides to unlock the front windshield.

3. Grasp the handle provided on the left/right sides of front windshield, hold it up and slide into the rear ceiling .

2-17

2. MACHINE FAMILIARIZATION 4. Be sure to lock the front windshield housed into ceiling by pushing up the lever (1).

5. Close the upper front windshield by following the above steps [1] through [4] in the reverse order.

CAUTION When closing the upper front windshield, slowly lower it, taking care not to catch fingers, etc.

Machine operation with insufficient locking is quite dangerous. Be sure to lock it.

D. HOUSING (LOWER) FRONT WINDSHIELD After housing the upper front windshield, the lower front windshield may also be removed. House it on the rail (1) in the cab for the safe storage.

1. Hold up the lower front windshield to remove it from the window frame.

2. Insert the lower front windshield into the rail (1) of rear window frame for storage.

E. ROOM LAMP Operate the room lamp switch, when required.

ON : The lamp is turned on.

OFF : The lamp is turned off.

F. OPENING/CLOSING THE WINDOW ON THE RIGHT SIDE 1. Release the lock (1) and move the slide glass.

2. Close the window by returning the slide glass to the normal position and lock it.

1

2-18

2. MACHINE FAMILIARIZATION G. SUPPLY WASHER LIQUID The washer tank is installed on the left rear of cab.

2

1. Check the washer tank (1) for liquid level.

2. When the liquid level is low, remove cap (2) and add automobile washer liquid.

1. WASHER TANK 2. CAP 3. MOTOR

1

3

2.4.6.

GUARD WITH LOCKING DEVICE & COVERS

WARNING BE SURE TO STOP THE ENGINE WHEN THE ENGINE GUARD OR RADIATOR COVER IS OPENED. A locking mechanism is provided for the engine guards.

Use the key to open and close engine guards.

1. KEY CYLINDER 2. SIDE COVER (R/H) 3. HOOD (ENGINE GUARD) 4. SIDE COVER (L/H) A. OPENING 1. Insert the key.

2. After releasing the lock, remove the key and open the cover.

3. Fit the cover in the open position with the rod.

1

2-19

2. MACHINE FAMILIARIZATION B. LOCKING 1. Return the rod to the original position, and fix it into the holder.

2

2. Close the cover.

3. Insert the key, and turn it counterclockwise direction to lock the cover. Then remove the key.

NOTE:Be sure to insert the key completely for proper operation; otherwise damage may occur to the key or locking mechanism.

3

CAUTION Always make sure to use the open door fastening struts to secure the engine covers whenever they are in the open position.

2.4.7.

4

SEAT ADJUSTMENT

1. Pull the seat adjustment lever to right side.

2. Move the seat forward or backward to desired position.

3. Release the lever to lock the seat in position.

2.4.8.

ELECTRICAL EQUIPMENT

A. WORKING LIGHT A working light is provided on the boom and the canopy to light up the visual field for work at night, etc.

2-20

2. MACHINE FAMILIARIZATION B. FUSE BOX (Main)

CAUTION Be sure the starter switch is in the "OFF" position when replacing fuses.

The fuses protect the electrical system from excess current. If operation is not normal, a fuse may be blown.

Replace blown or faulty fuses with the spare fuses as follows.

Replace any fuse generating white powder on it or in case of some looseness existing between the fuse and fuse holder.

NOTE: • When replacing a fuse, replace it with one of the same capacity.

•

The spare fuses are stored in the back side of fuse box cover.

No. AMPS

FUNCTION

1

30A WIPER, HEATER

2

30A RELAY, SOLENOID

3

30A WORKING LIGHT

4

30A HORN, ROOM LIGHT

5

30A ENGINE STOP SOLENOID

6

10A BATTERY RELAY, CLUSTER GAUGE

C. FUSIBLE LINK (For starter) In case power does not come when the starter switch is turned "ON", a disconnection of the fusible link is suspected.

Inspect and replace the fusible link.

1. FUSIBLE LINK (RED) NOTE: The fusible link is of a fuse wiring of big size provided in the electric wiring for large current. It protects the electrical equipment and wiring from abnormal current just like an ordinary fuse.

1

2-21

2. MACHINE FAMILIARIZATION 2.4.9.

STORAGE & OTHERS

A. STORING PLACE FOR MANUAL Store the manual in the storage box provided on the back of seat.

In the case of EU, keep this manual in the storage box located on the roof.

B. TOOLS Use the standard tools supplied with the machine for maintenance work.

Refer to 4-12 for the details of the tools.

2-22

2. MACHINE FAMILIARIZATION C. GREASE GUN Use the grease gun supplied with the machine for lubrication. After use, fold away the grease gun handle, wipe off the grease adhered to the nozzle with cloth and store it in place.

NOTE:Use the grease gun supplied with the machine for lubrication. After use, fold the grease gun handle, wipe off the grease adhering to the nozzle with cloth and store it in place.

•

Always facilitate air bleeding from the grease gun by fully opening the lever and fill grease to the section line portion.

•

Always operate the lever in full open or full close condition, otherwise the grease in the cartridge is not sucked up.

•

2

Some air may enter the cartridge via the fixing thread before the next use of the grease gun, causing difficulty to extrude grease. When this happens, remove the cartridge, bleed the air mixed in, and reset it.

A

1

B

1. NOZZLE 2. LEVER 3. CARTRIDGE A. CARTRIDGE FIXING THREAD B. GREASE

2-23

3

2. MACHINE FAMILIARIZATION

2-24

3. MACHINE OPERATION

3-1

3. MACHINE OPERATION

3-2

3. MACHINE OPERATION

3.1

BASIC MACHINE OPERATION

3.1.1.

PRE-START INSPECTION

A. DAILY INSPECTION Before starting the engine, walk around the machine to check for any loose nuts and capscrews, any oil, fuel or coolant leakage, and the condition of attachment and hydraulic system. Check for any looseness in the electrical wiring and for any accumulated material (leaves, dirt , etc.).

NOTE:The daily inspection must be carried out in accordance with the instructions provided in this OPERATOR’S MANUAL.

5

3

7 2

6

4 1

1. Check the engine for any oil, fuel or coolant leakage. Repair as required.

2. Check the area around the engine and radiator for any accumulated material and remove as required.

3. Check the hydraulic equipment, hydraulic oil tank, hoses, and joints for oil leakage, and repair as required.

4. Check the travel system, such as the tracks, idlers, and sprockets, for any damage or wear, and the capscrews for looseness.

5. Check the attachments, cylinders, linkages and hoses for any cracks, wear or looseness and repair as required.

6. Check the guards, steps and handrails for damage, and the capscrews for looseness.

Repair and tighten capscrews as required.

7. Verify that the gauges and the monitor panel (gauge cluster) function properly.

3-3

3. MACHINE OPERATION 3.1.2.

INSPECTION BEFORE OPERATION

The following items should be inspected before starting machine operation: A. CHECK COOLANT LEVEL

WARNING NEVER REMOVE RADIATOR CAP WHEN ENGINE IS HOT. ALLOW ENGINE TO COOL DOWN BEFORE REMOVING RADIATOR CAP. The radiator reservoir tank is provided on the right side of the engine compartment.

1. Check the coolant level with cold engine.

2. Open engine reservoir tank. The coolant level should be between the lines of FULL and LOW.

2 NOTE:Engine coolant level is higher than normal when the engine is warm. The coolant level will lower with engine temperature.

3

Maintain coolant level at the full mark with engine cold.

Refer to 4-10 for engine coolant specifications.

1

3. Open radiator reservoir tank cap (1) to refill with proper coolant mixture.

4

Check the radiator coolant level when the coolant level in the reservoir tank drops below the LOW level mark.

Make sure to check the engine cooling system for leakages and repair as needed, before resuming operation.

4. See 4-29 for reference. Remove the radiator cap (2), and check for proper coolant level.

5. Refill radiator with proper coolant mixture.

6. Install radiator cap (2) and tighten securely.

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.

B. CHECK COOLANT LEAKAGE If the coolant level in the radiator reservoir tank does not lower, but the coolant inside the radiator does, there is a possibility of air leakage in the cooling system.

Make sure coolant level is to specifications and pressurize system to check for leakages. Consult your Dealer for advise and/or repairs. Be sure to repair leakages before resuming operation.

3-4

3. MACHINE OPERATION C. CHECK ENGINE OIL LEVEL NOTE: • Make sure the machine is on firm level when checking engine oil level.

•

Always be sure to check engine oil level before starting the engine.

•

Keep the engine switched off for at least 30 minutes, when checking engine oil level after working.

2 1. Use the starter switch key to unlock and open engine covers.

2. Pull out engine oil dipstick (1), clean it and insert it fully into its sleeve. Remove dipstick to check oil level. Oil level should be between the marks "H" and "L".

If the oil is heavily contaminated or deteriorated, change it regardless of periodical schedule.

Refer to 4-10 for oil specifications.

1 H

3. If needed, remove the filler cap (2) to refill.

Make sure to check the oil level again after refilling.

L

4. Clean engine oil filler cap (2), before installing.

5. Close the engine cover and secure it with key.

D. CHECK HYDRAULIC OIL LEVEL

WARNING NEVER PERFORM MAINTENANCE OR INSPECTION ON A MACHINE THAT HAS JUST FINISHED WORKING. ALLOW SUFFICIENT TIME FOR THE MACHINE TO COOL OFF. RELEASE HYDRAULIC RESERVOIR PRESSURE BEFORE WORKING WITH ANY HYDRAULIC COMPONENT.

3-5

3. MACHINE OPERATION D.1 CHECK 1. Move the machine to firm level ground and set it in the hydraulic oil level check position, as shown in right figure.

1

2

2. Check the oil level through sight level gauge provided on the side of the hydraulic reservoir. Hydraulic oil level should be between H and L. Oil level varies depending on oil temperature.

Check the oil level referring to the followings.

Before starting: "L" level [oil temp. 10~30 C (50~86 F)] Normal operation: "H" level [oil temp. 50~80 C (122~176 F)] NOTE: Avoid overfilling. It causes damages to hydraulic equipment or oil spouting.

D.2 REFILL WITH OIL WHEN THE LEVEL IS BELOW "L" Refer to 4-10 for the recommended oil to be used.

1. CAPSCREW 2. COVER 3. O-RING 4. LEVEL GAUGE A. PROPER LEVEL 1. Open the side cover (R/H), and support it with the stay.

2. Release the internal pressure in the reservoir according to the procedure description "RELEASING INTERNAL PRESSURE FROM THE HYDRAULIC SYSTEM", 4-17.

3. Ensure that the internal pressure of the hydraulic oil reservoir is completely released, loosen the capscrews (1), remove the cover (2), and replenish with the specified hydraulic oil via the oil supply port till the specified level.

1 2

4. Check the O-ring (3) of the cover, and if wear or damage is found, replace it.

3

5. Install the cover (2) and fasten with the capscrews to the specified torque.

Tightening torque : 23.6±1.9 N•m (17.4±1.4 lbf•ft) 6. Start the engine and perform operation gently five to ten times while moving each cylinder uniformly.

Then return the machine to the position for hydraulic oil level inspection.

H A L

7. Stop the engine and check the oil level. If the amount of oil is insufficient, replenish with oil.

8. Remove the stay and return the cover to the normal position.

3-6

4

3. MACHINE OPERATION E. CHECK FUEL LEVEL

WARNING •

MAKE SURE TO USE DIESEL FUEL ONLY AND STOP ENGINE BEFORE REFILLING.

•

BE CAREFUL FUEL DOES NOT OVERFLOW WHEN REFILLING. CLEAN UP ALL SPILLED FUEL TO PREVENT FIRE.

•

DISPOSE OF HAZARDOUS WASTE ACCORDING TO ENVIRONMENTAL LAWS AND REGULATIONS.

1. STARTER SWITCH 2. FUEL METER 3. FUEL CAP 4. STRAINER

2

5. DRAIN PLUG 6. FUEL TANK

1

1. Turn starter key (1) to "ON" position to illuminate the monitor panel.

2. Check the fuel gauge (2), and remove filler cap (3) to refuel if needed.

3. Refer to 4-10 for fuel specifications.

3

Fuel tank capacity : 25 liter (6.6 gal) 4. Do not remove fuel tank strainer (4) for refilling to avoid contamination.

4

5. After refueling, install fuel cap (3) and tighten securely.

Close the engine cover and use key to lock it properly.

We recommend to refuel at the end of the work shift.

Refueling should be done to full mark to reduce air volume (condensation). Failure to do so could create problems such as rusting and fuel freezing, as well as other associated problems.

5

6

F. CHECK FOR FUEL LEAKAGE Check and repair any fuel leakage. Do not operate a machine leaking fuel. Fuel leakage may be caused by a faulty drain plug, crack on hose in fuel line, loosened hose clip, etc. Be sure to stop the engine immediately if any fuel leakage is found. Repair fuel leakage before resuming operation.

1

2

1. FUEL TANK

3

2. FUEL FILTER 3. WATER SEPARATOR 4. FUEL HOSE

4

3-7

3. MACHINE OPERATION G. INSPECT BELT CONDITION

WARNING ROTATING PARTS CAN CAUSE PERSONAL INJURY. KEEP AWAY FROM FAN AND BELT WHEN ENGINE IS RUNNING. MAKE SURE TO STOP ENGINE BEFORE SERVICING.

Check the fan belt for insufficient tension, wear, and damage. Insufficient belt tension may cause battery charge failure, engine overheating, or abnormal belt wear. Likewise, if too much tension is applied to the belt, the bearings or belt may be damaged prematurely.

Apply a force of 98 N (22 lb) to the centre of belt between pulleys, and measure the belt deflection. The table below shows normal condition.

2

3

1

Belt deflection : 8~10 mm (0.31~0.39 in) See the section "250-HOUR (3–MONTH) INSPECTION AND MAINTENANCE" for details on the inspection and adjustment procedure for the belt.

1. ATTACHING BOLT 2. ADJUSTING BOLT 3. ADJUSTING BOLT

3-8

3. MACHINE OPERATION 3.1.3.

CHECK BEFORE STARTING MACHINE ENGINE

A. CHECK WARNING LAMPS

WARNING

2

1

CARELESS MOVEMENT OF ANY OPERATING LEVERS MAY CAUSE SUDDEN MOVEMENT OF THE MACHINE. BE SURE TO SET THE SAFETY LOCK LEVER TO THE "LOCKED" (UP) POSITION BEFORE LEAVING THE CAB. REMEMBER THAT THE FUNCTIONS FOR DOZER AND BOOM SWING ARE STILL ACTIVE, EVEN WITH THE SAFETY LOCK LEVER IN THE "LOCKED" (UP) POSITION.

4

3

5 Before starting up the engine, check the warning lamps and indicator lamps, using the following procedures.

6

RED: Warning Lamp

1. Make sure the safety lock lever is in the "LOCKED" (up) position.

YELLOW: Indication Lamp Key Operation Lamp

2. Make sure all control levers are in the "NEUTRAL" position.

1

3. Use the starter switch key and the table below (as reference ) to check all warning lamps and indicators for proper functioning.

2

4. Do not operate the machine under faulty conditions. Consult your Dealer if necessary.

Refer to 2-7 and make sure all warning lights and indicators function properly. Repair any malfunctioning before resuming operation.

3

NOTE: Make sure all warning lamps and indicators function properly before operating the machine.

6

4 5

B. CHECK FOR WORKING LIGHT With the key position in the starter switch in "ON" position, turn on the working light switch to check the working light functions correctly.

If it does not presumably the light bulb is burned out or electrical wire is broken. Repair it referring to 4-30.

3-9

Engine Oil Pressure Lamp Battery Charge Lamp Engine Coolant Temp. Lamp Low Fuel Warning Lamp 2nd Speed Travel Lamp Air Cleaner Cloggiong Lamp

OFF->HEAT Pre-Heating.

OFF->ON Before Start

START->ON Just After Start

Light OFF

Light ON

Light OFF

Light OFF

Light ON

Light OFF

Light OFF

Light OFF

Light OFF

Light OFF

Light OFF

Light OFF

Light OFF

Light OFF

Light OFF

Light OFF

Light OFF

Light OFF

3. MACHINE OPERATION 3.1.4.

STARTING AND STOPPING MACHINE ENGINE

A. START-UP UNDER NORMAL CONDITIONS 1. Make sure that safety lock lever (1) is set to the "LOCKED" (up) position(A).

A

B

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

2

3. Slightly move the throttle control lever (2) from the low idling position.

3

4. Turn the starter switch key (2) to the START position to start the engine and release after starting the engine.

Release the key immediately after the engine starts.

The key will return to the "ON" position by itself.

WARNING MAKE CERTAIN THE SWING AREA OF MACHINE IS CLEAR OF PEOPLE AND OBSTACLES BEFORE OPERATING. KNOW THE POSITION OF THE TRAVEL MOTORS BEFORE STARTING TRAVELLING AND BE SURE TO SOUND HORN BEFORE STARTING THE ENGINE.

NOTE: • Do not increase the engine speed (high idling) with cold engine.

•

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

3-10

3. MACHINE OPERATION B. START-UP UNDER COLD CONDITIONS In cold weather, due to the increase in oil viscosity and decrease in battery performance, starting the engine may be difficult. Use the pre-heater to start the engine easily under these conditions.

1. Perform steps 1~3 mentioned in START-UP UNDER NORMAL CONDITIONS shown on the previous page.

2. Turn the key (3) to the HEAT position and hold in this position or 15 seconds to preheat before starting.

3. Turn key to the START position to start the engine.

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

4. Release the key immediately after starting the engine. The key will return to the ON position by itself.

3-11

3. MACHINE OPERATION C. START-UP WITH BOOSTER CABLES Observe the following precautions when using booster cables to jump-start the battery.

WARNING •

FLAMMABLE GAS (HYDROGEN GAS) IS GENERATED IN THE BATTERY. DO NOT ALLOW SPARKS OR FLAMES TO COME IN CONTACT WITH BATTERIES TO AVOID TRIGGERING AN EXPLOSION.

•

DO NOT ALLOW THE VEHICLE OR MACHINE USED FOR BOOSTING TO TOUCH METAL TO METAL WITH THE DISABLED MACHINE.

•

WEAR A HARD HAT, APPROVED SAFETY GLASSES OR FACE PROTECTION, GLOVES AND OTHER SAFETY EQUIPMENT WHEN WORKING WITH BATTERIES.

•

NEVER ALLOW THE BOOSTER CABLE CLIPS TO COME IN CONTACT WITH EACH OTHER ONCE CONNECTED TO A BATTERY.

•

THE NEGATIVE CABLE, WHEN CONNECTED TO THE UPPER FRAME OF DISABLED MACHINE, MAY ARC, CAUSING SPARKS. MAKE SURE TO CONNECT THE BOOSTER CABLE TO A GROUND SURFACE IN THE ENGINE COMPARTMENT AS FAR AS POSSIBLE FROM THE BATTERY.

•

WHEN THE BATTERY FLUID IS FROZEN, DO NOT START UP THE ENGINE WITH ANOTHER POWER SOURCE.

•

FOLLOW THE ORDER INDICATED IN THE NEXT PAGE FOR CONNECTING OR DISCONNECTING THE BOOSTER CABLES. 1. BATTERY

2

2. BOLT NOTE: Select suitable sizes for the booster cables and clips according to battery size.

Use the booster cables and clips without any signs of damage or corrosion.

3-12

1

3. MACHINE OPERATION D. CONNECTING/DISCONNECTING BOOSTER CABLES Make sure the starter switch key is in the OFF position before connecting the booster cables. Proceed as follows to connect and disconnect the boosting cables.

1. BATTERY COVER 2. BATTERY

WARNING •

•

1

ERRONEOUS CONNECTION OF BOOSTER CABLES MAY CAUSE EXPLOSION OF THE BATTERIES. PAY SPECIAL ATTENTION TO CONNECTING AND DISCONNECTING THE BOOSTER CABLES.

2

THE ELECTRICAL SYSTEM OF THIS MACHINE WORKS WITH 12V DC.

1. Set the starter switch key to "OFF" for both normal vehicle and troubled machine.

2. Refer to 2-19 and remove the left side cover. Then open the cover under the operator’s seat.

1

3. Remove the cover (1) from the battery terminals.

4. Connect the booster cable (red) clip to the positive (+) terminal on the battery of the disabled machine.

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

6. Connect the booster cable (black) clip to the negative (–) terminal on the battery of the normal vehicle.

C A

7. Finally, connect the clip from the other end of the negative (–) booster cable (black) to the upper frame of the disabled machine, away from the battery.

B

8. Start the engine of the normal vehicle, and operate it for around 10 minutes at high idling.

D

9. Start the engine of the disabled machine.

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

11. Make sure to check and repair the cause of the problem of the charging system on the disabled machine.

E

(A) Normal Battery (B) Discharged Battery (C) Red Cable (D) Black Cable (E) To the upper frame of the troubled machine Cable connecting order: 1>2>3>4 Cable disconnecting order: 4>3>2>1

3-13

3. MACHINE OPERATION 3.1.5.

STOPPING MACHINE ENGINE

Make sure to idle the engine for at least 5 minutes before machine shut down.

CAUTION

1

When the machine is suddenly stopped during high speed operation of the engine, temperature of the engine is rapidly increased causing deterioration of engine oil and seizure of seals.

1. Normally, place the attachment on the ground before stopping the engine (except for special situations).

2. Be sure to place the safety lock lever in the "LOCKED" (up) position before leaving the cab.

LOW IDLING POSITION

3. Push the throttle lever (1) all the way forward to low idle position for about 5 minutes.

Operate the engine at idling for a while to lower the coolant temperature.

4. Turn the starter switch key (2) to OFF to stop the engine.

5. Remove the starter switch key (2).

3.1.6.

INSPECTION AFTER STARTING MACHINE ENGINE

Check and make sure of the following items after starting the engine.

WARNING •

CARELESS CONTACT WITH ANY OPERATING LEVER WILL CAUSE UNEXPECTED SUDDEN MACHINE MOVEMENT. STAND OR SHIFT BODY POSITION ONLY AFTER SECURELY SETTING THE SAFETY LOCK LEVER AT "LOCKED" (UP) POSITION.

•

MAKE CERTAIN THE SWING AREA OF MACHINE IS CLEAR OF PEOPLE AND OBSTACLES BEFORE OPERATING. KNOW THE POSITION OF THE TRAVEL MOTORS BEFORE STARTING TRAVELLING AND BE SURE TO SOUND HORN BEFORE STARTING OPERATION.

3-14

3. MACHINE OPERATION A. EXHAUST GAS COLOUR, ABNORMAL SOUND & SMELL While operating the engine, check the following items.

1. Check for abnormal exhaust colour during the engine operation.

Avoid continuous operation if the engine exhaust is black. Black exhaust is an indication of an excessively rich fuel/air mixture. Check and service the engine accordingly if this condition is present.

1

2. Stop operation immediately when any abnormal sound is heard during the machine operation.

Check the cause of the abnormal sound, and repair as needed.

2

3. Avoid operation at the speed range with resonance.

There may be a certain rotating speed range at which the vibration suddenly becomes large due to resonance. Avoid the operation at such speed range because some parts may be damaged due to vibration.

4

4. If burning smell or smoke is generated, immediately stop the engine. Check for any abnormalities and repair as needed before resuming operation.

NOTE: When ever necessary, consult your Dealer for appropriate repairs.

NOTE: •

Do not apply any heavy load to the new engine for the first 50 hours operation.

•

Confirm the LIGHT-OFF for each warning lamp.

•

Carefully listen to any abnormal sound.

•

Check for leakages for oil and water around the engine.

•

At the first engine start-up of the day, operate the engine for around 5 minutes with no load to warm up the engine and for oil to reach to every part of the engine.

B. CHECK EACH SWITCH & LEVER After warming up the engine, check for the following items.

NOTE: Appropriate operation temperature range for hydraulic oil is 50 to 80 C (122 to 176 F). Avoid machine operation when the hydraulic oil temperature is below 20 C (68 F). Failure to do so will reduce the life of the hydraulic components.

3-15

3. MACHINE OPERATION B.1 SAFETY LOCK LEVER 1. With the engine running, set the safety control lever to the "LOCKED" (up) position.

2. Move all control levers, except the dozer and boom swing control lever.

3. Make sure that all functions, except the dozer/width and boom swing functions, are not active when the safety control lever is in the "LOCKED" (up) position.

4. Ensure that the travel levers are mechanically locked and do not move at all.

NOTE: When any abnormalities are found, immediately stop the engine, proceed with the appropriate repairs, and request assistance from your Dealer if necessary.

C. CHECK MONITOR PANEL (GAUGE CLUSTER) Check all gauges and indicators on the gauge cluster, after starting the engine. Red indicator (1) will light up with no battery charge. Check electrical system. Red indicator (2) will light up when engine oil pressure is low. Check that engine temperature gauge (3) and fuel level gauge (4) work properly.

3

4

3-16

2

1

3. MACHINE OPERATION 3.1.7.

MACHINE WARM-UP

A. WARMING UP

WARNING •

AVOID RAPID SPEED INCREASE OF ENGINE SPEED WITH A COLD ENGINE.

•

DO NOT IDLE THE ENGINE FOR MORE THAN 20 MINUTES. EXTENDED PERIODS OF IDLING REDUCE THE LIFE OF THE ENGINE.

Set the throttle lever in the middle position, between low idling and high idling, and operate the engine for around 5 minutes with no load.

B. WARMING UP HYDRAULIC OIL Appropriate operation temperature range for hydraulic oil is 50 to 80 C (122 to 176 F). Avoid machine operation when the hydraulic oil temperature is below 20 C (68 F). Failure to do so will reduce the life of the hydraulic components.

1

1. Set the throttle lever (1) in the "MIDDLE SPEED" position.

2. Set the safety lock lever (3) in the "UNLOCKED" (down) position.

3. Operate the boom control lever (2) to raise it all the way up.

MIDDLE SPEED POSITION 4. Operate the bucket control lever to retract it or extend it completely against relief. Hold in this position for one minute, then release lever (2) and wait for another minute before repeating process. Repeat this procedure at least 10 times or until the temperature of the pilot hydraulic oil is safe for smooth attachment operation.

5. After warming up hydraulic oil, slowly extend and retract each cylinder several times, and actuate traveling and slewing motors to complete the warmup operation.

WARNING IN EXTREMELY COLD CLIMATES IT MAY BE NECESSARY TO INCREASE THE WARM-UP TIME TO ENSURE PROPER AND SAFE OPERATION. WHEN OPERATING THE MACHINE WITH COLD HYDRAULIC OIL, THE OPERATOR MAY EXPERIENCE SLOW OR UNEXPECTED MOVEMENT OF FUNCTIONS. LIKEWISE, COLD HYDRAULIC OIL WILL NOT PROVIDE ADEQUATE LUBRICATION TO HYDRAULIC COMPONENTS; THUS, REDUCING THE LIFE EXPECTANCY OF THE MACHINE.

3-17

3

2

3. MACHINE OPERATION 3.1.8.

MACHINE OPERATION

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

A. MACHINE TRAVEL

WARNING MAKE CERTAIN THE SWING AREA OF MACHINE IS CLEAR OF PEOPLE AND OBSTACLES BEFORE OPERATING. KNOW THE POSITION OF THE TRAVEL MOTORS BEFORE STARTING THE TRAVEL FUNCTION AND BE SURE TO SOUND HORN BEFORE STARTING THE ENGINE. IF ANY ABNORMALITY IS FOUND DURING THE MACHINE OPERATION, IMMEDIATELY STOP WORKING. MAKE SURE TO REPAIR ANY FAULTY CONDITIONS BEFORE RESUMING OPERATION. 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. A.1 FORWARD/REVERSE TRAVEL 1. Make sure the safety lock lever is in the "UNLOCKED" (down) position. Operate the boom, dipper, and bucket control levers to raise the attachments from the ground.

2. Pull the dozer operating lever to raise the dozer.

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

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

A

A.2 PIVOT TURN •

Push the left travel lever toward front of machine to turn machine RIGHT.

•

Push the right travel lever toward front of machine to turn machine LEFT.

•

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

•

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

3-18

3. MACHINE OPERATION A.3 COUNTER ROTATING MACHINE (SPIN TURN) To counter rotate machine to the left, pull left travel lever back and push right travel lever forward.

To counter rotate machine to the right, pull right travel lever back and push left travel lever forward.

A.4 TRAVEL SPEED SHIFTING (1ST/2ND) 1. For HIGH travel speed, depress and release the travel speed selector switch once before operating the travel controls. The hare marked lamp indicator (1) will illuminate in the gauge cluster.

2. Start the machine travel by operating the travel levers.

1

3. To return to SLOW travel speed, stop travel and depress and release the travel speed selector switch once.

NOTE: The travel speed is always reset to SLOW speed every time the starter switch key is turned to the OFF position.

B. STOP TRAVELING

CAUTION When the operation for the attachment or slewing is inevitable during travel, pay attention not to operate it rapidly.

Put the travel levers, left and right, in neutral position to stop the machine travel. Avoid stopping the machine travel suddenly. Stop the machine travel as slowly as possible.

STOP TRAVELING

3-19

3. MACHINE OPERATION C. TRAVEL PRECAUTIONS

WARNING •

•

USE A FLAGMAN WHEN TRAVELLING ON THE SHOULDER OF A ROAD OR IN CONFINED AREAS.

2

NEVER ALLOW PERSONS TO RIDE ON THE MACHINE.

1

1. TRAVEL MOTOR A. TRAVEL DIRECTION B. LOW IDLING POSITION CONDITION WHERE THE TRAVEL DIRECTION IS REVERSED

C. LOW (1st) 1. Make certain the travel motor (1) location is known before performing any travel operation. Travel with travel motors at the back of the machine for long distance travel.

2. Travel on flat and firm ground and in straight lines (or large angles) as much as possible. When turning the machine, move forward and backward alternately as much as possible instead of making one sharp (pivot) turn.

3. Check the strength of bridges and road shoulders, and reinforce them if necessary.

4. Be careful not to come into contact with bridges or electrical power lines.

5. When travelling on rough ground, use low (1st) (C) speed to reduce the shock to the machine.

6. Do not allow large or heavy objects to strike travel motors (1). Likewise, do not travel over large objects such as boulders, rocks, etc.

B

7. On a snowy or icy road, travel with slower speed avoiding any sudden start, sudden stop and sudden slewing.

8. For loading/unloading during transport, remove any mud clogged in the crawler shoes to prevent the machine from side skidding on the ramps. Refer to 5-3 for the use of ramps, etc.

3-20

C

3. MACHINE OPERATION D. CARE ON UP/DOWN SLOPE

WARNING •

WHEN TRAVELLING NEVER CHANGE DIRECTION ON A SLOPE OR CROS A SLOPE. FIRST GET DOWN TO A FLAT GROUND AND MAKE A DETOUR, KEEPING IN MIND SAFETY DURING TRAVEL.

•

RAISE THE BUCKET 30 TO 40 cm (12~16 in) ABOVE GROUND LEVEL, WHILE TRAVELLING. AND DO NOT GO DOWN THE SLOPE IN REVERSE.

•

WHEN THE MACHINE SKIDS, IMMEDIATELY LOWER THE BUCKET AND BRAKE.

•

SLEWING ON A SLOPE MAY CAUSE THE MACHINE TO TURN OVER. IT IS QUITE DANGEROUS TO SLEW TO DOWN SIDE OF THE SLOPE WITH A FULL BUCKET LOAD. WHEN SUCH WORK IS UNAVOIDABLE, MAKE THE GROUND LEVEL ON THE SLOPE TO SECURE A FLAT WORKING AREA.

•

NEVER TRAVEL ON A SLOPE OF MORE THAN 30 GRADIENT.

•

WHEN PARKING ON THE SLOPE IS UNAVOIDABLE, MAKE SURE TO APPLY SKIDS TO THE TRACKS AND LOWER THE BUCKET TO THE GROUND.

1. The Max gradeability of the machine is 58% (30 ).

2. While going down a slope, slowly operate the travel levers.

3. Travel down the slope in low speed (1st speed).

4. While travelling on a slope, keep the bucket at 30~40 cm (12~16 in) of height above the ground level, and travel in low speed.

ON UP/DOWN SLOPE

3-21

3. MACHINE OPERATION 5. When the engine is stalls on a slope, place the attachment on the ground, and make sure each operating lever is in the neutral position. Then start the engine again.

2

6. If it is difficult to climb a slope with the travel motor due to skidding tracks, etc., the power of the dipper can be utilized to pull up the machine with the bucket engaged on the ground.

3 1

7. When parking the machine on a slope, even if it is for a short time, place all attachments on the ground, place each operating lever in the neutral position, set the safety lock lever to the "LOCKED" (up) position and block the tracks.

1. BLOCK 2. BUCKET 3. DOZER BLADE NOTE: When the hydraulic oil is not warmed up sufficiently, the machine may not be able to display its full performance. Make sure the machine is sufficiently warmed up before climbing a slope.

E. MACHINE OPERATION IN WATER/ON SOFT GROUND NOTE: Pay attention not to immerse the slewing bearing, slewing pinion and swivel joint into the water or mud.

If the machine is operated in water or mud, the slewing bearing and others may be worn abnormally. Immediate replacement of grease or overhaul of the slewing bearing, etc. is required.

1. UPPER ROLLER 2. SWING BEARING 3. WATER SURFACE 4. BOTTOM OF A RIVER 3

1. Where the river bottom is flat and water flow is slow, the machine may be operated in water up to depth (A), the upper roller.

2

4

(A)

2. Operate the machine in the water with care checking bottom conditions with bucket, etc. And never enter into the water of the depth beyond (A) in the right figure.

1

3. On soft ground, the machine body sinks little by little in some cases. Therefore, pay full attention to the machine at all times during operation.

3-22

3. MACHINE OPERATION 4. After travelling in seawater, thoroughly wash the machine to remove salt.

1

5. Make sure to lubricate bucket pins and bushing every 4 hours if working with materials in wet conditions, supply grease with a grease gun until grease oozes out.

2

3

GREASING POINT F. GETTING OUT OF SOFT GROUND If possible, avoid travelling on soft ground. Avoid getting caught in the mud. In the event that the machine gets caught in the mud, get out of it as follows.

F.1 ONE CRAWLER SHOE GETS CAUGHT IN MUD When both crawlers gets caught in mud, lay logs or boards on the mud to form a base. Operate the boom and dipper to form an angle between boom and dipper of about 90~110 and push on the ground with the bottom of the bucket to lift the machine body up to climb on the logs or boards.

F.2 BOTH CRAWLERS GET CAUGHT IN MUD When both crawlers get caught in mud and the machine does not move due to skidding, provide logs and boards, as described in the above section. And firmly catch the hard ground on which the machine should get out of mud with the bucket, and pull up the machine toward the hard ground with the same operation of digging.

In case the machine is not able to travel because a track is stuck in mud, sand or gravel on soft ground, raise each track off the ground by pushing the boom and dipper against the ground, scrape off mud, sand and gravel and then get the machine out of the trouble.

Gravel and mud may be cleared if you rotate the raised track back and forth.

CAUTION Operate the machine at the operator's seat. Do not allow any person to come near the machine.

3-23

3. MACHINE OPERATION G. SLEWING OPERATION

WARNING •

OPERATION OF THIS MACHINE ON AN INCLINE OR SLOPE MAY CAUSE THE MACHINE TO BECOME UNSTABLE OR UNBALANCED.

•

MAKE CERTAIN THE SLEWING AREA OF THE MACHINE IS CLEAR OF PEOPLE AND OBSTACLES BEFORE SLEWING.

•

WORK UP AND DOWN INCLINES OR SLOPES, NEVER ACROSS.

•

NEVER SLEWING OR TURN MACHINE AROUND ON SLOPES.

•

OPERATE CONTROL LEVERS CAREFULLY TO PREVENT SUDDEN MOVEMENTS WHICH MAY CAUSE THE MACHINE TO SLIDE OR TIP OVER.

•

PREPARE A LEVEL AREA FOR THE MACHINE TO OPERATE.

•

USE A FLAGMAN TO GUIDE THE OPERATOR. 1. LEFT OPERATING LEVER A. SLEWING RIGHT B. SLEWING LEFT

3-24

1 B

A

3. MACHINE OPERATION 3.1.9.

PRACTICES TO IMPROVE EFFICIENCY

WARNING •

SLEWING ON A SLOPE MAY CAUSE THE MACHINE TO BECOME UNSTABLE OR UNBALANCED. DO NOT SLEW TOWARDS THE DOWN SIDE OF THE SLOPE WITH A FULL BUCKET. WHEN WORKING ON SLOPES, PREPARE A LEVEL AREA FOR THE MACHINE TO OPERATE SAFELY.

•

MAKE CERTAIN THE SLEWING AREA OF THE MACHINE IS CLEAR OF PEOPLE AND OBSTACLES BEFORE SLEWING.

NOTE: Other than showing in the lower sketches, a wider range of machine applications is obtainable by means of utilizing the optional attachments.

Refer to 4-32 for changing the bucket.

A. DIGGING 1. Use Dipper In Action Operate the bucket at shallow depths, use the dipper mainly, and use the bucket as required, in action, to fill the bucket. Setting the bucket too deep will decrease the machine’s efficiency.

2. Maximum Digging Force Position The attachment will provide maximum digging force when the dipper and boom are at 90~110 of each other. Operate slowly to get maximum digging force.

3. Bucket Teeth Direction Always point bucket teeth in the direction in which the machine will be digging, and operate the bucket at shallow depths, to reduce digging resistance and the possibility of bucket teeth damage.

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

3-25

3. MACHINE OPERATION 5. Cleaning Sand & Soil from Bucket Operate dipper 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.

A.1 DITCH DIGGING The working efficiency is much improved by means of setting the bucket in a position suitable for ditch digging and setting the machine in parallel with the ditch to be dug.

For wide ditch digging, dig the two sides first, then dig the centre portion.

A.2 USING THE DOZER 1. The dozer is used to push the soil back into an excavated ditch, or for ground levelling.

2. Scrape the soil laid on the ground at its upper or side face with the dozer. Adjust the height of dozer with the dozer control lever to avoid overloading the engine.

3-26

3. MACHINE OPERATION A.3 OFFSET DIGGING

WARNING

B

AS THE BOOM SWING OPERATING RANGE IS WIDER, OPERATE THE ATTACHMENT PAYING ATTENTION TO THE SURROUNDING CONDITIONS. By depressing the left and right sides of the swing pedal alternatively, the boom swings in left and right directions enabling offset digging in narrow spaces.

By depressing the left side of swing pedal, the boom swings leftward, and by pressing the right side the boom swings to the right.

The advantage of this function is that it enables offset digging work as shown in the figure.

A. SLEWING RIGHT B. SLEWING LEFT

B. LOADING 1. The working efficiency is improved, if the dump truck is set at the position so that the slewing angle becomes minimum, assuring the operator of a good visual field.

2. It is recommended that loading be started from the front side of the dump truck body. This will make loading easier and more soil can be loaded than by loading from the side.

3-27

A

B

A

3. MACHINE OPERATION C. WORKING IN NARROW SPACES The position shown in the figure is available for slewing in narrow spaces.

C.1 MINIMUM SLEWING POSITION 1. Extend dipper cylinder and bucket cylinder to maximum length, and fold bucket.

2. Extend boom cylinder to maximum length.

3. Depress the left side of swing pedal, and then swing boom to the left end of swing.

4. Handle operating lever to slew upper frame.

NOTE: Use care to protect attachment from interference.

MINIMUM SLEWING RADIUS unit : mm (ft-in) BOOM

E40.2SR Canopy

Cab

At swing

1,740 {5' 8.5"} (Left 70 )

2,000 {6' 7.1"} (Left 70 )

No swing

2,100 {6' 10.7"}

2,410 {7' 10.9"} unit : mm (ft-in)

BOOM

E50.2SR Canopy

Cab

At swing

1,770 (5' 9.7") (Left 70°)

2,130 (6' 11.9") (Left 70°)

No swing

2,150 (7' 0.6")

2,560 (8' 4.8")

3-28

3. MACHINE OPERATION 3.1.10.

MACHINE PARKING

WARNING •

ALWAYS PARK THE MACHINE ON A FIRM, LEVEL SURFACE.

•

AVOID PARKING ON A SLOPE. WHEN PARKING ON A SLOPE IS UNAVOIDABLE, MAKE SURE BUCKET TEETH ARE DUG IN THE GROUND, REST THE DOZER BLADE ON THE GROUND, AND BLOCK THE TRACKS.

•

2 3 1

BE SURE TO SET THE SAFETY LOCK LEVER TO THE "LOCKED" (UP) POSITION TO AVOID ANY UNEXPECTED MACHINE MOVEMENT AND STOP THE ENGINE BEFORE LEAVING THE CAB.

1. Place both travel levers (4) into the "NEUTRAL" position.

6

4

2. Set the throttle lever (5) to "LOW IDLING" position.

3. Place the bucket (2) on the ground.

5

4. Place the dozer blade (3) on the ground.

5. Block the tracks.

6. Set the safety lock lever (6) to the "LOCKED" (A) position.

A

B

3-29

3. MACHINE OPERATION 3.1.11.

CHECKING & VERIFICATION AFTER WORK

Regularly check the monitor panel (gauge cluster) for warning lamps and indicators.

1. If the fuel is insufficient, fully refill the tank with fuel, after stopping the engine.

2. If any troubles are indicated with the warning lamps for the coolant temperature and/or engine oil, move the machine to a safe place, immediately stop the engine, and repair as necessary before resuming operation. Refer to "INSPECTION & MAINTENANCE CHART ", 4-26 for details on preventive maintenance.

3.1.12.

PRECAUTIONS AFTER OPERATION

1. Check for any oil or coolant leakage. Check the attachment, exterior, and travel system components.

Repair as needed before resuming operation.

2. Fully refill with fuel. However, do not overfill (to the top of the tank) to avoid overflowing due to fluid expansion under normal temperature.

3. Remove mud, etc., sticking to the travel components.

3.1.13.

MEASURES AFTER EMERGENCY STOP

•

Avoid the emergency stop of the engine as much as possible.

It should be kept in mind that the engine is to be operated for around 5 minutes with no load, before stopping the engine.

The most important matter is always to pay attention to safety so that the emergency stop of the engine will not be required.

•

When the emergency stop of the engine is unavoidable due to dangerous conditions or trouble on the machine, take the following preventive measures to avoid any injury or damages to the machine.

•

Do not restart the engine until its temperature is completely lowered.

CAUTION Sudden stop of the engine just after the operation at high speed causes a sudden rise of engine temperature resulting in deterioration of oil, seizure of sealing components, etc.

3-30

3. MACHINE OPERATION

1. Even if the engine ceases its operation, keep the safety lock lever in the "LOCKED" position.

2. When the emergency stop is made without placing the bucket (2) on the ground, support it with safety blocks (1) under the attachment or the bucket (2), and block the tracks.

2 3

3. When the emergency stop is activated on a slope, block both tracks at their lower sides.

1

4. Make sure to set limits around the machine while it is down for repairs and tag it properly.

5. Consult your Dealer for repairs if needed.

6. After an emergency stop, do not restart the engine until the temperature of the engine is completely lowered.

1

3-31

1

3. MACHINE OPERATION 3.1.14.

LOCKING UP WITH KEY

Be sure to use the starter switch key to lock the following items : •

Hood (Engine guard)

•

Cab door (If equipped)

•

Side cover (R/H)

•

Fuel filler cap 1. KEY BARREL

1

3.1.15.

EMERGENCY MEASURES AGAINST SUDDEN FAILURE OF MACHINE

A. RELEASING LOCK ON TRAVEL MOTOR While travel motors are at a standstill, they are hydraulically locked by the counter balance valve, and also mechanically locked by the brake system. When the machine becomes unable to travel due to failure of the travel motors, etc., it is possible to temporarily move the machine by means of releasing the lock for the travel motor with either of the following methods:

CAUTION

1

2

(1) Support

Avoid contamination of reduction units while their covers are removed.

(2) Block

A.1 REMOVING GEARS FROM TRAVEL REDUCTION UNIT

1

12 9 10

This is the preferred method.

WARNING MAKE CERTAIN CHOCK BLOCKS ARE SECURE AT FRONT AND REAR OF EACH TRACK BEFORE ATTEMPTING TO RELEASE BRAKES. NEVER STAND IN THE PATH OF THE TRACKS WHEN RELEASING BRAKES. AND PROVIDE A SUPPORT FOR THE ATTACHMENT IF NECESSARY.

8 11 7 13 5 6 2 4 14 3

1. Place chock blocks at front and rear of each track to prevent machine from moving when brakes are released.

2. Lower attachment to ground.

3-32

3. MACHINE OPERATION 3. Provide an empty container under the travel motor to collect drained oil, see figure right.

Slowly remove upper plug, then remove drain plug (4) to drain reduction unit oil.

4

Plug (4): Opposing flat 6mm

CAUTION Avoid oil spills, use containers, rags, and/or paper towels to contain any oil leakage.

Dispose all waste oils, fluids, lubricants and other hazardous waste properly, according to government regulations.

4. Insert a flat screwdriver into gap between the body (1) and snap ring (3), and remove the snap ring.

3

5. Remove the cover (2). See right figure.

CAUTION

2

Use caution when removing cover (2) because the ball (5) falls. If the ball (5) was contaminated, clean the ball (5).

6. Remove sun gear (6), then remove carrier assy (7).

Then loosen capscrews (8) from carrier assy (7), and remove thrust washer (9).

6 5

7. Remove planetary gear (12), needle bearing (11) and inner ring (10).

Fix thrust washers (9) with capscrews (8).

8. Remove all planetary gears (12) in a similar way.

9. Install the carrier assy. (7) and thrust washer (13) without planetary gears (12) to body (1).

Then install sun gear (6) and ball (5).

8 9

CAUTION To prevent the falling of ball (5) from sun gear (6), coat ball (5) with grease.

3-33

12

3. MACHINE OPERATION 10. Install cover (2) with snap ring (3).

NOTE: The sprocket for this crawler becomes free rotation from the travel motor.

11. Install drain plug (4) and refill unit with drained oil that stored in the container before.

12. Remove the planetary gear (12) of the opposite side travel motor in a similar procedure 3 to 11.

CAUTION Avoid oil spills, use containers, rags, and/or paper towels to contain any oil leakage.

Dispose all waste oils, fluids, lubricants and other hazardous waste properly, according to government regulations.

Tow the machine to a safe place to proceed with the appropriate repairs.

3

13. After all repairs are completed, assemble the travel motor units.

2

14. Remove cover (2). See right figure.

CAUTION Use caution when removing cover (2) because the ball (5) falls. If the ball (5) was contaminated, clean the ball (5).

15. Remove sun gear (6), then remove carrier assy (7) and thrust washer (13).

16. Then loosen capscrews (8) from carrier assy (7), and remove thrust washer (9).

8 9

17. Fit thrust washer (13) to carrier assy (7), then install inner ring (10), needle bearing (11) and planetary gear (12) to the shaft of carrier (7) in this order. And install thrust washer (9) with capscrews (8). Install all planetary gears (12) in the same way. Tightening torque : 33.3±4.9 N•m {3.4±0.5 kgf•m}

12

7

CAUTION Remove completely the adhesive, which was left in the thread hole of shaft.

The residual adhesive causes loosening of capscrews.

18. Install carrier assy (7) to body (1).

3-34

3. MACHINE OPERATION 19. Install sun gear (6) and ball (5).

6 5

CAUTION To prevent the falling of ball (5) from sun gear (6), coat ball (5) with grease.

20. 1.Replace O-ring (14) with new one. Lubricate the O-ring (14) with grease and fit this in groove of cover (2).

Install cover (2) with snap ring (3).

CAUTION Be very careful when installing the cover. Do not damage the O-ring.

21. Replace the O-ring with new parts, and install the drain plug (4).

Tightening torque : 58.8±9.8 N•m {6.0±1 kgf•m}

CAUTION Be careful not to damage the O-ring in this case..

22. Add the specified gear oil through the OIL FILL plug until oil starts flowing out of the OIL LEVEL plug.

CAUTION Refer to "MAINTENANCE", 4-1 for proper oil and capacities.

Clean up all spilled oil.

3-35

8 9

12

3. MACHINE OPERATION B. LOWERING BUCKET

WARNING THIS PROCEDURE IS TO BE USED ONLY AS AN EMERGENCY TO LOWER THE POSITION OF THE BUCKET. EXTREME CAUTION SHOULD BE EXERCISED SINCE THE WEIGHT OF THE BUCKET WILL TEND TO MOVE THE BUCKET ABRUPTLY WHEN THE LINES ARE DISCONNECTED. BE SURE TO BLOCK THE ATTACHMENTS TO AVOID SUDDEN CHANGES IN THEIR POSITION. SLOWLY REMOVE HYDRAULIC LINES UNTIL OIL PRESSURE IS COMPLETELY RELEASED. THEN CONTROL THE BUCKET MOVEMENT BY SLOWLY REMOVING THE BLOCK. To lower the bucket position, proceed as follows: When the bucket is in digging position (A) (bucket cylinder completely extended, see figure right, disconnect hose (head) side (H). Conversely, when the bucket is in dump position (B) (bucket cylinder completely retracted, see the right figure), disconnect the hose (rod) side (R).

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

R H

CAUTION Clean up all spilled oil. Dispose of all hazardous waste in accordance with local government environmental regulations.

3-36

3. MACHINE OPERATION C. LOWERING DIPPER & BOOM

WARNING •

THIS PROCEDURE IS TO BE USED ONLY AS AN EMERGENCY TO LOWER THE POSITION OF ATTACHMENT. EXTREME CAUTION SHOULD BE EXERCISED SINCE THE WEIGHT OF THE ATTACHMENTS WILL TEND TO MAKE THEM DROP ABRUPTLY WHEN THE LINES ARE DISCONNECTED.

•

BE SURE TO BLOCK THE ATTACHMENTS TO AVOID SUDDEN CHANGES IN THEIR POSITION. SLOWLY REMOVE HYDRAULIC LINES UNTIL OIL PRESSURE IS COMPLETELY RELEASED. THEN CONTROL THE ATTACHMENT MOVEMENT BY SLOWLY REMOVING THE BLOCK.

•

DO NOT ENTER INTO THE AREA UNDER ATTACHMENTS, WHILE LOWERING THEM.

R H

1. Lowering Dipper (Step 1) Gradually loosen the hose of rod side (R) connected to the dipper cylinder.

2. Lowering Boom (Step 2) Gradually loosen the hose of head side (H) connected to the boom cylinder.

CAUTION Clean up all spilled oil. Dispose of all hazardous waste in accordance with local government environmental regulations.

3. Keep the attachment at 30~40 cm (12~16 in) above ground level, taking the occasion of moving the machine into consideration.

4. Securely retighten the hoses not to lower the attachment anymore.

5. After moving the machine to a safe place, get touch the attachment with the ground.

6. Call up a serviceman to have the machine investigated.

NOTE: If necessary, contact your Dealer for advice and/or repairs.

3-37

3. MACHINE OPERATION 3.1.16.

CAUTION ON USING RUBBER TRACKS

A. PROPER USAGE The rubber track offers excellent features which a steel track does not possess.

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

Less vibration

•

Smooth run

Rubber shoe

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

Iron shoe

' 2 ' ' '

Low noise Harmless for paved road Easy handling

'

Not damageable Large traction force

Excellent

2: Good

': Ordinary

Comparison between rubber and iron crawler shoe

B. GUARANTEE OF RUBBER TRACKS Guarantee does not cover such damages to the rubber track that result from improper working and/or operation as; execution of site work in such places where there are steel plates, U-drains, block corners, sharp slashed gravel and stones, ferro-concrete debris, metal scrap and other which may tear off the rubber track and neglect to observe prohibited operations.

C. PROHIBITED WORK Do not carry out the following operations: 1. Do not operate and/nor travel in gravel-mixed land, rugged and solid rock bed, ferro-concrete, iron scrap, edges of iron plates.

2. Do not operate and/nor travel in such places as river beds where there are lots of stones of different sizes. The rubber track tends to be damaged or come off from the rollers as the result of being caught in the grooves on the rubber tracks. The service life of the rubber track will be reduced if soil is pushed by force with dozer blade when the rubber crawler is running idle.

3-38

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

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

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

Do not work in asphalt leveling.

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

Refer to 3-44 for the storing procedures.

6. If the machine travel using one side crawler, with the track on the other side floating, the rubber track may come off from the rollers or be damaged.

D. CAUTIONS ON USAGE Use care of the following when working.

1. Rubber tracks slip easily on icy surfaces Take the necessary safety precautions, such as not driving on snowy/icy slopes.

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

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

3-39

3. MACHINE OPERATION 4. Exercise care so the rubber track is not damaged by the bucket while working.

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

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

7. If the machine is operated in salty or corrosive places, the adhesion of the core metal of the track will get loose. Refrain from using the track, or wash it with water after use.

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

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

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

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

3-40

3. MACHINE OPERATION 11. If you travel on a slope or a concave with one side of the machine lifting, it will damage the rubber track. Always travel with both sides of the machine in level.

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

3-41

3. MACHINE OPERATION 3.1.17.

MACHINE OPERATION IN ADVERSE WEATHER CONDITIONS

A. OPERATION IN EXTREME COLD

CAUTION When the temperature is extremely low, oil flow is reduced due to increased viscosity, making start-up difficult. Coolant may freeze damaging radiator and/or engine.

A.1 FUEL AND OIL Use fuel and oil of high quality and low viscosity for each system. See 4-Maintenance chapter, "LUBRICANT, FUEL & COOLANT SPECIFICATIONS" 4-10 for details.

A.2 COOLANT •

When operating or storing the machine in cold regions, the ratio of mixing antifreeze into the cooling system should conform with the lowest predicted ambient temperature. If coolant freezes, the radiator, crankcase and cylinder head may be damaged.

•

When shipped from the factory, the machine contains coolant mixed with all-season-type LONG LIFE COOLANT.

•

When operating or storing the machine in extreme cold, inspect the coolant to maintain proper concentration.

NOTE: In extremely frigid climates, covering the radiator is a method to aid the machine warm up. If necessary to maintain 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 coolant heater, fuel heater, engine heater jacket, and/or additional battery power to aid engine starting. Likewise, mix coolant to a protection temperature of 5°C (9°F) lower than the machine will experience during operation, storage or transport.

A.3 BATTERY When the temperature becomes low, the charging ability goes down or the battery may freeze. Keep the charging rate as around 100% as possible and cover the battery with insulation material.

Perform a test on the battery. We recommend the test be performed at room temperature for best results. Use a hydrometer to check the specific gravity of each cell and compare the readings with the table provided below.

Temp. of battery fluid -10°C (14°F)

0°C (32°F)

20°C (68°F)

100% Charging rate

1.28

1.27

1.26

90% Charging rate

1.26

1.25

1.24

80% Charging rate

1.24

1.23

1.22

75% Charging rate

1.23

1.22

1.21

Do not measure the specific gravity of battery fluid just after operation.

NOTE: Keep battery terminals free of ice and snow to avoid short circuits. Check the battery electrolyte (acid) level frequently and fill as needed with distilled water. In extremely cold climates, remove the battery and store it overnight at room temperature.

A.4 AFTER OPERATION Mud and water adhering to the machine may freeze interfering with proper machine operation. Use the following general guidelines as reference to prevent malfunctions: •

Remove mud and water adhering to the machine. Remove water adhering to the travel system thoroughly and park on dry ground to prevent the travel system from freezing.

3-42

3. MACHINE OPERATION •

Retract the cylinder rods to minimum length to reduce exposed area of the rods. This will prevent mud or water on the rod faces from damaging the seal.

B. OPERATION IN MARITIME OR SALTY CLIMATE B.1 BEFORE OPERATION •

Check all mounting hardware for proper tightness. Torque to proper value to help prevent salt from entering the machine systems.

•

Apply grease to the electrical equipment as required to prevent corrosion.

B.2 AFTER OPERATION Wash the machine thoroughly to remove salt. Apply oil or grease as necessary to prevent corrosion.

C. CARE FOR ELECTRICAL EQUIPMENT The electrical equipment is especially sensitive to water. Be careful not to expose the electrical equipment to water when washing the machine or when it is raining. The electrical components (relays, fuses, etc.) are installed in the vicinity of the operator's seat.

Never expose the operator's seat to water.

D. OPERATION IN DUSTY AREAS D.1 AIR CLEANER Clean or replace the element at the corresponding interval. See Maintenance Section for details.

D.2 RADIATOR Clean the radiator regularly to prevent the radiator core from becoming clogged with dust.

D.3 FUEL Be careful not to let contamination in the fuel when refuelling. Inspect the elements and filters at the corresponding interval.

D.4 ELECTRICAL EQUIPMENT Clean the starter and generator especially, at the corresponding interval, to prevent dust from accumulating. See 4.

"MAINTENANCE" chapter for details.

3-43

3. MACHINE OPERATION 3.1.18.

PRECAUTIONS WHEN STORING THE MACHINE FOR A LONG PERIOD

When storing the machine for more than one month, observe the following points to prevent the machine function from deteriorating.

ITEM WASHING MACHINE

ACTION Wash the machine thoroughly.

Check the travel system for any malfunctions and service as required.

Lubricate every required part.

Check the lubrication oil to make sure it is at the proper level and for contamination.

Replenish if necessary, and change if contaminated.

LUBRICATION

• Lubricating oil deteriorates even when the machine is not used.

• Be sure to check the oil before operating the machine again.

Apply sufficient rust inhibitors to portions where rust is likely to occur, especially the exposed rod of the cylinder.

BATTERY

Remove the negative terminal from battery and cover the battery, or remove the battery from the machine and store it at room temperature placing it over a wooden deck.

Charge the battery once a month to replenish spontaneous discharging.

COOLANT

If there is a possibility that the coolant may freeze, add antifreeze in the coolant.

Normally, long life coolant is mixed in, so it is not necessary to change the coolant.

DUST AND HUMIDITY PREVENTION Keep the machine in a dry place indoors. If the machine must be kept outdoors, lay wooden blocks on the flat ground and protect the machine with cover.

• Park the machine with the exposed piston rod of the cylinder retracted as much as possible.

• Lower the bucket to the ground and place blocks under the tracks.

If the oil film on the parts is insufficient, rust occurs and abnormal wear may occur when the machine is operated.

Start the engine and operate the machine and attachment, etc. once a month to lubricate all of the parts.

PERIODICAL • Before starting the engine, check the engine oil and coolant level, and replenish if insufOPERATION FOR LUficient.

BRICATION • Wipe off the rust inhibitors from the cylinder and piston rod thoroughly.

(DURING STORAGE) • Apply rust inhibitors to cylinder rods after the above operation.

• After starting the engine, warm up the machine completely. Repeat travelling, slewing, and digging several times to lubricate each part of the machine.

• Ensure proper ventilation during warming-up operations.

OPERATION AFTER LONG TERM STORAGE

Before placing the machine back into operation, proceed as follows before starting up.

• Fully wiped off the rust inhibitors from the cylinders and piston rods.

• Refill fluids to proper levels and lubricate as required.

3-44

4. MAINTENANCE

4-1

4. MAINTENANCE

4-2

4. MAINTENANCE

4.1

GENERAL INFORMATION

WARNING READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS CONTAINED IN THIS MANUAL BEFORE PERFORMING ANY INSPECTION OR MAINTENANCE PROCEDURES ON THIS MACHINE, ITS SYSTEMS OR COMPONENTS. NOTE: Be sure to consult your Dealer for the adjustment, disassembly and repair of the engine, reduction gear and electronic equipment (controller, etc.). a. We recommended that an inspection and maintenance schedule be developed and maintained on a regular basis for this machine. Developing and maintaining such a schedule helps to keep the machine in optimum operating condition. b. The information contained in this section gives the proper procedures for performing inspection and maintenance functions for this machine. Use these procedures when performing inspection and maintenance as they will guide the technician step by step for each procedure. Also, refer to the Inspection and maintenance charts for general service interval recommendations. c. Basically, lubrication and maintenance intervals are determined by the hour meter. If performing lubrication and maintenance according to calendar time is preferred, the hour meter reading corresponds to the lubrication and maintenance period (daily, weekly, monthly, etc.) in calendar time; thus calendar time can be used. Items for which service time cannot be specified are explained in the section WHEN REQUIRED. NOTE: The inspection and maintenance charts provided in this section give only general time intervals. It may be necessary to develop a custom schedule to perform machine maintenance at more frequent intervals based on the work conditions such as severe applications, work in dusty or humid circumstances, etc. d. Be sure to dispose of all waste materials correctly. e. Use only specified oils, fluids, lubricants, filters and replacement parts to keep machine in optimum operating condition. Furthermore, use the oils and greases with the specified viscosity depending on the ambient temperature.

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

4-3

4. MAINTENANCE

4.2

GENERAL SAFETY & PRECAUTIONS

Do not carry out any other inspection and maintenance procedures than those specified in the manual.

Carry them out after parking the machine in a flat and conveniently situated place.

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

B. CONFIRMATION FOR HOUR-METER Read the hour-meter daily, and check with the scheduled maintenance book. See 4-26 for better reference.

Proceed with any maintenance as required.

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

Otherwise, there is a possibility of danger that your hand may be caught in the cooling fan or fan belt resulting in injury.

If it is unavoidable to operate the engine for the inspection or maintenance, carry out the work with two persons. One person to stop the engine at any time at the signal from his partner.

4-4

4. MAINTENANCE D. TAG-OUT MACHINE Before beginning any inspection or maintenance procedures, secure a "DO NOT OPERATE" tag to the operator’s console to inform the operator that the machine will be inoperable for inspection and maintenance. This tag will help prevent accidental starting of the machine.

E. OBSERVE PRECAUTIONS Start the inspection and maintenance work only if you fully understand the contents of safety precautions indicated on the machine decals.

PV20T01005P1

F. HOT SURFACES & FLUIDS Use caution and wear the proper safety equipment when working around hot areas. Never change oils, engine coolant or filters immediately after machine has been stopped. Allow machine to cool down before performing maintenance procedures.

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

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

4-5

4. MAINTENANCE H. USE CAUTION IN REGARD TO THE INTERNAL PRESSURE Release the internal pressure before removing the hydraulic system, air system, or fuel system; piping or coupling of the cooling system; other related parts to which internal pressure is applied.

See "RELEASING INTERNAL PRESSURE OF HYDRAULIC SYSTEM" TO RELEASE INTERNAL PRESSURE.

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

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

J. INSPECT WASTE OILS AND FILTERS Before disposal, inspect all waste oils, fluids and filters for debris and foreign matter.

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

K. CAUTION FOR OIL FILLING When a strainer is provided on the filling port, do not remove it when refilling with fuel, oil or fluid.

4-6

4. MAINTENANCE L. DISPOSAL OF HAZARDOUS WASTE Dispose of waste oils, fluids, lubricants, filters and other hazardous waste properly.

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

M. SEALS AND O-RINGS After removing the O-ring or gasket, clean the installing face, and replace with a new one.

Always replace seals and O-rings with new parts.

Never reuse a seal or O-ring during reassembly of components. Be sure to lubricate all new seals with the appropriate oil before installation.

N. INTALLING LOCKING DEVICE When inspection or maintenance is carried out under the attachment, install proper support or blocks to secure the attachment.

O. CAUTION ON CHANGING BUCKET Never insert your finger into the pin bore.

When aligning the pin bores, never insert your finger, hand or arm into the pin bore.

The alignment check must be carried out visually.

4-7

4. MAINTENANCE P. DUSTY CIRCUMSTANCES When the machine is operated in dusty circumstances, take the following precautions.

•

Frequently check for the alarm lamp for air cleaner restriction. Clean up the air cleaner element ahead of the specified period.

•

Clean up the radiator core ahead of the specified period to prevent it from clogging.

•

Clean up and replace the fuel filter element ahead of the specified period.

•

Clean up the electric equipment, especially for starter and generator, so as not to allow deposits of dust to form on them.

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

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

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

WARNING NEVER USE GASOLINE, DIESEL FUEL OR OTHER FLAMMABLE SOLVENTS TO CLEAN PARTS. ALWAYS CLEAN PARTS IN A WELL VENTILATED AREA.

4-8

4. MAINTENANCE T. HYDRAULIC RESERVOIR PRESSURE Always release the internal pressure of the hydraulic reservoir before performing inspection or maintenance procedures.

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

CAUTION Gases from hydraulic reservoirs may be hot.

Wear safety equipment.

U. WELDING SAFETY 1. Turn starter switch key to "OFF" position. Wait 4 seconds for electrical power to disconnect.

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

3. Attach welder ground cable 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.

4-9

4. MAINTENANCE

4.3

LUBRICANT, FUEL & COOLANT SPECIFICATIONS

The following information is designed to allow usage of the proper oils, grease, fuels and coolants in various climates and certain working conditions.

Components

Type of Lubricant

Capacities (When changed)

Hydraulic oil reservoir

Hydraulic oil

Reservoir: 42 L (11 gal) Total system: 63 L (16.6 gal)

Engine oil pan

Engine oil

H level: 7.4 L (2.0 gal) L level: 3.4 L (0.9 gal)

Fuel tank

Diesel fuel

53 L (14 gal)

Coolant

Radiator: 2.6 L (0.69 gal) Total volume: 6.0 L (1.59 gal)

Radiator

Travel motor Upper rollers Idlers

Specified Lubricant

Classification Specifiction

Constructor Specification

Viscosity

Ambra HI-TECH 46

DIN 51524 Part 1 & 2 HV QFK583/HD

ISO VG 46

Ambra Hydrosystem 46 BIO-S

DIN 51524 Part 2 HV

NH 646 BS

ISO VG 46

Ambra Mastergold HSP

API CH4 ACEA E5

NH 330 H

SAE 15W40

ASTM D-975 Grade 2-D, Grade 1-D

Ambra Agriflu (1)

NH 900 A

0.9 L (55 cu·in) X 2 Gear oil

20 cc (1.2 cu·in) X 2 80 cc (4.9 cu·in) X 2

Lower roller

70 cc (4.3 cu·in) X 10

Attachment and dozer pin

20-places

Ambra Hypoide 90

API GL5

NH 520 A

GRS PLUS

NLGI 2

QFK 586/GR

MG 2

NLGI 2

QFK 586/GR

SAE 80W90

Swing cylinder pin Slewing bearing

Grease

1-place

Idler adjuster

2-place

Operating lever & pedal

As required

Slewing gear

1-place

(1) Fluid to be mixed with water at 50% NOTE: USE OF BIO-DEGRADABLE OILS When you use Bio-degradable Oil (BIO OIL), refer to the following information.

1. There are two types of BIO OIL available; vegetable-based and synthetic-based. You are recommended to use the synthetic-based type, because the vegetable-based oil has a maximum usage temperature of 80 C (176 F).

Because of this the degradation of vegetable-based oil occurs more rapidly, and causes reduced service life.

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

3. If you use BIO OIL, slewing and travel 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 your Dealer.

4-10

4. MAINTENANCE

4.4

FAST MOVING PARTS

A. FILTERS & ELEMENTS, AND BUCKET Replace consumable parts, such as filters and elements, during the periodical maintenance or before the service life.

The machine can be used economically if the consumable parts are changed properly and timely.

Fast moving Parts Table No.

Device

Parts Name

Q’ty

Replacement interval

1

Hydraulic oil reservoir

Repair kit

1

After 50 hours (first change) Every 1000 hours (from 2nd change) (Breaker specification : Every 250 hours)

2

Hydraulic oil reservoir

Suction strainer (O-ring)

1

Every 2000 hours

Element (Outer)

After cleaning of 6th time or an elapse.

3

Air cleaner

Element (Inner)

1

For machines equipped with W (double) element and the inner element.

Don't fail to replace the inner element with new one.

4

Engine oil filter

Cartridge

1

After 50 hours (first change) Every 250 Hours

5

Fuel filter

Cartridge

1

Every 500 Hours

6

Water separator

Element (O-ring)

1

When required

Bucket

Side Cutter (Right) (7a) Side Cutter (Left) (7b) (Cap Screw) (Nut)

1 1 6 6

When required

Bucket

Tooth Locking Pin Rubber Locking Pin

4 4 4

When required

7

8

3

7b

7a

8

6

1 5 4 2

4-11

4. MAINTENANCE

4.5

ACCESSORY TOOLS

No.

TOOL NAME

REMARKS

1

LABEL

2

TOOL CASE

3

WRENCH

For engine oil filter

4

WRENCH

For fuel filter

5

PIPE

For grease nipple of idler adjuster

If tools become lost or damaged, contact an approved Dealer to order the tools.

4-12

4. MAINTENANCE

4.6

TORQUE SPECIFICATIONS FOR CAPSCREWS & NUTS

The following torque specifications are provided for use when actual torque value of a fastener is not known.

Check the capscrews and nuts for their looseness and dropping off before the start of daily work and at the periodical maintenance intervals. Retighten the loosened ones, and install new ones for those that have dropped off. For the new machine, the check and retightening of them must be carried out at first 50 hours operation. When replacement is needed, make sure to use genuine parts to the same dimensions.

Refer to the below table for proper tightening of capscrews.

•

The table below is not applicable for the capscrews to fix plastic covers, etc. For the tightening torque for such capscrews, consult your Dealer. Over-tightening may cause for damages on the parts to be fixed.

•

If the tightening torque is specified in the manual, use such torque values irregardless of the table below.

•

Numerical indication on the capscrew head shows the classification (A) for strength (e.g., 4 = 4.8T). No indication is provided for smaller size of capscrews, M 5 or less.

A P M

1. Metric coarse thread standard tightening torque values. Be certain to tighten all capscrews & nuts to proper torque values.

Metric Coarse Thread (Not plated) Torque value Unit : N•m (lbf•ft) Classification Nominal size

4.8T

7T

10.9T

No lubrication Oil lubrication No lubrication Oil lubrication No lubrication Oil lubrication

M6

P=1

4.4±0.5 (3.2±0.4)

3.7±0.4 (2.7±0.3)

9.6±1.0 (7.1±0.7)

8.1±0.8 (6.0±0.6)

17.4±1.8 (12.8±1.3)

14.7±1.5 (10.8±1.1)

M8

P=1.25

10.7±1.1 (7.9±0.8)

9.0±0.9 (6.6±0.7)

23.5±2.0 (17.3±1.5)

19.6±2.0 (14.5±1.5)

42.2±3.9 (31.1±2.9)

35.3±3.9 (26.0±2.9)

M10

P=1.5

21.6±2.0 (15.9±1.4)

17.9±1.8 (13.2±1.3)

46.1±4.9 (34.0±3.6)

39.2±3.9 (28.9±2.9)

83.4±8.8 (61.5±6.5)

70.6±6.9 (52.1±5.1)

M12

P=1.75

36.3±3.9 (26.8±2.9)

31.4±2.9 (23.2±2.1)

79.4±7.8 (58.6±5.8)

66.7±6.9 (49.2±5.1)

143±15 (105±11)

121±12 (89.2±8.9)

M14

P=2

57.9±5.9 (42.7±4.4)

49.0±4.9 (36.1±3.6)

126±13 (92.9±9.6)

106±10 (78.2±7.4)

226±20 (167±15)

191±19 (141±14)

M16

P=2

88.3±8.8 (65.1±6.5)

74.5±6.9 (55.0±5.1)

191±20 (141±15)

161±16 (119±12)

343±39 (253±29)

284±29 (209±21)

M18

P=2.5

122±12 (90.0±8.9)

103±10 (75.8±7.2)

265±29 (195±21)

226±20 (167±15)

481±49 (355±36)

402±39 (297±29)

M20

P=2.5

172±17 (127±13)

144±14 (106±10)

373±39 (275±29)

314±29 (232±21)

667±69 (492±51)

559±59 (412±44)

M22

P=2.5

226±20 (167±15)

192±20 (142±15)

500±49 (369±36)

422±39 (311±29)

902±88 (665±65)

755±78 (557±58)

M24

P=3

294±29 (217±21)

235±29 (173±21)

637±69 (470±51)

520±49 (383±36)

1160±118 (856±87)

941±98 (694±72)

M27

P=3

431±39 (318±29)

353±39 (260±29)

941±98 (694±72)

765±78 (564±58)

1700±167 (1250±123)

1370±137 (1010±101)

M30

P=3.5

588±59 (434±44)

490±49 (361±36)

1285±127 (948±94)

1079±108 (796±80)

2300±235 (1700±173)

1940±196 (1430±145)

M33

P=3.5

794±78 (586±58)

667±69 (492±51)

1726±177 (1270±131)

1451±147 (1070±108)

3110±314 (2290±232)

2610±265 (1930±195)

M36

P=4

1030±98 (760±72)

863±88 (637±65)

2226±226 (1640±167)

1863±186 (1370±137)

4010±402 (2960±297)

3360±333 (2480±246)

4-13

4. MAINTENANCE 2. Metric fine thread standard tightening torque values. Be certain to tighten all capscrews & nuts to proper torque values.

Metric Fine Thread (Not plated) Torque value Unit : N•m (lbf•ft) Classification Nominal size

4.7

4.8T

7T

10.9T

No lubrication Oil lubrication No lubrication Oil lubrication No lubrication Oil lubrication

M8

P=1.0

11.3±1.1 (8.3±0.8)

9.5±1.0 (7.0±0.7)

24.5±2.0 (18.1±1.5)

20.6±2.0 (15.2±1.5)

44.1±3.9 (32.5±2.9)

37.3±3.9 (27.5±2.9)

M10

P=1.25

22.6±2.0 (16.7±1.5)

18.7±1.9 (13.8±1.4)

48.1±4.9 (35.5±3.6)

41.2±3.9 (30.3±2.9)

87.3±8.8 (64.4±6.5)

73.5±6.9 (54.2±5.1)

M12

P=1.25

39.2±3.9 (28.9±2.9)

33.3±2.9 (24.6±2.1)

85.3±8.8 (62.9±6.5)

71.6±6.9 (52.8±5.1)

154±16 (114±12)

129±13 (95.2±9.6)

M16

P=1.5

92.2±8.8 (68.0±6.5)

77.5±7.8 (57.2±5.8)

196±20 (145±15)

169±17 (125±13)

363±39 (268±29)

304±29 (224±21)

M20

P=1.5

186±19 (137±14)

155±16 (114±12)

402±39 (297±29)

333±29 (246±21)

726±69 (535±51)

608±59 (448±44)

M24

P=2

314±29 (232±21)

265±29 (195±21)

686±69 (506±51)

569±59 (420±44)

1240±118 (915±87)

1030±98 (760±72)

M30

P=2

637±59 (470±44)

530±49 (391±36)

1390±137 (1030±101)

1157±118 (853±87)

2500±255 (1840±188)

2080±206 (1530±152)

M33

P=2

853±88 (629±65)

706±70 (521±52)

1860±186 (1370±137)

1550±155 (1140±114)

3350±334 (2470±246)

2790±275 (2060±203)

M36

P=3

1070±108 (789±80)

892±88 (658±65)

2330±226 (1720±167)

1940±196 (1430±145)

4200±422 (3100±311)

3500±353 (2580±260)

TORQUE SPECIFICATIONS FOR JOINTS & HYDRAULIC HOSES

A. SLEEVE TYPE TUBE FITTINGS TUBE SIZE WRENCH SIZE OD X THICKNESS (mm) (mm)

TIGHTENING TORQUE N•m (lbf•ft)

10 u 1.5

19

44±4.9 (33±4)

15 u 2.0

27

147±20 (110±14)

18 u 2.5

32

177±20 (130±14)

22 u 3.0

36

216±20 (160±14)

28 u 4.0

41

275±29 (200±22)

35 u 5.0

55

441±44 (330±33)

B. JOINTS FOR PIPING (O-ring sealing type) NORMAL SCREW WRENCH SIZE SIZE (mm) (PF)

TIGHTENING TORQUE N•m (lbf•ft)

1/8

14

17±2 (12±1)

1/4

19

36±2 (27±1)

3/8

22

74±5 (54±4)

1/2

27

108±9.8 (80±7)

3/4

36

162±9.8 (119±7)

1

41

255±9.8 (188±7)

4-14

4. MAINTENANCE C. HYDRAULIC HOSE NORMAL SCREW WRENCH SIZE SIZE (mm) (PF)

TIGHTENING TORQUE N•m (lbf•ft)

1/8

17

15±2.0 (11±1)

1/4

19

29±4.9 (22±4)

3/8

22

49±4.9 (36±4)

1/2

27

78±4.9 (58±4)

3/4

36

118±9.8 (87±7)

1

41

137±15 (101±11)

NOTE: All torque values are subject to a dry condition.

4.8

INSTALLING HYDRAULIC HOSE AND PIPE JOINTS

The following two types of joint are used on the joint part of hose piping.

A. METAL JOINT Sealing is performed with metal compression of the opening of connector (tee, elbow) and hose. Use cautions to disassemble and assemble it to protect from damage to the seat surface.

A

3

1. HOSE 2. UNION NUT

1

2

3. CONNECTOR A. SEAL FACE B. SEAT (HOSE SIDE)

B

C. SEAT (CONNECTOR SIDE)

C

B. O-RING SEAL JOINT O-ring is equipped with hose fitting which seals the oil pressure on the joint and protects it from oil leakage.

1

The tightening torque of the joint of each hydraulic hose is determined by the diameter of the hose fitting screws. In case of any abnormality detected, the hose piping joint should be repaired or replaced according to the following procedure even before the periodic inspection of the unit of hydraulic equipment.

2 3

4

1. HOSE

A

2. UNION NUT 3. CONNECTOR 4. O-RING A. O-RING FITTING

4-15

4 4

4. MAINTENANCE B.1 O-RING 1. On reassembling, be sure to replace the O-ring with a new one.

2. Where the union is loosened and oil is leaking, never tighten it as it is. Install a new O-ring and check that the O-ring is securely fitted, and then tighten it.

3. Never install a damaged and deteriorated O-ring even if it is new one. The use of an O-ring other than that specified causes oil leakage and short life of hydraulic equipment, because the material and hardness differ even if they are the same size.

B.2 JOINT 1. Care must be exercised not to damage a hose, pipe and O-ring groove face and seal face (dent, etc.) of hydraulic equipment. The use of damaged parts causes oil leakage.

2. Use care to prevent contamination.

Fitting with foreign matter inside causes oil leakage.

B.3 HOSE 1. The hose should not be twisted and sharply bent for installation.

If the hose is twisted or sharply bent, the life of the hose is decreased.

2. Clean the joints and surrounding of joints, and remove and dry the cleaning solvent completely prior to installing the joint.

Lubricants on threads shall be wiped off prior to installing the joints.

4-16

4. MAINTENANCE

4.9

RELEASING INTERNAL PRESSURE FROM THE HYDRAULIC SYSTEM

WARNING WHEN REPLACING ANY HOSE OR SEALS, MAKE SURE THE ATTACHMENTS ARE WELL SECURED TO AVOID SUDDEN MOVEMENT OF ATTACHMENT. SLOWLY REMOVE BOLTS TO RELEASE ANY HYDRAULIC PRESSURE DURING DISASSEMBLY. Release the internal pressure of hydraulic system before carrying out maintenance work such as on hydraulic oil, return filter, suction strainer, cylinder.

Pressurize the hydraulic oil reservoir after maintenance and releasing air in the system.

A. RELEASING HYDRAULIC SYSTEM AND RESERVOIR PRESSURE

WARNING •

NEVER CHANGE OILS OR FILTERS ON A MACHINE THAT HAS JUST FINISHED WORKING. ALLOW MACHINE TO COOL FIRST UNTIL OILS AND FLUIDS ARE WARM, NOT HOT.

•

RELEASE HYDRAULIC RESERVOIR PRESSURE, BEFORE WORKING WITH ANY HYDRAULIC COMPONENT, ACCORDING TO THE PROCEDURES PROVIDED BELOW.

•

WHEN REPLACING ANY HOSE OR SEALS, MAKE SURE THE ATTACHMENTS ARE WELL SECURED TO AVOID SUDDEN MOVEMENT OF ATTACHMENT. SLOWLY REMOVE BOLTS TO RELEASE ANY HYDRAULIC PRESSURE DURING DISASSEMBLY.

HYDRAULIC OIL LEVEL CHECK POSITION

1. Place the machine in the "hydraulic oil check position" as shown in the right figure. Fully retract the dipper cylinder and bucket cylinder, then lower the boom to place the bucket on the ground, and lower the dozer to the ground.

2. In case of pilot operating lines (boom, dipper, bucket, swing) stop the engine then operate the control levers to release pressure in each line.

NOTE: The above procedure is the only way to release the internal pressure.

4-17

4. MAINTENANCE 3. Set the safety lock lever to "LOCKED" position.

1

4. Make sure the hydraulic oil temperature is below 40 C (104 F).

5. Stop the engine. (Starter switch key is at "OFF" position) 6. Open the cover of hydraulic reservoir (1), and hold it with stay.

7. Press the rubber cap (2) on the upper surface of hydraulic reservoir several times (5 to 7 times).

8. This completes the bleeding of pressure remaining in the hydraulic reservoir.

Check and service the hydraulic system.

4-18

2

4. MAINTENANCE

4.10

BLEEDING AIR IN FUEL SYSTEM

If air enters the fuel system, the engine may become hard to start or it will malfunction. Bleed the air whenever the fuel tank is empty, the water separator is drained, or the fuel filter element is replaced.

1. FUEL FILTER 2. WATER SEPARATOR 3. AIR BREATHER PLUG 4. FUEL VALVE

1

5. DRAIN VALVE A. IN

3 2

B. OUT C. CLOSE

C

B

A 4

D. OPEN

D

1. Place the safety lock lever in "LOCKED" position, and stop the engine.

2. Fill up the tank.

5

3. Confirm that the handle of water separator is set at "OPEN" position.

4. Loosen air breather plug (3) on the upper part of water separator 2 or 3 turns with a screw driver (+).

5. Turn starter on for engine cranking. During cranking, the fuel is fed and the fuel injection starts, and the engine starts immediately after air is bled.

6. Tighten air plug (3) when the fuel coming out through air breather plug hole does not contain air bubbles.

4-19

4. MAINTENANCE

4.11

REPLACEMENT OF RUBBER TRACK

WARNING •

THIS WORK MUST BE CARRIED OUT WITH TWO PERSONS. THE OPERATOR OPERATES THE MACHINE IN ACCORDANCE WITH THE SIGNAL FROM THE PARTNER. THE RUBBER TRACK REPLACEMENT IS CARRIED OUT BY LIFTING THE MACHINE BODY. ERRONEOUS FALLING OF THE MACHINE BODY DURING THE WORK ON THE TRACK IS QUITE DANGEROUS. DO NOT OPERATE ANY OTHER ATTACHMENTS THAN THE TRACK.

•

GREASE IN TRACK TENSIONING MECHANISM IS UNDER EXTREME PRESSURE AND CAN PENETRATE SKIN CAUSING SEVERE INJURY. KEEP FACE AND BODY AWAY FROM GREASE FITTING AREA. NEVER LOOSEN GREASE FITTING MORE THAN ONE TURN. IF GREASE DOES NOT RELEASE AFTER ONE TURN OF THE FITTING, CALL YOUR DEALER FOR ASSISTANCE.

•

BEFORE REMOVING THE RUBBER TRACK, CHECK THAT THE PRESSURE INSIDE GREASE HAS BEEN COMPLETELY RELEASED. THEN TURN THE SPROCKET.

•

IT IS QUITE DANGEROUS TO ALLOW THE SPOUTING OUT OF GREASE WITH ANY PROCEDURES OTHER THAN THE ONE DESCRIBED IN THE, "REMOVAL OF RUBBER TRACK". IF THE TENSION ON THE TRACK IS NOT RELEASED, CONSULT YOUR DEALER FOR ITS REPAIR.

4.11.1

REMOVAL OF RUBBER TRACK

1. Operate boom, dipper, and bucket to set the attachment on the ground.

Slowly and gradually lower the boom to lift one side of the machine.

2. Support the lower travel structure of the machine with a safety support (1), etc.

1

4-20

4. MAINTENANCE 3. Slowly loosen the grease nipple on the grease cylinder to allow to discharge the grease, and release tension.

4. Slowly loosen the grease nipple less than one turn.

1

5. Engage some steel pipes into the rubber track, then slowly rotate the sprocket backward.

When the rubber track floats from the steel pipes, slide the shoe to the side to remove it.

A

1. STEEL PIPE A. DIRECTION OF ROTATION

1 4.11.2

INSTALLING RUBBER TRACKS

1. Operate boom, dipper, and bucket to set the attachment on the ground.

Slowly and gradually lower the boom to lift one side of the machine.

2. Support the lower travel structure of the machine with a safety support (1), etc.

1

3. Engage the rubber track with the sprocket, and hang it on the idler.

4.

Slowly rotate the sprocket backward and push the rubber track into its position, then stop the rotation.

5.

Engage a steel pipe into the rubber track, and rotate the sprocket backward again to securely engage the rubber track with the idler.

A

1. STEEL PIPE A. DIRECTION OF ROTATION

1

4-21

4. MAINTENANCE 6. Stop the rotation of sprocket to confirm that the rubber track is securely engaged to the sprocket, idler and lower rollers.

1

7. Referring to the next Section "CHECK AND ADJUSTMENT OF TENSION ON RUBBER TRACK", carry out the check and adjustment of tension on rubber track.

6

2 5

8. After the confirmation for the engagement of rubber track to the sprocket, idler and lower roller, and also for the proper tension on the rubber track, lower the machine to the ground.

4

1. LOWER ROLLER 2. RUBBER TRACK 3. SPROCKET 4. IDLER 5. LUG

7

6. METAL CORE 7. TRAVEL MOTOR

3

4.11.3

CHECK AND ADJUSTMENT OF TENSION ON RUBBER TRACK

An appropriate adjustment of tension on the rubber track is important not only for prolonging the service life on the rubber track and machine but also preventing the rubber track from coming out of place.

WARNING SINCE THE CHECK AND ADJUSTMENT FOR THE TENSION ON THE RUBBER TRACK IS CARRIED OUT WITH THE MACHINE LIFTED UP, IT IS QUITE DANGEROUS IF THE MACHINE IS ERRONEOUSLY DROPPED TO GROUND. NEVER MOVE THE MACHINE WHILE CHECKING AND ADJUSTING IT. WORK HAS TO BE PERFORMED BY TWO PERSONS, AND THE OPERATOR MUST OPERATE THE MACHINE IN ACCORDANCE WITH THE SIGNAL FROM THE PARTNER. A. RUBBER TRACK Since the abrasion on the rubber track varies depending on the working conditions and the nature of the soil, a frequent check is required for wear and the tension condition. Especially, on the new rubber track, there is an initial stretch.

Therefore, frequently check track tension during the first 30 hours on a new machine or new tracks.

RUBBER TRACK

4-22

4. MAINTENANCE A.1 CHECKING 1. Move the rubber track so that the jointing part (M mark) comes to the upper centre position.

2. Slew the upperstructure to place it at 90 (right angle) to the crawler frame. Operate boom, dipper, and bucket to set the attachment on the ground.

Slowly and gradually lower the boom to lift one side of the machine.

And place a suitable support (1) under the machine to prevent the machine from falling.

1

3. Measure the clearance (A) between the lower face of track frame and the upper face of track at the centre position of track frame.

2

1

1. TRACK FRAME 2. LOWER ROLLER 3. RUBBER TRACK

A

4. STEEL TRACK

A

Measure the clearance (A) Rubber track: 85~95 mm (3.35~3.74 in) Steel track: 130~150 mm (5.12~5.91 in)

3

4

RUBBER TRACK (3)/STEEL TRACK (4)

4. If the tension is not right, adjust it referring to the next Item "A.2 ADJUSTMENT ".

NOTE: The machine operation with loosened rubber track causes coming out of place and wear prematurely.

4-23

4. MAINTENANCE A.2 ADJUSTMENT It is required to adjust the tension on the track depending on the working place of the machine. When working at the place with a lot of gravel or boulder, looser tension (upper limit range of tension) is preferable. And at hard ground, stronger tension (lower limit range of tension) is preferable.

WARNING •

GREASE IN TRACK TENSIONING MECHANISM IS UNDER EXTREME PRESSURE AND CAN PENETRATE SKIN CAUSING SEVERE INJURY.

•

KEEP FACE AND BODY AWAY FROM GREASE FITTING AREA. NEVER LOOSEN GREASE FITTING MORE THAN ONE TURN. IF GREASE DOES NOT RELEASE AFTER ONE TURN OF THE FITTING, CALL OUR DISTRIBUTOR FOR ASSISTANCE.

1

A.2.1 Making tension tighter

B

Provide a grease gun.

1. Feed grease to the grease fitting (1) with the grease gun so that proper tension on the track is obtainable.

2. Move the machine forward and backward to equalize the tension on both tracks of left and right.

1

1. GREASE NIPPLE 2. GREASE CYLINDER

A

A. GREASE FILL B. PRESSURE 3. Again check for the tension on the tracks, and repeat the adjustment to obtain the proper tension on both tracks.

NOTE: When the tension on the track is still loose even when grease is supplied to the grease fitting, it is presumable that some faulty conditions may exist on the seal in the cylinder or machine body.

Request repair your Dealer to repair as necessary.

4-24

2

4. MAINTENANCE A.2.2 MAKING TENSION LOOSER

WARNING •

GREASE IN TRACK TENSIONING MECHANISM IS UNDER EXTREME PRESSURE AND CAN PENETRATE SKIN CAUSING SEVERE INJURY. KEEP FACE AND BODY AWAY FROM GREASE FITTING AREA. NEVER LOOSEN GREASE FITTING MORE THAN ONE TURN.

•

IF GREASE DOES NOT RELEASE AFTER ONE TURN OF THE NIPPLE, CALL YOUR DEALER FOR ASSISTANCE.

1. Gradually loosen the grease fitting to discharge grease.

Do not loosen the grease fitting (1) more than one turn.

2. Move the machine (track) forward and backward, when grease is not discharged adequately.

3. Tighten up the grease fitting.

1

Tightening torque : 73.5±14.7 N•m (54±11 lbf•ft) Move the machine forward and backward to confirm the correct tension on the tracks.

Again check for the tension, and if it is not correct, adjust it again.

1

DETAIL A (Grease removal)

4-25

A

4. MAINTENANCE

4.12

INSPECTION & MAINTENANCE CHART

Follow the chart below for recommended intervals of regular inspection and maintenance procedures. Perform inspection and maintenance according to the calendar time or operation time shown by the hour meter, whichever comes first.

See the inspection and maintenance procedure mentioned below for details.

WARNING READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS FOUND IN THIS MANUAL BEFORE PERFORMING INSPECTION & MAINTENANCE. Symbols and their meanings :

Components

: Necessary regular inspection item to hour meter. : Only first replacing is performed. : Inspection and/or maintenance is needed.

When

Item

Interval

required

Checking the level Engine oil

Prestart 8H

Every

Every 3 Every 6

week

months months

50H

2,000H

ence

ing part)

pages

Engine oil

O O

Replacing

O O

4-47

Cartridge

4-49

Element

4-42

Cartridge

4-55

Element O

Element

O

Checking the level

Engine

1,000H

O

Air cleaner Checking/Cleaning element Replacing

Fan belt

months

Refer-

etc. (Replac-

3-5

Replacing

Water sepaDraining/Cleaning rator

Radiator Coolant

500H

Lubricant

12

O

Engine oil filter

Fuel filter

250H

Every

4-51 3-4

Replacing

Tap water (LLC)

O

4-57

Checking leakage

O

3-18

Checking

O

3-8

Adjusting

O

4-48

Radiator core

O

4-29

Radiator cap

O

4-29

Hoses in cooling system Checking/Replacing Checking the colour, sound, smell of exhaust gas

O

4-50

O

3-15 O

Valve clearance

4-58

Compression pressure

O

4-67

Injection timing Checking/Adjusting

O

4-67

Starter and generator Checking/Adjusting

O

Check and adjustment for contact surface of intake and exhaust valve

4-58 O

4-26

4-67

Hydraulic system

Fuel System Components

4. MAINTENANCE When

Item

Interval

required

Fuel Checking/Adjusting Fuel tank

start 8H

Draining water and deposits

Every 3 Every 6

week

months months

50H

250H

Upper frame

months 1,000H

2,000H

Refer-

etc. (Replac-

ence

ing part)

pages

4-44

O

3-7

O O

Cleaning/ Replacing

O O

Return filter

O

Hydraulic oil Strainer Element

3-5

4-59

4-54

(Breaker)

Checking oil leakage and damage of cylinders, etc.

O

4-39 O

Slewing bearing

O

O

Lithium base

Gear oil

O

4-67

O

Checking

4-34 O

4-40 O

Checking oil leakage and wear of sprocket/travel reduction motor

Gear oil

O

Boom & Arm cylinder

O

Bucket

O

Replacing/Adjusting mounting gap

O

Checking wear and damage of the tooth and side cutters

O

4-64 4-40

O

Bucket

4-26 4-22

Replacing

Greasing for pins

4-48

MoS2 grease

Checking/Adjusting for tension of rubber track

Lower roller Idler

Greasing O

Oil Replacing

Checking wear and damage of rubber track

4-61

N.L.G.I No.2

Grease in the slewing Replacing grease bath Travel reduction motor

Lower frame

Lubricant

12

3-7

Line filter In-line filter/Cleaning

Attachment

500H

Every

O

Checking Hydrauthe level lic oil Replacing Suction strainer

Every

O

Checking leakage

Hydraulic reservoir

Pre-

Grease

4-41

Grease

4-46 4-32 4-31

4-27

Components

4. MAINTENANCE When

Item

Interval

quired

Electrical equipment

Checking damage of the electrical wirings

start 8H

Every

Every 3 Every 6

week

months months

50H

250H

500H

Every

Lubricant

12 months 1,000H

2,000H

Refer-

etc. (Replac-

ence

ing part)

pages

O

4-38

Battery Checking the fluid level Measuring the specific gravity

O

Distilled water

4-45

Checking the function of warning lamps

O

3-9

Checking switches/levers

O

3-15

Replacing working light (Lamp)

Others

re-

Pre-

12V 55W (Halogen lamp)

O

4-30

Checking abnormal deformation and damage of the machine exterior

O

4-39

Checking looseness and missing of the capscrews and nuts

O

4-39

O

3-15

Operating lever

Checking Lubrication

O

Grease

4-28

4-37

4. MAINTENANCE

4.13

WHEN REQUIRED

Thoroughly read and understand the chapter "SAFETY PRECAUTIONS" of this MANUAL before operating or servicing the machine.

A. CLEANING FOR RADIATOR CORES

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.

CAUTION Direct contact with compressed air, steam and high pressure water causes injury.

Be sure to wear the protective glasses, mask, safety cap, safety shoes, etc.

1. Open the left side cover and the cover under the seat, referring to "GUARD WITH LOCKING DEVICE & COVERS", 2-19.

2. Check for clogging on the radiator fins with dust and mud.

3. Remove the dust and mud on the radiator cores and fins with compressed air.

NOTE: To avoid damage to the fins, leave some distance between the compressed air spray nozzle and the fins. If the fins get damaged, it may cause water leakage resulting in overheating.

B. CLEANING OR REPLACEMENT OF RADIATOR CAP

WARNING USE EXTREME CARE WHEN REMOVING THE RADIATOR CAP. THE COOLANT IS UNDER HIGH PRESSURE WHEN HOT. •

NEVER REMOVE THE RADIATOR CAP WHEN THE SYSTEM IS HOT.

•

ALLOW SUFFICIENT TIME FOR THE MACHINE TO COOL DOWN BEFORE REMOVING THE RADIATOR CAP.

CAUTION If the tightness of cap is insufficient, it may cause the risk of getting burned due to spouting out of hot water or steam during operation.

4-29

4. MAINTENANCE 1. Remove the radiator cap after the engine has cooled down to touchable with a bare hand. Slowly loosen the cap to release the inside pressure.

Remove the radiator cap after all pressure is released.

2. Check the cap for damages or adhesion of dust.

Clean it and/or replace it if needed.

3. Securely tighten the cap.

C. REPLACEMENT OF WORKING LIGHT A light bulb of 55W is used for the working light.

CAUTION Since the light bulb develops high temperature while working, the service life of the light bulb becomes shorter if oil or grease adhere to it.

When replacing the light bulb, hold it at the flange portion without touching its glass portion.

When the working light is not lightened even though the working light switch is turned on, the light bulb or fuse may be blown. If there is no trouble with the light bulb, check the fuse referring to 2-21. The following is the description for the light bulb changing procedures.

C.1 ATTACHMENT 1.

Place the attachment on the ground, and set the safety lock lever to "LOCKED" position, then stop the engine.

1

4 3 5

2. Disconnect the connector, then remove the working light from the boom with a wrench.

3. Remove the screw (1) (4 pieces), then remove the rim (2) and lens (3) from the housing (4) .

6

7

4. Remove the spring (6) for fixing the socket (5).

5. Remove the bulb (7) from the socket (5) and replace the bulb with new one.

ATTACHMENT WORK LIGHT PARTS

6. Assemble the working light proceeding in the reverse order from the above.

NOTE: Pay attention not to break the light bulb during replacement. Hold the lens when removing the screw (1), otherwise, the lens falls off.

4-30

2

4. MAINTENANCE D. CHECK FOR ABRASION/DAMAGES ON TOOTH TIPS & SIDE CUTTER

CAUTION When replacing the tooth point and side cutter, apply a safety block to the bottom face of the bucket.

Check for wear and looseness of the bucket tooth tips.

Tooth tip life cannot be determined only by the number of operating hours; operating conditions must also be considered.

8~ 10mm

2~ 3mm

1. Adapter 2. Tooth tip 3. Rubber locking pin

TOOTH POINT

4. Locking pin

4

3

5. Adapter nose 6. Safety block 7. Hammer 8. Punching tool

1 2

5

D.1 REPLACING THE TOOTH TIPS Replace the bucket tooth in the following cases.

•

When little holes appear on the tooth point.

•

When the edge lines of the tooth point are worn.

7

WARNING WEAR, GOGGLES, SAFETY SHOES, HARD HAT, WORK CLOTHES AND WORK GLOVES TO PERFORM INSPECTION AND MAINTENANCE ON THIS MACHINE.

8

6 2

1. Using a hammer and punching tool, hammer out the locking pin. Be careful not to damage the rubber locking pin (3).

4

2. Inspect the locking pin (4) and rubber locking pin (3).

Replace them if the locking pin (4) is too short or the rubber locking pin (3) is in poor condition.

3 5 2

3. Clean the surface of the adapter nose (1) with a putty knife to remove the adhered soil.

6

4. Fit the tooth tip (2) onto the adapter nose (1).

5. Push the rubber locking pin (3) in the hole of the adapter nose (1).

6. Drive in the locking pin (4) until it is aligned with the point face.

4-31

4

4. MAINTENANCE D.2 REPLACING THE SIDE CUTTERS

WARNING WEAR, GOGGLES, SAFETY SHOES, HARD HAT, WORK CLOTHES AND WORK GLOVES TO PERFORM INSPECTION AND MAINTENANCE ON THIS MACHINE. 1. Completely remove all sand and soil adhering around the capscrews completely. Use an acetylene torch to cut off the capscrews, then remove the side cutter.

2. Clean the mounting face and install a new side cutter. When replacing the side cutter, replace the capscrews and nuts with new ones.

2

Tightening torque: 279±29.4 N•m (206±21.7 lbf•ft)

2

3. After tightening the nuts, spot-weld them.

1. NUTS 2. SIDE CUTTER

1

4

3. CAPSCREW 4. TOOTH TIP

3

E. REPLACEMENT OF BUCKET

WARNING •

REPLACE THE BUCKET ON FIRM FLAT GROUND. PAY CLOSE ATTENTION TO SAFETY.

•

WHEN ALIGNING THE PIN BORES, DO NOT INSERT YOUR FINGER INTO THE BORES. IT MAY CAUSE SEVERE INJURY. NEVER INSERT YOUR FINGER INTO THE PIN BORES. BE SURE TO ALIGN THEM VISUALLY.

4-32

4. MAINTENANCE E.1 REMOVAL OF BUCKET

7

1. Slightly operate the boom and the arm to remove load from the pins.

A

8

2. Roll O-rings (1) onto the bucket boss.

After removing the pins, get them back to the original position.

A

3. Remove the lock ring (2) and lock pin (3), then remove the pins (4) and (5) to remove the bucket (6).

6

NOTE: Pay attention not to let any sand or dust stick to the pins removed.

1

NOTE: Pay attention not to damage the dust seals (9) which are installed in both ends of the dipper (7) and bucket link (8).

3 2

4-33

9 A-A

4,5

4. MAINTENANCE E.2 INSTALLING BUCKET 1. Clean each pin and pin hole and grease sufficiently.

7

2. Move the bucket cylinder to match the pin bores or the bucket (6) and bucket link (8) with each other, then insert the pin (4).

8 5

3. Raise the boom and slightly raise the bucket from the ground.

4

4. Align bucket (6) with the pin hole of dipper (7) moving dipper (7), and insert pin (5).

6

5. Insert pin (3) and fit lock ring (2).

Fit O-ring (1) to the normal position.

6. Apply grease on the grease nipples for respective pin until the grease oozes out through the space between pins and bore.

6

9 2

NOTE: Replace any O-ring (1) showing cracks or losing elasticity with a new one.

3

(9)

4

5

1

2 3

B

B

B-B

F. INSPECTING RUBBER TRACK Repair or replace rubber track if it falls into the following condition.

(Contact your Dealer for repair or replacement of rubber tracks.)

1

5

2

1. LOWER ROLLER 2. RUBBER TRACK

3

3. LUG 4. STEEL CORD

4

5. METAL CORE

4-34

4. MAINTENANCE F.1 THE HEIGHT OF LUG

A

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

2. If the lug wears out at an extent that the steel cord (1) in the track is exposed over two links, replace the track with a new one.

1 F.2 BREAKAGE OF STEEL CORD If the steel cords (B) of the rubber track are broken by more than one half of one side row, replace the track with a new one.

B

F.3 CRACKS IN RUBBER TRACKS If a crack (A) which has developed to about 60 mm (2.4 in) length is seen between the lug of rubber track, repair the track. However, repair the track immediately if the steel cord (1) inside is seen exposed even though a crack is small and short (B).

A 1

NOTE: For repairs or replacement of rubber tracks, contact your Dealer.

B

4-35

4. MAINTENANCE F.4 PEELING OFF OF METAL CORE ON RUBBER TRACKS

1 A

Depending on the usage of rubber tracks, there may occasionally be peeling off of metal core on the tracks (inner side) due to contact with the rollers and idler/ sprocket or abrasion, even though there are no external damages or abrasion on the lug side (outer side) of it.

2 4

1. LOWER ROLLER 2. METAL CORE

5

3. RUBBER

3

4. HOOD CLOTH 5. STEEL CORD A. INTERFERENCE WITH ROLLER NOTE: The metal core starts out of track with the prohibited usage of the rubber track.

NOTE: Fully understand the prohibited usage of the rubber track referring to "CAUTION ON USING RUBBER TRACKS", 3-38.

NOTE: Note that the warranty is not applicable for any damages due to the prohibited usage of the rubber track or the use of it with improper tension on it.

1. The rubber track on which the peeling off of metal core (1) shows even at one place must be replaced to new one.

2.

1

The cracked rubber track in which the metal core (1) comes to the surface must be replaced by new one.

1

4-36

4. MAINTENANCE 3. The cracked (A) rubber track on the contacting portion of the metal core with the roller is not required to repair.

A

NOTE: The metal core starts out of the track with the prohibited usage of the rubber track.

NOTE: Fully understand the prohibited usage of the rubber track referring to "CAUTION ON USING RUBBER TRACKS", 3-38.

G. LUBRICATION FOR OPERATING LEVERS When any operating levers become heavy to operate or do not move smoothly, apply grease to the sliding and rotating portion (A) and the top portion (B) of the universal joint.

2 1

1. Move the machine to firm and level ground, set the attachment on the ground, place the safety lock lever in "LOCKED" position, then stop the engine.

2. Carefully raise up the rubber boot on the concerned operating lever by hand, paying attention not to damage it.

3. Apply grease to the sliding and 4 places of rotating portion (A) and the top portion (B) of the universal joint.

4. Set back the rubber boot to the original position.

A

5. Check for any looseness on the pilot valve, and if loosened, retighten the socket bolt.

3

B

1. OPERATING LEVER

4

2. RUBBER BOOT 3. UNIVERSAL JOINT 4. SOCKET BOLT A. ROTATING PORTION

APPLY GREASE

B. TOP PORTION

4-37

4. MAINTENANCE H. CHECKING ELECTRICAL WIRING AND FUSES

WARNING •

WHEN FREQUENT REPLACEMENT IS REQUIRED FOR THE FUSES OR THERE ARE ANY TRACES OF SHORT CIRCUITING ON THE ELECTRICAL WIRING, CONSULT YOUR DEALER.

•

BEFORE CHECKING THE ELECTRICAL SYSTEM, BE SURE TO DISCONNECT THE BATTERY CABLE OF NEGATIVE (–) SIDE.

•

ERRONEOUS SHORT CIRCUITING MAY CAUSE FIRE.

NOTE: Refer to 2-21 for the replacement of fuses.

4-38

4. MAINTENANCE

4.14

PRE-START (EVERY 8 HOURS) INSPECTION & MAINTENANCE

Thoroughly read and understand the chapter "SAFETY PRECAUTIONS" of this MANUAL before operating or servicing the machine. The following inspection and maintenance shall be carried out before starting/after starting and after work.

Refer to chapter 3 "MACHINE OPERATION" Items.

• CHECK COOLANT LEVEL

3-4

• CHECK ENGINE OIL LEVEL

3-5

• MACHINE OPERATION

3-18

• CHECK EACH SWITCH & LEVER 3-15

• CHECK FUEL LEVEL

3-7

• CHECK HYDRAULIC OIL LEVEL

3-5

• CHECK FOR FUEL LEAKAGE

3-7

• CHECK FOR WORKING LIGHT

3-9

• INSPECT BELT CONDITION

3-8

• CHECK WARNING LAMPS

3-9

• EXHAUST GAS COLOUR ABNORMAL SOUND & SMELL 3-15 A. CHECK FOR EXTERNAL CONDITIONS OF MACHINE A dent or distortion which apparently seems not to be severe damage, may cause abnormal contact on internal parts or hoses.

Consult your Dealer for the judgement of necessity for the repair.

B. CHECK CAPSCREWS AND NUTS FOR LOOSENESS AND/OR MISSING Check for missing capscrews and nuts and replace as needed. Check and make sure all capscrews and nuts are properly tightened. Likewise, check and make sure all hose clamps are properly tightened.

An abnormal sound during operation may cause leakage or fire. Use torque values from 4-13 and 4-14 NOTE: Use the tools suitable for the work referring to "ACCESSORY TOOLS", 4-12.

C. CHECK FOR LEAKAGES AND DAMAGES ON EACH CYLINDER, PIPING AND HOSE

WARNING HYDRAULIC LINE IS ALWAYS HIGHLY PRESSURIZED. BE SURE TO RELEASE THE PRESSURE IN THE LINE BEFORE STARTING SERVICE AND/OR MAINTENANCE, OR REFILLING. NEVER USE HANDS TO CHECK FOR LEAKS. HIGH PRESSURE FLUID LEAKS WILL PENETRATE THE SKIN AND CAUSE SEVERE INJURY.

4-39

4. MAINTENANCE Hydraulic oil leakage will slow down a machine. Move the machine to firm level ground and place the attachment in the oil check position and stop the engine.

1

1. Place the safety lock lever in "LOCKED" position, then stop the engine.

2. To check the location of leakage, allow the temperature on each portion of the machine to drop to around 40 C (104 F).

Be sure to wear protective glasses and gloves for the check.

3. Press breather valve with rubber cap on the upper surface of hydraulic reservoir several times (5 to 7 times) and release the pressure in the hydraulic reservoir.

1. HYDRAULIC RESERVOIR 2. AIR BREATHER NOTE: When any abnormalities occur on the machine, immediately stop work and ask your Dealer to make any necessary repairs.

When the volume becomes insufficient for the engine coolant or oil due to leakage, and warning lamp is illuminated.

D. CHECK TRAVEL SYSTEM FOR LEAKAGES AND ABRASION 1. TRAVEL MOTOR 2. SPROCKET 3. LOWER ROLLER 4. CRAWLER SHOE 5. UPPER ROLLER 6. IDLER 1. Check the lower roller, idler and travel motor for any leakages.

2. Check the lower roller, idler and sprocket for abnormal wear and loosened fixing bolts.

3. Slowly travel with the machine and check for any abnormal sound.

NOTE: Consult your Dealer for advice and/or repairs as needed.

4-40

2

4. MAINTENANCE

4.15

50-HOUR (WEEKLY) INSPECTION AND MAINTENANCE

Thoroughly read and understand the chapter "SAFETY PRECAUTIONS" of this MANUAL before operating or servicing the machine.

Perform together with 8-hour (daily) inspection and maintenance.

A. ADJUSTING TRACK TENSION Proper adjustment of the rubber track tension is essential for extending service life of the track and the travel system, and prevention of coming off the track due to insufficient tension.

WARNING THE INSPECTION OF THE TRACK TENSION IS CARRIED OUT WITH ONE SIDE OF MACHINE RAISED. IT IS QUITE DANGEROUS IF THE MACHINE IS ERRONEOUSLY DROPPED. NEVER OPERATE THE MACHINE DURING THE INSPECTION. BE SURE TO CARRY OUT THE WORK WITH THE HELP OF ANOTHER PERSON. OPERATE THE MACHINE IN ACCORDANCE WITH THE SIGNAL FROM THE PARTNER. Refer to 4-22 for the checking and adjustment of rubber track tension.

RUBBER TRACK B. GREASING PINS AROUND BUCKET Request for Greasing Generally the greasing is required at every 50 hours operation or weekly.

1. Move the machine to firm level ground and place the attachment on the ground in the oil check position.

GREASING POSITION

4-41

4. MAINTENANCE 2. Clean the grease fittings before greasing. Replace the grease fitting with a new one, if damaged.

3. Lubricate with a grease gun through the grease fittings shown in right figure with arrows and the table below.

4. Properly wipe off any grease oozed out around the pin connection.

D

C

A B

CAUTION Dispose of all hazardous waste in accordance with government environmental regulations.

No. A

GREASING POINTS Bucket cylinder rod pin

Q’ty 1

B

Idler link/arm connecting pin

1

C

Bucket link pin

1

D

Dipper/bucket connecting pin

1

C. DRAINING WATER FROM WATER SEPARATOR AND CLEANING If the red ring (5) in the water separator sinks down to bottom of the case (8), no water is mixed in. When the ring (5) is floating, water is mixed in up to the level of the ring. Drain the mixed water in accordance with the following procedures.

WARNING FUEL OIL SPILLAGE MAY CAUSE FIRE. WIPE IT UP THOROUGHLY.

1

1. AIR DRAIN PLUG

C

2. FUEL COCK 3. DRAIN COCK

2

4

4. ELEMENT 5. RING (Red)

B

A

D

5 F 6

6. SPRING 7. O-RING

3

8. CASE 9. RING

WATER SEPARATOR

A. IN B. OUT

2

C. CLOSED D. OPEN

7

4

5 6

4-42

8

9

4. MAINTENANCE 1. Place the safety lock lever in "LOCKED" position, then stop the engine.

2. Open the engine guard. After cooling down of each portion, push the handle (2) of the water separator upward to the "CLOSE" position (C).

3. Loosen the ring (9) to remove the case (8) and drain the water out.

NOTE: Pay attention not to lose the red float (5) and spring (6).

CAUTION Dispose of all hazardous waste in accordance with government environmental regulations.

4. Check the water drained for its contamination. And when it is dirty, clean up the element (4) and inside the case (8).

5. Remove the element (4), and clean it with diesel fuel.

6. Replace the O-ring (7) with a new one.

Install the element (4) on the water separator body.

7. Place the O-ring (7) on the case (8), then tighten it up with ring (9).

8. Push the handle (2) downward to "OPEN" position (D).

9. After draining the water, make sure to bleed out the air from the fuel system referring to 4-19.

NOTE: Do not clean up the element with petrol.

4-43

4. MAINTENANCE D. DRAINING WATER AND DEPOSITS FROM FUEL TANK

WARNING • •

MAKE SURE TO STOP THE ENGINE WHEN DISCHARGING FUEL FROM THE FUEL TANK (1).

2

THOROUGHLY WIPE UP THE SPILLED FUEL.

Loosen the drain plug to drain the water and deposits in an empty container.

Since the water is deposited during the night, it is effective to drain before starting up the engine in the morning.

Slew the upperstructure of the machine so that the drain plug (2) comes to midway between the left and right crawlers.

Place a empty container under the drain plug (2) to catch the fuel discharged.

Slowly loosen the drain plug (2) to drain water and deposits mixed in with the fuel.

1

When pure fuel begins to discharge, tighten up the drain plug (2).

NOTE: Check for fuel leakage after tightening up the drain plug.

If fuel is leaking, be sure to stop the engine, and consult your Dealer.

4-44

4. MAINTENANCE E. CHECK FOR BATTERY FLUID LEVEL AND SPECIFIC GRAVITY The battery fluid easily decreases with high temperature in summer season. Check the battery fluid level in the morning before starting operation.

Continuous use of the battery with low fluid lowers battery performance. Check for the battery fluid level periodically, and if insufficient, refill the battery with distilled water before the engine start-up (before charging battery).

WARNING •

•

•

FLAMMABLE GAS (HYDROGEN GAS) IS GENERATED IN THE BATTERY. DO NOT ALLOW SPARKS OR FLAMES TO COME IN CONTACT WITH BATTERIES TO AVOID TRIGGERING AN EXPLOSION.

(H)

BATTERY FLUID HAS STRONG ACID. IT CORRODES METAL VERY RAPIDLY. IF IT ADHERES TO SKIN OR ENTERS INTO EYES, IT CAUSES A BURN OR BLINDNESS.

C

(I)

D

D

(J)

E

E

D

3

IN SUCH CASES, IMMEDIATELY WASH SKIN OR EYES WITH LOTS OF WATER, AND ASK A DOCTOR TO TREAT IT AS SOON AS POSSIBLE.

Check the indicator (A) on the battery, and always keep it at blue colour. Red colour and white colour means insufficient battery fluid and battery charging.

2

1 B

A

1. CAP

INDICATOR INDICATIONS (A)

2. TERMINAL

2

3. TERMINAL COVER A. INDICATOR INDICATIONS

1

B. AIR VENT HOLE

F

C. BLUE

G

D. RED E. WHITE F. UPPER LIMIT G. LOWER LIMIT H. GOOD I.

REFILLING REQUIRED

J. CHARGING REQUIRED 1. Place the safety lock lever in "LOCKED" position, then stop the engine.

2. Referring to "GUARD WITH LOCKING DEVICE & COVERS", 2-19, remove the floor mat and remove the cover of batterie.

The battery is located under floor plate.

3. Remove the caps (1) of each cell to check the fluid level.

4. If battery fluid level is low, refill the cell with distilled water up to the specified level {10~15 mm (0.4 ~ 0.6 in) above the polar plate}.

5. Make sure the air vent holes in the caps (1) are clean and securely tighten the caps (1).

4-45

4. MAINTENANCE 6. If the terminals (2) are dirty, wash it with warm water, then install in position applying grease or spraying rust preventive solution. If the terminal is oxidized, polish it with a wire brush or emery paper.

When it is difficult to obtain enough cranking speed for engine start-up, check the battery fluid for its specific gravity.

If it is insufficient, re-charging is required for the battery.

Standard specific gravity for battery fluid: 1.28 (at 20 C or 68 F) For the specific gravity of battery fluid at cold climate or other specific conditions, refer to 3-42, and set the charging rate around 100%.

If it is difficult even though re-charging is carried out, replacement of the battery by a new one is required.

NOTE: Measure the specific gravity of battery fluid with a gravimeter.

The measured value varies depending on the ambient temperature. Consult your Dealer for advice and/or repairs as needed.

4.16

250-HOUR (3–MONTH) INSPECTION AND MAINTENANCE

Thoroughly read and understand the chapter "SAFETY PRECAUTIONS" of this MANUAL before operating or servicing the machine.

Perform together with 8-hour and 50-hour inspection and maintenance.

A. GREASING ATTACHMENT AND DOZER BLADE PINS Request when apply grease: In ordinary operation, apply grease ever 250 hours of operation or every six months, but under special conditions, observe the following lubrication intervals: •

When operating the machine with a special attachment, apply grease every day before starting work.

•

For underwater digging operations, apply grease to the areas to be immersed in water ever day before and after work.

•

GREASING POSITION

Where the machine is stored for more than one month, apply grease before work.

1 2

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

3

DOZER GREASING POINTS

4-46

4. MAINTENANCE 2. Be sure to clean the grease fittings before the greasing. Replace the grease fittings with new ones, if damaged.

7 4

8

5

3. Use table below to lubricate all connections through grease fittings as shown in Fig. "DOZER GREASING POINTS" and Fig. "ATTACHMENT GREASING POINTS" until grease oozes out.

10 6

11

9

4. Properly wipe off any grease oozed out around the pin connection.

ATTACHMENT GREASING POINTS (1/2)

12

NOTE: Since the dozer foot pin (3) is supported by an iron bushing, earlier greasing is required for it when the dozer is frequently used at the work.

And when greasing for the attachment, make sure to grease to dozer foot pin (3), too.

14

13 ATTACHMENT GREASING POINTS (2/2) No.

GREASING POINTS

Q’ty

No.

GREASING POINTS

Q’ty

No.

GREASING POINTS

Q’ty

1

Dozer cylinder rod pin

1

2

Dozer cylinder foot pin

1

3

Dozer foot pins

1

4

Boom foot pin

1

5

Boom cylinder foot pin

1

6

Boom cylinder rod pin

1

7

Dipper cylinder foot pin

1

8

Dipper cylinder rod pin

1

9

Boom/dipper connecting pin

2

10 Bucket cylinder foot pin

1

11 Bucket cylinder rod pin

1

13 Swing cylinder rod pin

1

14 Swing bracket/frame connecting pin

B. OIL CHANGE FOR ENGINE

WARNING •

DO NOT CARRY OUT THE OIL CHANGE JUST AFTER STOPPING THE ENGINE WHICH REMAINS AT HIGH TEMPERATURE. ALLOW SUFFICIENT TIME FOR THE ENGINE TO COOL DOWN BEFORE MAINTENANCE.

•

THE FIRST OIL CHANGE MUST BE CARRIED OUT AT 50 HOURS OPERATION FOR A NEW MACHINE ENGINE.

Container to receive drained oil : 8.0 L (2.11 gal) or more capacity Oil volume to be refilled : 7.4 L (1.95 gal) (Upper limit of standard volume.)

4-47

12 Swing cylinder foot pin

1 2

4. MAINTENANCE 1. Place an empty container to receive the drained oil under the drain plug (1) located at the bottom of engine.

H

2. Remove the bottom cover (2) under the drain plug.

3. Slowly loosen the drain plug (1) so that the oil does not splash over yourself.

Make sure to clean up any oil spillage.

L 3

4. Check the drained oil. If it contains lots of metal particles and/or foreign materials, consult your Dealer.

4

5. Securely tighten the drain plug (1).

6. Open the engine guard, and remove the filler port (4) cap (Yellow). Refill the engine with the specified oil. Refer to 4-10 for the recommended oil.

7. Start up the engine, operate it for several minutes at idling, and stop the engine. Check the oil level if it exists between the "H" and "L" marks on the dipstick (3) refer to section "C. CHECK ENGINE OIL LEVEL", 3-5.

1

2

C. GREASING THE SLEWING BEARING

WARNING NEVER SLEW THE MACHINE, WHILE FEEDING GREASE TO THE SLEWING BEARING. Feed grease to the slewing bearing, slewing the machine 4 times by 90 each, up to the old grease being oozed out. Only one grease nipple is provided for the slewing bearing.

D. ADJUSTMENT FOR BELT TENSION

WARNING BE SURE TO STOP THE ENGINE WHILE INSPECTION AND MAINTENANCE. OTHERWISE, YOUR FINGER OR HAND MAY BE CAUGHT BY THE FAN OR FAN BELT RESULTING IN INJURY. Check the fan belt for its tension, wear conditions and damages.

Be sure to adjust tension properly.

4-48

4. MAINTENANCE D.1 ADJUSTMENT FOR FAN BELT

1

Fan belt tension adjustment procedure.

1. In case of adjustment of fan belt tension; Loosen cap screw (2) mounting center cover (1) and open center cover (1).

2

4

5

2. Loosen mounting bolt (3) and adjusting bolt (4) slightly.

3. Loosen adjusting bolt (5) to adjust to the specified tension, and tighten mounting bolt (3) and adjusting bolt (4).

3

4. After adjustment, start engine and run it at low idle for about 5 minutes. Then recheck belt tension.

5. Install center cover correctly.

E. REPLACEMENT OF ENGINE OIL FILTER

WARNING THE ENGINE REMAINS AT HIGH TEMPERATURE JUST AFTER STOPPING THE ENGINE. TAKE TIME TO ALLOW THE ENGINE TO COOL DOWN FOR INSPECTION AND MAINTENANCE. NOTE: The oil filter is of a cartridge type which it is not possible to reuse nor clean during filter disassembly.

NOTE: Replace it after 50 hours operation for the first use of new machine.

NOTE: The filter wrench provided on the machine is used for the removing.

1. Stop the engine, and open the engine guard, and remove the under cover.

2. Apply the filter wrench (2) to the filter cartridge (1), and turn the wrench to counterclockwise to remove it.

3. Wipe off any dust on the seal face of filter base, and avoid contamination.

2

1

REMOVAL OF ENGINE OIL FILTER

4-49

4. MAINTENANCE 4. Thinly apply clean engine oil to the packing (A) of new filter cartridge, and install and tighten it up with hand. Then retighten it by about 2/3 turns.

A

5. Start up the engine, and operate it at idling for several minutes to check for any leakage at the installing face.

6. Close the engine guard and install the under cover.

NOTE: When the machine is operated in dusty circumstances, a shorter interval is required for the replacement.

NOTE: When some metal particles are found on the element removed, consult your Dealer.

CAUTION Dispose of all hazardous waste in accordance with government environmental regulations.

F. CHECKING RADIATOR HOSES Replacing the hoses before any problems occur is both economical and good maintenance practice. This will reduce costs and minimize unexpected interruption of working. Immediately replace the hose if it is cracked, worn, or if water is leaking from it. This will prevent serious problems, such as the engine overheating.

1. Check the hoses for water leakage due to loose clamps or cracked and worn hoses.

2. Tighten any loose clamps and replace any cracked or worn hoses following the procedures below.

4-50

4. MAINTENANCE G. REPLACING RADIATOR HOSES

WARNING

1

DANGER OF HIGHLY PRESSURIZED STEAM GENERATED IN THE RADIATOR. WHILE THE COOLANT IS KEPT AT HIGH TEMPERATURE AND PRESSURE, DO NOT LOOSEN NOR OPEN THE RADIATOR CAP. •

WHEN OPENING THE RADIATOR CAP, STOP THE ENGINE.

•

TAKE SUFFICIENT TIME TO ALLOW THE COOLANT TEMPERATURE TO COOL DOWN.

1. Loosen the radiator cap (1) slowly. Ensure that pressure has been released. Push the cap down and hold it down while turning to remove.

3

2. Remove the under cover located lower position of radiator, and loosen the drain plug (2). Then drain the coolant into a suitable container.

4

3. Loosen the hose clamp and disconnect the damaged hose; then replace with a new one.

4. Install the drain plug.

2

5. Fill the radiator (3) with coolant, then fill the reservoir (4) with coolant, too. Refer to 3-4.

6. After filling, tighten securely the radiator cap.

7. Install the under cover to original position.

H. CHECKING/CLEANING/REPLACING AIR CLEANER ELEMENT

CAUTION Wear protective glasses or goggles when using compressed air.

NOTE: The air cleaner restriction lamp will not illuminate if the element is torn or if the air cleaner housing is not sealed properly. If "AIR CLEANER RESTRICTION" lamp is illuminated, inspect, clean, and/or replace the air cleaner elements.

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

NOTE: When replacing element, cover the engine intake port to prevent the entry of dust.

Cleaning and replacement of outer element.

•

Cleaning When warning is indicated on multi display.

•

Replacement After cleaning for the 6th time or an elapse of 1 year.

4-51

4. MAINTENANCE H.1 CLEANING OR REPLACEMENT OF OUTER ELEMENT

2

1 3

2

1 3

a. Release two clamps (2) from the air cleaner cover. b. Remove the air cleaner outer element (1) from the housing. c. Clean the inside of air cleaner housing d. To clean the outer element (1), blow compressed air {less than 0.3 MPa (43 psi)} up and down along the folds of the filter element interior to remove clogged dust or other contaminants. e. 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. f.

Install the outer element (1) in the housing.

g. Install the cover on two clamp (2) positions, directing the mark "TOP" on the cover to the inlet side.

CAUTION Install the air filter so that the "TOP" position mark is facing up but to avoid interference by intake hose, incline the air filter casing 15 to engine side.

CAUTION Carefully hold the o-ring. Water inside cause engine failure. h. If the illuminated lamp appears on the monitor panel within the 6 times cleaning of outer element, replace the element with new one.

H.2 REPLACEMENT OF INNER ELEMENT a. Remove the inner element (3). b. Fit new inner (3) and outer elements (1), and install the cover.

CAUTION Carefully hold the o-ring. Water inside causes engine failure.

NOTE: For machines equipped with W (double) element the inner element must be replaced together with the outer element. Do not fail to replace the inner element with a new one.

4-52

4. MAINTENANCE

4.17

500-HOUR (6-MONTH) INSPECTION AND MAINTENANCE

Thoroughly read and understand the chapter "SAFETY PRECAUTIONS" of this MANUAL before operating or servicing the machine.

Perform together with 8 to 250 hour inspection and maintenance.

A. REPLACEMENT OF FUEL FILTER

WARNING •

EACH PORTION OF THE ENGINE IS KEPT AT HIGH TEMPERATURE JUST AFTER THE OPERATION. START THE SERVICING AFTER COOLING DOWN EACH PORTION.

•

THOROUGHLY WIPE UP THE FUEL SPILLED OVER, OTHERWISE IT MAY CAUSE FOR FIRE.

NOTE:The oil filter is of a cartridge type which is not able to reuse nor make it clean with the filter disassembling.

Replace it with unit.

1. Stop the engine, and open the engine guard, and remove the under cover.

1

2. Apply the filter wrench to the filter cartridge (1), and turn the wrench with spanner to counter-clockwise (A) to remove it.

3. Wipe off any dust on the seal face of filter base, and avoid contamination.

A

REMOVAL OF FUEL FILTER 4. Thinly apply clean engine oil to the packing (A) of new filter cartridge, and install and tighten it up with hand. Then retighten it by about 2/3 turns.

A

5. Start up the engine, and operate it at idling for several minutes to check for any leakage at the installing face.

6. Close the engine guard and install the under cover.

Dispose of all hazardous waste in accordance with government environmental regulations.

CAUTION Dispose of all hazardous waste in accordance with government environmental regulations.

4-53

4. MAINTENANCE

4.18

1000-HOUR (12-MONTH) INSPECTION AND MAINTENANCE

Thoroughly read and understand the chapter "SAFETY PRECAUTIONS" of this MANUAL before operating or servicing the machine.

Perform together with 8 to 500 hour inspection and maintenance.

A. REPLACEMENT OF HYDRAULIC RETURN FILTER The return filter keeps the hydraulic oil clean by removing any foreign material that may be in the oil. This will prevent the hydraulic equipment from becoming damaged and prolong the equipment's life. Thus, since the return filter is a very important part, treat it with care.

WARNING •

NEVER CHANGE OILS OR FILTER ON A MACHINE THAT HAS JUST FINISHED WORKING. ALLOW MACHINE TO COOL FIRST UNTIL OILS AND FLUIDS ARE WARM, NOT HOT.

•

RELEASE HYDRAULIC RESERVOIR PRESSURE, BEFORE WORKING WITH ANY HYDRAULIC COMPONENT, ACCORDING TO THE PROCEDURES PROVIDED BELOW.

•

WHEN REPLACING ANY HOSE OR SEALS, MAKE SURE THE ATTACHMENTS ARE WELL SECURED TO AVOID SUDDEN MOVEMENT OF ATTACHMENT. SLOWLY REMOVE BOLTS TO RELEASE ANY HYDRAULIC PRESSURE DURING DISASSEMBLY.

1. Place the machine on the level ground, lower the bucket to the ground and stop the engine.

2. Open the cover on the hydraulic reservoir with the aid of starter switch key, and hold it with a stay.

3. Clean around the filter mounting section so that foreign matter, dirt and dust do not get into the return filter.

HYDRAULIC OIL LEVEL CHECK POSITION

4-54

4. MAINTENANCE 4. Press the valve (several times : 5 to 7 times) together with the breather cap (8), and bleed the hydraulic oil reservoir of the remaining pressure.

1 2

5. Remove capscrew (1), spring washer (2) and cover (3) from the upper surface of the reservoir.

3

6

6. Take out spring (4), valve (5) and element (6) out from the reservoir.

7

7. Replace O-ring (7) fitted on the face of cover (3).

4

8. Clean the parts taken out with light oil.

5

9. Install element by the reverse procedures of items (5) and (6) above-mentioned.

10. Install cover (3).

8

Tightening torque : 23.5±2 N•m (17±1.4 lbf•ft) 11. Start the engine, move respective operating lever, place the machine in the position to check the oil level and check the hydraulic oil level.

12. Remove the stay, return the cover on the hydraulic oil reservoir to the normal position, and lock it.

NOTE: For a machine with a hydraulic hammer, the deterioration of hydraulic oil is hastened by the hammer work compared with the standard digging with bucket. Earlier replacement for the line filter and hydraulic oil is required. Follow the replacement interval on page 7-11.

B. REPLACEMENT OF FUEL FILTER

WARNING •

EACH PORTION OF THE ENGINE REMAINS AT HIGH TEMPERATURE JUST AFTER THE OPERATION. START THE SERVICING AFTER COOLING DOWN EACH PORTION.

•

THOROUGHLY WIPE UP ANY FUEL SPILLED, OTHERWISE IT MAY CAUSE FIRE.

NOTE: The oil filter is of a cartridge type which it is not possible to reuse nor clean during filter disassembling.

Replace it with unit.

4-55

4. MAINTENANCE 4. Press the valve (several times : 5 to 7 times) together with the breather cap (8), and bleed the hydraulic oil tank of the remaining pressure.

1 2 3

5. Remove capscrew (1), spring washer (2) and cover (3) from the upper surface of the tank.

6

7

6. Take out spring (4), valve (5) and element (6) out from the tank.

4

7. Replace O-ring (7) fitted on the face of cover (3).

5

8. Clean the parts taken out with light oil.

8

9. Install element by the reverse procedures of items (5) and (6) above-mentioned.

10. Install cover (3).

Tightening torque : 23.5±2 N•m {17±1.4 lbf•ft} 11. Start the engine, move respective operating lever, place the machine in the position to check the oil level, and be sure of the hydraulic oil level.

12. Remove the stay, return the cover on the hydraulic oil tank to the normal position, and lock it.

NOTE: For the machine with the breaker, the deterioration of hydraulic oil is hastened by the breaker work compared with the standard digging with bucket. Earlier replacement for the line filter and hydraulic oil is required. Follow the replacement interval for them to 711.

4-56

4. MAINTENANCE B. REPLACEMENT OF COOLANT

WARNING •

DANGER OF HIGHLY PRESSURED STEAM GENERATED IN THE RADIATOR. WHILE THE COOLANT IS KEPT AT HIGH TEMPERATURE, DO NOT LOOSEN NOR OPEN THE RADIATOR CAP.

•

WHEN OPENING THE RADIATOR CAP, STOP THE ENGINE•WHEN OPENING THE RADIATOR CAP, STOP THE ENGINE.

•

ALLOW SUFFICIENT TIME FOR THE ENGINE TO COOL DOWN BEFORE SERVICING.

CAUTION •

The anti-freeze agent is flammable and detrimental to human body. Keep away from flames and sparks.

•

Pay attention the anti-freeze agent does not splash on skin or enter into eye. If it splashes on skin or enters into eye, immediately wash skin or eye with lots of clean water, and ask a doctor to treat it.

Use soft water with less impurities as basic coolant.

Use "Long Life Coolant" mixing it in the coolant to more than 30% of density to prevent the cooling line from corroding and freezing. The density of "Long Life Coolant" must correspond to the expected lowest ambient temperature.

Refer to 4-10 for the required density of "Long Life Coolant". Provide an empty container to receive the coolant discharged.

1

1. Stop the engine. Open the engine guard. Start the servicing with the coolant cooled down enough.

2. Loosen the radiator cap (1) slowly. After ensuring that the pressure has been released, push the cap down and hold it down while turning to remove.

3

3. Discharge the coolant through the drain hose into the empty container.

4

4. After discharging, install the drain plug (2). Then fill the cooling line with a mixture of water and cleaning solvent (radiator cleaner).

2

4-57

4. MAINTENANCE 5. Operate the engine at a speed slightly faster than idling to raise the coolant temperature to 80 C (176 F) or more within white range on the thermometer for coolant temperature. Then, operate the engine for approximately 10 minutes.

6. Stop the engine and loosen the radiator drain plug (2). Flush the radiator (3) with tap water until the water draining becomes clean.

7. Install the radiator drain plug (2). Fill the radiator with tap water in which LONG LIFE COOLANT has been mixed (30% or more) up to the radiator cap (1). Rotate the engine for a while to fully release air from the cooling system.

8. Stop the engine. Check the coolant level (the reservoir (4) water level should be between FULL and LOW). Refer to 3-4. Make sure level is to specifications.

9. After checking for leakages, close the engine guard.

NOTE: When "Long Life Coolant" is not used, replace the coolant two times a year in spring and autumn.

CAUTION The following procedures require professional skill because they are for the inspection and maintenance for inside the engine. Since the adjustment also requires special knowledge and skill, consult your Dealer.

C. CHECKING AND ADJUSTMENT FOR VALVE CLEARANCE This is to correct the time lag on the operating timing of exhaust and intake valves. Negligence for this service causes faults such as output shortage, improper exhaust gas colour, noise and so on.

D. CHECKING AND ADJUSTMENT FOR STARTER AND GENERATOR (DYNAMO) There is a possibility of worn-out brushes and/or lack of grease lubrication on bearing.

Adjustment is necessary to ensure good starting and power generation.

4-58

6

4. MAINTENANCE

4.19

2000-HOUR INSPECTION AND MAINTENANCE

Thoroughly read and understand the chapter "SAFETY PRECAUTIONS" of this MANUAL before operating or servicing the machine. Perform together with 8 to 1000-hour inspection and maintenance.

A. OIL CHANGE IN HYDRAULIC OIL RESERVOIR AND CLEANING OF SUCTION STRAINER

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 RESERVOIR PRESSURE BEFORE WORKING WITH ANY HYDRAULIC COMPONENT. Container to receive discharged fluid : 65 L (17.2 gal) or more capacity Volume for filling : 63 L (16.6 gal) 1. Slew the machine so that the drain plug on the hydraulic oil reservoir comes to midway between the both crawlers.

2. Remove the right side guard.

3. Carry out the work in the same procedure referring to items [2] to [4] in 4-54.

8

4. Release the remaining pressure of the hydraulic tank, put a oil pan (8) under drain plug (1). Remove drain plug (1) with a spanner (27 mm), and drain the remaining oil.

1

5. Tighten drain plug (1).

Tightening torque : 73.5±5 N•m {54.2±3.7 lbf•ft} 6. Loosen four capscrews (2) and lock washers, and remove cover (4).

7. Check O-ring (5) for possible damage, and replace it with new one when it is damaged.

2 3

NOTE • When loosening the drain plug (1), pay attention not to pour the fluid over yourself.

• Don’t drop tools or capscrews and so on into hydraulic tank.

4 F

CAUTION Dispose of all hazardous waste in accordance with government environmental regulations.

4-59

5

4. MAINTENANCE 8. Remove the suction strainer (6).

9. Remove the dust, etc. adhered on suction strainer (6) and wash it with clean diesel fuel or wash solvent. When suction strainer (6) is damaged, replace it with new one.

7

10. Check the bottom of strainer (6) and O-ring (7) for possible damage. When it is worn or damaged, replace it with new one.

m

m

0 46

11. Insert and fit suction strainer (6).

12. Fill the hydraulic oil tank with the hydraulic oil from filling port (F) referring to the item "LUBRICANT, FUEL & COOLANT SPECIFICATIONS".

2 3

13. Install cover (4) with capscrew (2) and lock washer (3).

4

Tightening torque : 23.5±2 N•m {17±1.4 lbf•ft}

6

14. Install the right side guard.

F

15. After starting the engine and rotating it for several minutes (5 to 7) at low idling speed, carry out the telescopic motion of each cylinder and the slewing operation, return the machine to the hydraulic oil level check position, and after oil level check, make up the shortage of oil.

5

4-60

4. MAINTENANCE B. CLEANING LINE FILTER OF PILOT VALVE AND IN-LINE FILTER OF SOLENOID VALVE

WARNING •

THE HYDRAULIC LINE IS ALWAYS PRESSURIZED. DO NOT CARRY OUT ANY CHECK AND SERVICING BEFORE RELEASING THE INSIDE PRESSURE.

•

TO RELEASE INSIDE PRESSURE IN THE HYDRAULIC OIL RESERVOIR, DEPRESS RUBBER CAP ON THE RESERVOIR SEVERAL TIMES (5 TO 7 TIMES).

•

MAKE SURE TO CONTAIN ANY SPILLAGE TO AVOID FIRE.

The "P port" of right and left pilot valves (for operation and travel) and solenoid valve are equipped with a connector with a filter. Dust, etc. on the filter will decrease oil flow. If dust, etc. enter in the valve it may cause trouble.

Take out and clean filter, periodically.

1. Move the machine to firm level ground, place the attachment in the oil check position and stop the engine.

5

4

2. Carry out the air releasing for the hydraulic line referring to 4-17.

2

3. Loosen 2 bolts (3) on the operating box to remove the cover.

1

4. Disconnect the hose (1) connected to "P port" on the pilot valve (4) at first, then remove connector with filter (2).

After removal, plug the bore to prevent entry of foreign matter.

5. Wash and clean the filter with diesel fuel and use compressed air to remove dust.

3 3

6. Check the O-ring (5) for damages, and replace it a with new one, if damaged.

7. After cleaning, install it in the original position in the reverse order of the above [3] and [4].

Refer to 4-14 for the tightening torque for connector and hose.

Then the in-line filter (7) of solenoid valve (6) is removed for cleaning.

8. Remove the right-hand guard (8).

4-61

4. MAINTENANCE 9. After removal of the hose, remove the in-line filter assy (7) from the tee installed on the solenoid valve (6). After removal, the oil holes of the tee and hose should be plugged.

7a. CASE 7b. STRAINER 7c. LABEL 7d. O-RING 7e. NIPPLE 7f. O-RING 10. Remove the case (7a) and the nipple (7e), and then remove strainer (7b) with screwdriver (–).

11. Spray the light oil or air on the strainer (7b) to clean.

Don't forget to clean the inside of the case (7a).

Then, check the O-ring (7d) for possible damage, if it is damaged, replace it with a new one.

12. Install the strainer (7b) on the nipple (7e) with screwdriver (–), and fit it in the in-line filter case (7a).

Tightening torque : 59 to 79 N•m (43 to 58 lbf•ft) 13. Remove the plug, install the in-line filter assy (7) on the solenoid valve (6), and then install hose (1).

Then elbow with filter (9) of pilot valve (10) for travel is removed for cleaning.

7a

7b

7c

7d

IN-LINE FILTER 14. Remove the floor mat and floor plate. Disconnect the hose (11) connected to "P port" on the pilot valve (10) at first, then remove the elbow (9). After removal, plug the bore to prevent entry of foreign matter.

12 9 11

P

10

4-62

7e

7f

4. MAINTENANCE 15. Dust tends to accumulate on the inside elbow (9) (dented portion). Make sure to clean parts properly to avoid contamination (projected portion).

12

16. Check the O-ring (12) for damage, and replace it with a new one, if damaged.

13

17. After cleaning, install it to the original position in the reverse order of the above removal. Refer to 4-14 for the tightening torque for the adapter hose (11).

18. Install the floor mat and floor plate.

9

C. OIL CHANGE FOR TRAVEL SPEED REDUCTION UNIT

WARNING •

THE OIL TEMPERATURE IS VERY HOT JUST AFTER THE MACHINE OPERATION.

•

START THE SERVICING AFTER LOWERING THE OIL TEMPERATURE. RESIDUAL PRESSURE REMAINING IN THE TRAVEL MOTOR MAY CAUSE FLYING OUT OF PLUG OR SPOUTING OUT OF OIL ON LOOSENING THE PLUG. SLOWLY LOOSEN THE PLUG WITH CARE.

Container to receive discharged oil : 1.0 L (0.26 gal) or more capacity Oil volume for filling : 0.9 L (0.24 gal) -LH/RH each

2 3

Change the oil after 50 hours operation for the first use of new machine.

1. Set the machine on a level ground so that the DRAIN port (1) comes just to the bottom.

GL

2. Provide a container under the DRAIN port (1) to receive the discharged oil.

1

3. Slowly remove the plugs of FILL port (2) and LEVEL port (3) with an Allen wrench.

Then remove the plug of DRAIN port (1) to discharge oil into the container.

4. Apply a sealing (teflon) tape on the thread of plug for DRAIN port (1) and securely tighten it.

5. Slowly fill with oil through the FILL port (2), up to overflowing of oil from the LEVEL port (3). See "LUBRICANT, FUEL & COOLANT SPECIFICATIONS", 4-10, for the recommended gear oil.

DISCHARGE OIL

4-63

4. MAINTENANCE 6. Apply a sealing (teflon) tape on the thread of plug for LEVEL port (3), and securely tighten it.

Thoroughly wipe off any oil spilled.

7. Confirm no oil leakages traveling the machine slowly.

NOTE: Check the waste oil. If any metal particles are found, consult your Dealer.

GREASING D. GEAR OIL CHANGE FOR IDLER

WARNING HIGHLY PRESSURIZED GREASE IS CONTAINED IN THE TRACK TENSIONING GREASE CYLINDER. WHEN LOOSENING THE GREASE NIPPLE FOR THE TENSION ADJUSTMENT OF TRACKS OR DISASSEMBLING, GRADUALLY LOOSEN THE GREASE NIPPLE ONE TURN TO RELEASE THE PRESSURIZED GREASE SLOWLY. 1. TRAVEL MOTOR 2. SPROCKET 3. LOWER ROLLER 4. TRACK 5. UPPER ROLLER 6. IDLER The idlers have to be removed from the track frame to change the gear oil for each of them. The following is to describe procedures to remove/reinstall and change the gear oil each of them. Refer to 4-10 for the oil and grease to be used and the required volume.

4-64

4. MAINTENANCE D.1 LOWER ROLLER 1. Loosen the rubber crawler shoe of the side to change the gear oil referring to 4-25.

2. The fixing capscrews (1) of lower roller is a bit loosened in advance. (around one turn)

5

3. Start up the engine, and lift up one side of the machine, with boom and arm getting down the back side of bucket to the ground.

4. Support the machine with a safety support (5), etc., then stop the engine.

5. Remove the capscrews (1) with washers (2) which are provided to install the lower roller to the crawler frame at two positions of inside and outside. Then remove the lower roller (3).

3

4

6. Remove the feeding port plug (4) with the allen wrench, and discharge the old gear oil.

1

1

2

2

7. Fill in the specified volume (70 cc or 4.3 cu•in) of gear oil through the feeding port.

8. Apply a sealing (teflon) tape to thread on the plug (4), and securely tighten it. Thoroughly wipe off oil adhered to periphery.

9. Apply Loctite #262 to thread on the capscrews (1), and temporarily install the lower roller (3) to the crawler frame.

LOWER ROLLER

10. Remove the safety support which supports the machine to get down the machine to the ground, then tighten up the capscrew (1).

Tightening torque : 28.5 ± 3 kgf•m {21 ± 2 lbf•ft} 11. Again lift up the machine to adjust the crawler shoe tension referring to 4-46.

D.2 IDLER For the gear oil change of idler, the rubber crawler shoe of the changing side has to be removed.

WARNING THE REMOVAL AND INSTALLATION OF THE RUBBER CRAWLER SHOE REQUIRES TO LIFT UP ONE SIDE OF THE MACHINE. IT IS QUITE DANGEROUS IF THE MACHINE IS ERRONEOUSLY FALLEN DOWN. NEVER OPERATE THE MACHINE EXCEPT THE RUBBER CRAWLER SHOE DURING SUCH WORK.

4-65

4. MAINTENANCE 12. Remove the rubber track referring to 4-20. Be sure to apply the safety support, etc. Stop the engine.

A

13. Pull off the idler (1) and adjuster (2) from the track frame.

2 1

Weight of idler + Idler Adjuster = approx. 69.3 kg (153 lb)

6

14. Remove the feeding port plug (3) with an Allen wrench to discharge the old gear oil.

5

15. Fill in specified volume (70 cc to 80 cc (4.3 to 4.9 cu•in) of gear oil through feeding port.

3

4

GREASING POINTS 5. Apply a sealing (teflon) tape to thread on the plug (3), and securely tighten it. Thoroughly wipe off oil in the periphery.

3

6. Apply grease to the sliding face (A) on the piston (4) and cylinder (5) of the idler adjuster (2).

7. Install the idler so that the feeding port plug (3) of idler and the grease nipple (6) of idler adjuster (2) are facing outwards.

8.

Install the rubber track referring to 4-20.

9. Adjust the tension on the rubber track referring to 424. After confirmation of rubber track engagement with the idler and the conditions for tension, lower the machine to the ground, removing the safety support, etc.

IDLER D.3 UPPER ROLLER For idler gear oil change, the rubber track on the corresponding side has to be removed.

1. After stopping the engine, ensure that the machine is in parking position.

2.

Loosen the rubber track (6) of the side on which gear oil is to be changed according to 4-25.

3. Raise the track with a hydraulic jack (5).

4-66

4. MAINTENANCE 4. Remove the nuts (2) and the capscrews (3) of the support part fixing the shaft of the upper roller (1), and remove this roller.

5. Remove the oil supply port plug (4) with an Allen wrench, and drain old gear oil.

6. Fill the specified amount (45 cc) of gear oil through the oil supply port.

7. Wind seal tape on the plug (4) and tighten it securely.

Wipe off any oil around the plug.

8. Install the roller in reverse order from removal.

After applying thread lock sealant (Three Bond #1324) on thread of the capscrews (3), tighten the screws.

UPPER ROLLER

Tightening torque: 66±7 N•m (48±5 lbf•ft) E. REPLACEMENT OF GREASE IN SLEWING GREASE BATH If water is mixed in with the grease, it may become muddy or white. When such machine work as immersing in water closely to the slewing bearing is repeated, grease in the slewing bearing as well as in the grease bath may be deteriorated. The deteriorated grease may cause damage on the pinion gear of the slewing motor and internal gears of the slewing bearing. Consult an approved Dealer for the judgement for the replacement of grease.

1. UPPER ROLLER 2. SLEWING BEARING A. SURFACE B. RIVER BED C. GREASE NOTE: The following jobs require professional skill because they concern the inspection and maintenance for inside the engine. Since the adjustment also requires special knowledge and skill, consult an approved Dealer.

F. CHECKING AND ADJUSTMENT FOR FUEL INJECTION TIMING This is to adjust the fuel injection timing to optimize the engine performance.

G. CHECKING AND ADJUSTMENT FOR CONTACT SURFACE OF INTAKE AND EXHAUST VALVE This is to ensure the gas-tightness on the exhaust and intake valves to optimize the engine performance.

4-67

4. MAINTENANCE

4.20

INSPECTION MAINTENANCE CHECK LIST

MACHINE MODEL:________________ SERIAL No.:________________ MACHINE HOURS:________________ Table 1:

ITEM

Table 1:

OK

MAINT.PERFORMED

ITEM

OK

ENGINE OIL LEVEL

SLEWING REDUCTION OIL

ENGINE COOLANT LEVEL

SLEWING RING GEAR

CHECK FOR FLUID LEAKS

GREASE BATH LEVEL

CHECK BELT TENSION

SLEWING RING PINION

CHECK FUEL LEVEL

SLEWING RING SEAL

DRAIN WATER SEPARATOR

SWIVEL JOINT SEAL

CHECK AIR CLEANER

DRAIN WATER FROM BATH

CHECK ENGINE ELECTRICAL

GREASE SLEWING RING

DRAIN WATER FROM FUEL

CHANGE GREASE BATH

CHANGE ENGINE OIL

CHECK BOLT/HARDWARE

CHANGE OIL FILTER

CHECK LINES FOR DAMAGE

CHANGE FUEL FILTER

CHECK STEPS

CHANGE WATER SEPARATOR

CHECK FRAME STRUCTURE

CHECK AIR INTAKE INDICATOR

CHECK CRAWLERS

CHECK FAN ASSEMBLY

CHECK SPROCKET WEAR

CHECK BELT TENSIONER

CHECK IDLER WEAR

CLEAN RADIATOR

CHECK ROLLER WEAR

CHANGE ENGINE COOLAND

CHECK CRAWLER TENSION

AIR CLEANER ELEMENTS

ADJUST CRAWLER TENSION

ADJUST VALVE CLEARANCE

TRAVEL REDUCTION

HYDRAULIC OIL LEVEL

CHECK BOOM & ARM

CHECK HYD FUNCTION

BUCKET TEETH

CHECK FOR OIL LEAKS

SIDE CUTTERS

CHECK HOSES/PIPINGS

GREASE BOOM PINS

CLEAN SUCTION SCREEN

GREASE ARM PINS

CHANGE RETURN FILTER

GREASE BUCKET PINS

PILOT MANIFOLD FILTER

GREASE SWING PIN

CHANGE HYDRAULIC OIL

GREASE DOZER PIN

CLEAN HYDRAULIC TANK

CHECK COOLANT ADDITIVE

INSPECT ALL WIRING

CHECK CRAWLER SHOE

MAINT.PERFORMED

BATTERY ELECTROLYTE BATTERY SERVICE HYD.FUNCTION OPERATION CHECK SWITCHES CHECK WARNING LIGHTS CHECK HORN CHECK DISPLAY MONITOR

These item include non-equipped part by the machine specification.

MECHANIC: SIGNATURE:

4-68

DATE:

5. TRANSPORTATION

5-1

5. TRANSPORTATION

5-2

5. TRANSPORTATION

5.1

WHEN PREPARING TRANSPORTATION PLANS

•

Before preparing to transport the machine, refer to the chapter 6. "SPECIFICATIONS"and check the total weight, height, width, length, traveling speed, ground pressure,etc.

•

Survey the width of roads, bridges, road surface conditions and traffic conditions for transportation.

•

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

A. LOADING/UNLOADING THE MACHINE

WARNING •

SLOW SPEED TRAVEL IS NECESSARY TO LOAD AND UNLOAD THE MACHINE.

•

IT IS DANGEROUS TO USE THE ATTACHMENT FOR LOADING AND UNLOADING THE MACHINE. DO NOT USE SUCH METHODS.

•

DO NOT OPERATE OTHER OPERATING LEVERS THAN THE TRAVEL LEVER WHEN ON THE RAMP

•

PAY ATTENTION TO THE SUDDEN TRANSFER OF THE CENTRE OF GRAVITY OF THE MACHINE ON THE BORDER BETWEEN THE TRUCK/TRAILER AND THE RAMP.

Refer to section "TRANSPORTATION, 1-41" for caution on loading/unloading the machine.

B. USE OF PLATFORM OR EARTH BANKING 1. Make the width of the earth banking (raising the ground level) sufficient for the machine width.

2. Make the earth banking strong enough in order not to turn over the machine during loading/unloading due to broken sides slope on the earth banking. If necessary, provide some supporting posts to reinforce both side of the banking.

3. The height of the platform or banking must correspond to that of the base of the truck/trailer.

A

4. When loading the machine, climb up to the truck/ trailer from front end of the machine in the case of a machine with attachment, and from back end for the machine without attachment.

5. Set the machine at the prescribed position on the truck/trailer.

A. 15 or less

5-3

5. TRANSPORTATION C. SECURING THE MACHINE After the machine is loaded and positioned, fix the machine by the following procedures.

1. Lower the dozer blade.

2. Fully extend the bucket and dipper cylinders, then slowly lower the boom.

A. OVERALL HEIGHT B. OVERALL LENGTH

A

B

B

NOTE:To prevent the bucket cylinder from damages during transport, apply a wooden block to the edge of bucket link so it does not touch the floor.

3. Pull up the safety lock lever and place it in "LOCKED" position (B).

A

A

4. Turn OFF all switches and pull out the starter switch key. Lock all the covers and the door (CAB SPEC).

1

5. Apply the blocks to both the front and rear of the track and fix them with a wire cable (1) of sufficient strength. This will prevent the machine from moving forward/backward or rolling due to vibration from the truck/trailer.

1. WIRE CABLE A. PAD FOR EDGE B. LOCKED (Up) POSITION

5-4

5. TRANSPORTATION

5.2

LIFTING PROCEDURES FOR THE MACHINE COMPLETE (E40.2SR)

WARNING THE WIRE CABLES TO BE USED FOR LIFTING THE MACHINE SHOULD HAVE SUFFICIENT STRENGTH TO SUPPORT THE MACHINE WEIGHT.

•

IMPROPER LIFTING METHODS AND/OR CABLE RIGGING MANNER MIGHT CAUSE A MOVEMENT OR SLIP OF THE MACHINE WHILE IT IS BEING LIFTED, RESULTING IN SERIOUS INJURY OR DAMAGE TO THE MACHINE.

•

DO NOT IMPOSE A LOAD SUDDENLY ON THE WIRE CABLES AND SLINGS.

•

WHEN THE LIFTING WORK IS CARRIED OUT IN COOPERATION WITH MULTIPLE PERSONS, BE SURE TO CHECK EVERY SITUATION BY EXCHANGING SIGNALS WITH EACH OTHER.

•

DURING THE LIFTING WORK, KEEP ANY PERSONS AWAY FROM THE LIFTED MACHINE, ESPECIALLY UNDER THE MACHINE.

A

4800mm {15’9"}

•

(B)

Carry out the lifting work on level ground.

1. Manipulate each operating lever to put the machine in a position as shown in the figure.

(A)

2. Operate the boom swing pedal to face the boom directly forwards.

3. Stop the engine, and place the safety lock lever in "LOCKED" position. Then leave the machine after ensuring there are no abnormalities around the operator’s seat.

65mm {2.6"}

4. Install shackles to both bores (A) provided at both ends of the dozer blade, and put the wire cables on them.

B

5. Put the wire cables on the (B) portion of the boom.

7. Slightly lift the machine to ensure the balance, then lift up the machine.

4800mm {15’9"}

6. If any portions of the wire cables directly touch the machine when the wire cables are lifted, protect the machine from damage by means of applying a piece of wood or rag between them.

(B)

A Canopy version (weight machine) - with rubber shoe: 4200 kg (9620 lbs) - with iron shoe: 4300 kg (9480 lbs)

(A)

B Cab version (weight machine) - with rubber shoe: 4340 kg (9570 lbs) - with iron shoe: 4400 kg (9790 lbs) 65mm {2.6"}

5-5

5. TRANSPORTATION

5.3

LIFTING PROCEDURES FOR THE MACHINE COMPLETE (E50.2SR)

WARNING THE WIRE CABLES TO BE USED FOR LIFTING THE MACHINE SHOULD HAVE SUFFICIENT STRENGTH TO SUPPORT THE MACHINE WEIGHT.

•

IMPROPER LIFTING METHODS AND/OR CABLE RIGGING MANNER MIGHT CAUSE A MOVEMENT OR SLIP OF THE MACHINE WHILE IT IS BEING LIFTED, RESULTING IN SERIOUS INJURY OR DAMAGE TO THE MACHINE.

•

DO NOT IMPOSE A LOAD SUDDENLY ON THE WIRE CABLES AND SLINGS.

•

WHEN THE LIFTING WORK IS CARRIED OUT IN COOPERATION WITH MULTIPLE PERSONS, BE SURE TO CHECK EVERY SITUATION BY EXCHANGING SIGNALS WITH EACH OTHER.

•

DURING THE LIFTING WORK, KEEP ANY PERSONS AWAY FROM THE LIFTED MACHINE, ESPECIALLY UNDER THE MACHINE.

A

4800mm {15’9"}

•

(B)

Carry out the lifting work on level ground.

1. Manipulate each operating lever to put the machine in a position as shown in the figure.

(A)

2. Operate the boom swing pedal to face the boom directly forwards.

3. Stop the engine, and place the safety lock lever in "LOCKED" position. Then leave the machine after ensuring there are no abnormalities around the operator’s seat.

30mm {1.2"}

4. Install shackles to both bores (A) provided at both ends of the dozer blade, and put the wire cables on them.

B

5. Put the wire cables on the (B) portion of the boom.

7. Slightly lift the machine to ensure the balance, then lift up the machine.

4800mm {15’9"}

6. If any portions of the wire cables directly touch the machine when the wire cables are lifted, protect the machine from damage by means of applying a piece of wood or rag between them.

(B)

A Canopy version (weight machine) - with rubber shoe: 4630 kg (10210 lbs) - with iron shoe: 4730 kg (10430 lbs)

(A)

B Cab version (weight machine) - with rubber shoe: 4770 kg (10520 lbs) - with iron shoe: 4870 kg (10740 lbs) 30mm {1.2"}

5-6

5. TRANSPORTATION

5.4

LOAD SPECIFICATIONS

A. BOOM WITH DIPPER CYLINDER (E40.2SR) L×H×W

mm (ft-in)

Weight

kg (lbs)

2,790 × 1,070 × 310 {9’1.8" × 3’6.1" × 12.2"} 240 {530}

A. BOOM WITH DIPPER CYLINDER (E50.2SR) mm (ft-in)

Weight

kg (lbs)

2,910 × 1,040 × 310 {9’6.6" × 3’4.9" × 12.2"} 240 {530}

H

L×H×W

B. DIPPER & STANDARD BUCKET (E40.2SR) Dipper 1.43 m {4’8.30"} + Bucket 0.14 m3 {0.183 cu•yd}

Combination L×H×W

mm {ft-in} 2,630 × 510 × 600 {8’7.5" × 20.1" × 23.6"}

Weight

kg {lbs}

280 {620}

Dipper 1.70 m {5’6.93"} + Bucket 0.14 m3 {0.183 cu•yd} 2,890 × 510 × 600 {9’5.8" × 20.1" × 23.6"} 300 {660}

B. DIPPER & STANDARD BUCKET (E50.2SR) Dipper 1.50 m {5’1.42"} + Bucket 0.16 m3 {0.209 cu•yd}

Combination L×H×W

mm {ft-in} 2,770 × 510 × 650 {9’1.1" × 20.1" × 25.6"}

Weight

kg {lbs}

3,080 × 510 × 650 {10’1.3" × 20.1" × 25.6"} 320 {705}

H

295 {650}

Dipper 1.87 m {6’1.62"} + Bucket 0.16 m3 {0.209 cu•yd}

L

5-7

5. TRANSPORTATION C. DIPPER (E40.2SR) Type LuHuW

mm {ft-in}

Weight

kg {lbs}

1.43 m {4’8.30"}

1.70 m {5’6.93"}

1,870 u 420 u 250 {6’1.6" u 16.5" u 9.8"}

2,140 u 420 u 250 {7’0.3" u 16.5" u 9.8"}

170 {375}

190 {420}

1.56 m {5’1.42"}

1.87 m {6’1.62"}

C. DIPPER (E50.2SR) Type LuHuW

mm {ft-in} 2,010 u 420 u 250 {6’7.1" u 16.5" u 9.84"}

Weight

kg {lbs}

2,320 u 440 u 250 {7’7.4" u 17.3" u 9.84"} 205 {450}

H

180 {395}

L

D. STANDARD BUCKET (E40.2SR) Capacity

m3 {cu•yd}

LuHuW

mm {ft-in}

Weight

kg {lbs}

0.14 {0.183} 780 u 690 u 600 {30.7" u 27.2" u 23.6"} 107 {235}

D. STANDARD BUCKET (E50.2SR) m3 {cu•yd}

LuHuW

mm {ft-in}

Weight

kg {lbs}

0.16 {0.209} 780 u 690 u 650 {30.7" u 27.2" u 25.6"} 112 {245}

H

Capacity

L

5-8

5. TRANSPORTATION E. DOZER BLADE (E40.2SR) LuHuW

mm {ft-in}

Weight

kg {lbs}

1,140 u 320 u 1,960 {3’8.9" u 12.6" u 6’5.2"} 170 {375}

E. DOZER BLADE (E50.2SR) mm {ft-in}

Weight

kg {lbs}

1,190 u 320 u 1,960 {3’10.9" u 12.6" u 6’5.2"} 175 {385}

H

LuHuW

L

5-9

5. TRANSPORTATION

5-10

6. SPECIFICATIONS

6-1

6. SPECIFICATIONS

6-2

6. SPECIFICATIONS

6.1

GENERAL SPECIFICATIONS (E40.2SR)

6.1.1

MACHINE DIMENSIONS (E40.2SR) Unit : mm (ft-in)

1960 {6'5.2"} 750 {2'5.5"} 725 {2'4.5"} 70 {2.76"}

A. CANOPY

115 {4.53"}

5000 {16'4.9"}

2140 {7'0.3"} 1570 {5'1.8"} 980 {3'2.6"}

635 {2'1.0"}

345 {13.6"}

2600 {8'6.4"}

0

1940 {6'4.4"}

R980 } {3'2.6"

1630 {5'4.2"} 1820 {5'11.7"} 2330 {7'7.7"} 2780 {9'1.4"}

400 {15.7"} 1560 {5'1.4"} 1960 {6'5.2"}

R980 } {3'2.6"

5000 {16'4.9"}

2140 {7'0.3"} 1570 {5'1.8"} 980 {3'2.6"}

635 {2'1.0"}

345 {13.6"}

2600 {8'6.4"}

1940 {6'4.4"}

115 {4.53"}

0

1960 {6'5.2"} 750 {2'5.5"} 725 {2'4.5"} 70 {2.76"}

B. CAB

1630 {5'4.2"} 1820 {5'11.7"} 2330 {7'7.7"} 2780 {9'1.4"}

400 {15.7"} 1560 {5'1.4"} 1960 {6'5.2"}

6-3

6. SPECIFICATIONS 6.1.2

GENERAL SPECIFICATIONS (E40.2SR)

A. SPEED AND GRADEABILITY Item

Rubber track

Slewing Speed

Steel track 8.8 min-1 (8.8 rpm)

Travel Speed

Low (1st)

High (2nd)

Low (1st)

High (2nd)

2.8 km/h

4.6 km/h

2.5 km/h

4.2 km/h

Gradeability

58% (30 )

B. ENGINE Model

4TNV88–XYB

Type

Water-cooled, 4-cycle type Swirl chamber type diesel engine 4 - 88 mm u 90 mm {4 - 3.46" u 3.54"}

Number of cylinders-Bore x Stroke Total Displacement

2.189 liters {133.6 cu•in} 30.4 kW / 2,400 min-1 {41.3 PS / 2,400 rpm}

Output Rating

139.3 N•m / 1,440 min-1 {102.7 lbf•ft / 1,440 rpm}

Maximum Torque Starting Motor

12 V / 2.3 kW

Generator

12 V / 55 A

C. HYDRAULIC COMPONENTS Hydraulic Pump

Variable displacement axial piston + gear pump

Hydraulic Motor

Axial piston

Hydraulic Motor w/Reduction gear (Travel)

2-Axial piston, 2-Speed motor

Control Valve

10-spool multiple control valve

Cylinder (Boom, Dipper, Swing, Bucket, Dozer)

Double action cylinder

Return Filter

Safety valve containing/Filter Type (30P)

D. SIDE DIGGING & DOZER BLADE Type Boom Swing Angle Stroke of Dozer blade (above/below)

Boom swing by hydraulic cylinder Right

60

Left

70

mm (in)

505 / 325 {19.9 / 12.8}

6-4

6. SPECIFICATIONS 6.1.3

CRAWLER SHOE TYPE (E40.2SR)

Type

Ground Pressure kPa (psi)

Shoe width mm (in)

Total crawler width mm (ft-in)

CANOPY

CAB

400 {15.7"}

1,960 {6’5.2"}

26 {3.8}

27 {3.9}

400 {15.7"}

1,960 {6’5.2"}

26 {3.8}

27 {3.9}

Rubber track

Steel track (Option)

6.1.4

BUCKET TYPE (E40.2SR)

Backhoe bucket

Heaped Capacity 3 m (cu•yd)

0.14 {0.183}

Outer width mm (in) with side cutter

without side cutter

600 {1’11.6"}

550 {1’9.7"}

6-5

Number of teeth

Weight kg (lbs)

4

107 {236}

6. SPECIFICATIONS 6.1.5

ATTACHMENT WORKING RANGES (E40.2SR)

A. CANOPY A A'

L

B

J

F

K

Y

X

E

H D

C

G

UNIT : mm (ft-in) No. Attachment

Dipper

STD. DIPPER 1.43 m {4’8.30"}

LONG DIPPER 1.70 m {5’6.93"}

Bucket

0.14 m {0.183 cu•yd}

0.14 m3 {0.183 cu•yd}

3

A

Max. digging reach

5,660 {18’684"}

5,920 {19’5.07"}

A'

Max. digging reach at ground level

5,510 {18’0.93"}

5,770 {18’11.17"}

B

Max. digging depth

3,390 {11’1.47"}

3,660 {12’0.09"}

C

Max. digging height

5,490 {18’0.14"}

5,680 {18’7.62"}

D

Max. dumping clearance

3,910 {12’9.94"}

4,100 {13’5.42"}

E

Min. dumping clearance

1,530 {5’0.24"}

1,270 {4’2.00"}

F

Max. vertical wall digging depth

2,630 {8’7.54"}

2,910 {9’6.57"}

G

Min. front slew radius

2,100 {6’10.68"}

2,200 {7’2.61"}

H

Height at min. slew radius

4,170 {13’8.17"}

4,170 {13’8.17"}

J

8-feet level digging depth

2,960 {9’8.54"}

3,270 {10’8.74"}

K

Horizontal digging stroke Stroke at ground level Minimum

2,540 {8’4.00"}

2,910 {9’6.57"}

1,770 {5’9.69"}

1,650 {5’4.96"}

Above

505 {1’7.90"}

505 {1’7.90"}

Below

325 {1’0.80"}

325 {1’0.80"}

L X Y

Dozer strokes

6-6

6. SPECIFICATIONS B. CAB A A'

L

B

J

F

K

Y

X

E

H D

C

G

UNIT : mm (ft-in) No. Attachment

Dipper

STD. DIPPER 1.43 m {4’8.30"}

LONG DIPPER 1.70 m {5’6.93"}

Bucket

0.14 m3 {0.183 cu•yd}

0.14 m3 {0.183 cu•yd}

A

Max. digging reach

5,660 {18’6.84"}

5,920 {19’5.07"}

A'

Max. digging reach at ground level

5,510 {18’0.93"}

5,770 {18’11.17"}

B

Max. digging depth

3,390 {11’1.47"}

3,660 {12’0.09"}

C

Max. digging height

5,180 {16’11.94"}

5,340 {17’6.24"}

D

Max. dumping clearance

3,620 {11’10.52"}

3,790 {12’5.21"}

E

Min. dumping clearance

1,380 {4’6.33"}

1,120 {3’8.09"}

F

Max. vertical wall digging depth

2,630 {8’7.54"}

2,910 {9’6.57"}

G

Min. front slew radius

2,410 {7’10.88"}

2,430 {7’11.67"}

H

Height at min. slew radius

4,010 {13’1.87"}

4,020 {13’2.27"}

J

8-feet level digging depth

2,960 {9’8.54"}

3,270 {10’8.74"}

K

Horizontal digging stroke Stroke at ground level Minimum

2,540 {8’4.00"}

2,910 {9’6.57"}

1,770 {5’9.69"}

1,650 {5’4.96"}

Above

505 {1’7.90"}

505 {1’7.90"}

Below

325 {1’0.80"}

325 {1’0.80"}

L X Y

Dozer strokes

6-7

6. SPECIFICATIONS 6.1.6

MACHINE & COMPONENTS WEIGHT (E40.2SR) UNIT : kg (lbs) ITEM COMPLETE MACHINE

1.

UPPER FRAME ASSEMBLY (Assy of following)

1.1

UPPER FRAME

1.2

CANOPY/CAB

1.3

ENGINE

1.4

HYDRAULIC PUMP

1.5

RADIATOR

1.6

HYDRAULIC RESERVOIR

1.7

FUEL TANK

1.8

SWING BRACKET

1.9 1.10 1.11 1.12 1.13 1.14 2.

LOWER FRAME ASSEMBLY (Assy of following)

2.1

LOWER FRAME

RUBBER TRACK CANOPY

CAB

STEEL TRACK CANOPY

CAB

4,200 {9,260}

4,340 {9,565}

4,300 {9,480}

4,440 {9,790}

1,930 {4,255}

2,070 {4,565}

1,930 {4,255}

2,070 {4,565}

570 {1,257}

m

m

m

85 {187}

220 {485}

85 {187}

220 {485}

* 170 {375}

m

m

m

* 35 {77}

m

m

m

* 5 {11}

m

m

m

* 37 {82}

m

m

m

* 4 {9}

m

m

m

110 {243}

m

m

m

SWING CYLINDER

* 39 {86}

m

m

m

SLEWING MOTOR

* 40 {88}

m

m

m

CONTROL VALVE

* 35 {77}

m

m

m

COUNTERWEIGHT

270 {595}

m

m

m

GUARD HOOD

145 {320}

m

m

m

BOOM CYLINDER

* 47 {104}

m

m

m

1,670 {3,680}

m

1,770 {3,903}

m

525 {1,158}

m

m

m

2.2

SLEWING BEARING

76 {168}

m

m

m

2.3

TRAVEL MOTOR

* 65 {143} u 2

m

m

m

2.4

LOWER ROLLER

9 {20} u 10

m

m

m

2.5

FRONT IDLER

42 {93} u 2

m

m

m

2.6

IDLER ADJUSTER

30 {66} u 2

m

m

m

2.7

SPROCKET

14 {31} u 2

m

m

m

2.8

RUBBER TRACK

2.9

STEEL TRACK

210 {463} u 2

m

—

—

—

—

260 {573} u 2

—

2.10

SWIVEL JOINT

* 22 {49}

m

m

m

2.11

DOZER BLADE

170 {375}

m

m

m

2.12

DOZER BLADE CYLINDER

3.

ATTACHMENT ASSEMBLY (Assy of following)

3.1

BOOM ASSEMBLY

* 27 {60}

m

m

m

505 {1,115}

m

m

m

230 {510}

m

m

m

160 {353}

m

m

m

3.1.2 DIPPER CYLINDER

* 42 {93}

m

m

m

3.2

170 {375}

m

m

m

3.2.1 DIPPER (STD.)

105 {232}

m

m

m

3.2.2 BUCKET CYLINDER

* 27 {60}

m

m

m

3.1.1 BOOM DIPPER ASSEMBLY

3.2.3 BUCKET LINK

13 {29}

m

m

m

3.2.4 IDLER LINK

4 {9} u 2

m

m

m

3.3

BUCKET ASSEMBLY (STD.)

107 {236}

m

m

m

4.

FLUIDS (Assy of following)

95 {210}

m

m

m

4.1

HYDRAULIC OIL

45 {99}

m

m

m

4.2

FUEL

44 {97}

m

m

m

4.3

COOLING WATER

6 {13}

m

m

m

* MARKS SHOW DRY WEIGHT

6-8

6. SPECIFICATIONS

6.2

GENERAL SPECIFICATIONS (E50.2SR)

6.2.1

MACHINE DIMENSIONS (E50.2SR) Unit : mm (ft-in)

140 {5.51"}

R980 } {3'2.6"

25 {0.98"}

1960 {6'5.2"} 750 {2'5.5"} 725 {2'4.5"} 70 {2.76"}

A. CANOPY

5230 {17'1.9"}

2140 {7'0.3"} 1570 {5'1.8"} 980 {3'2.6"}

635 {2'1.0"}

345 {13.6"}

2600 {8'6.4"}

1940 {6'4.4"}

1690 {5'6.5"} 1970 {6'5.6"} 2480 {8'1.6"} 2910 {9'6.6"}

400 {15.7"} 1560 {5'1.4"} 1960 {6'5.2"}

140 {5.51"}

R980 } {3'2.6"

25 {0.98"}

1960 {6'5.2"} 750 {2'5.5"} 725 {2'4.5"} 70 {2.76"}

B. CAB

5230 {17'1.9"}

2140 {7'0.3"} 1570 {5'1.8"} 980 {3'2.6"}

635 {2'1.0"}

345 {13.6"}

2600 {8'6.4"}

1940 {6'4.4"}

1690 {5'6.5"} 1970 {6'5.6"} 2480 {8'1.6"} 2910 {9'6.6"}

400 {15.7"} 1560 {5'1.4"} 1960 {6'5.2"}

6-9

6. SPECIFICATIONS 6.2.2

GENERAL SPECIFICATIONS (E50.2SR)

A. SPEED AND GRADEABILITY Item

Rubber crawler shoe

Slewing Speed

Iron crawler shoe

8.8min {8.8 rpm} -1

Travel Speed

Low (1st)

High (2nd)

Low (1st)

High (2nd)

2.8 km/h

4.6 km/h

2.5 km/h

4.2 km/h

Gradeability

58% (30 )

B. ENGINE Model

4TNV88–XYB

Type

Water-cooled, 4-cycle type Swirl chamber type diesel engine 4 - 88 mm u 90 mm {4 - 3.46" u 3.54"}

Number of cylinders-Bore x Stroke Total Displacement

2.189 liters {133.6 cu•in} 30.4 kW / 2,400 min-1 {41.3 PS / 2,400 rpm}

Output Rating

139.3 N•m / 1,440 min-1 {102.7 lbf•ft / 1,440 rpm}

Maximum Torque Starting Motor

12 V / 2.3 kW

Generator

12 V / 55 A

C. HYDRAULIC COMPONENTS Hydraulic Pump

Variable displacement axial piston + gear pump

Hydraulic Motor

Axial piston

Hydraulic Motor w/Reducion gear (Travel)

2-Axial piston, 2-Speed motor

Control Valve

11-spool multiple control valve

Cylinder (Boom, Dipper, Swing, Bucket, Dozer) Return Filter

Double action cylinder Safety valve containing/Filter Type (30P)

D. SIDE DIGGING & DOZER BLADE Type Boom Swing Angle Stroke of Dozer blade (above/below)

Boom swing by hydraulic cylinder Right

60

Left

70

mm (in)

495 / 375 {19.5 / 14.8}

6-10

6. SPECIFICATIONS 6.2.3

CRAWLER SHOE TYPE (E50.2SR)

Type

Ground Pressure kPa (psi)

Shoe width mm (in)

Total crawler width mm (ft-in)

CANOPY

CAB

400 {15.7"}

1,960 {6’5.2"}

26 {3.8}

27 {3.9}

400 {15.7"}

1,960 {6’5.2"}

27 {3.9}

27 {3.9}

Rubber track

Steel track (Option)

6.2.4

BUCKET TYPE (E50.2SR)

Backhoe bucket

Heaped Capacity m3 (cu•yd)

0.16 {0.209}

Outer width mm (in) with side cutter

without side cutter

650 {25.6"}

600 {23.6"}

6-11

Number of tooth

Weight kg (lbs)

4

112 {245}

6. SPECIFICATIONS 6.2.5

ATTACHMENT WORKING RANGES (E50.2SR)

A. CANOPY A A'

L

B

J

F

K

Y

X

E

H D

C

G

UNIT : mm (ft-in) No. Attachment

Dipper

STD. DIPPER 1.56 m {5’1.42"}

LONG DIPPER 1.87 m {6’1.62"}

Bucket

0.16 m3 {0.209 cu•yd}

0.16 m3 {0.209 cu•yd}

A

Max. digging reach

5,890 {19’3.89"}

6,190 {20’3.70"}

A'

Max. digging reach at ground level

5,750 {18’10.38"}

6,050 {19’10.19"}

B

Max. digging depth

3,590 {11’9.34"}

3,900 {12’9.54"}

C

Max. digging height

5,670 {18’7.23"}

5,880 {19’3.50"}

D

Max. dumping clearance

4,090 {13’5.02"}

4,290 {14’090"}

E

Min. dumping clearance

1,510 {4’11.45"}

1,210 {3’11.64"}

F

Max. vertical wall digging depth

2,810 {9’2.63"}

3,120 {10’2.84"}

G

Min. front slew radius

2,150 {7’0.65"}

2,230 {7’3.80"}

H

Height at min. slew radius

4,290 {14’0.90"}

4,290 {14’0.90"}

J

8-feet level digging depth

3,160 {10’4.41"}

3,510 {11’6.19"}

K

Horizontal digging stroke Stroke at ground level Minimum

2,760 {9’0.66"}

3,190 {10’5.59"}

1,780 {5’10.08"}

1,650 {5’4.96"}

Above

495 {1’7.49"}

495 {1’7.49"}

Below

375 {1’2.76"}

375 {1’2.76"}

L X Y

Dozer strokes

6-12

6. SPECIFICATIONS B. CAB A A'

L

B

J

F

K

Y

X

E

H D

C

G

UNIT : mm (ft-in) No. Attachment

Dipper

STD. DIPPER 1.56 m {5’1.42"}

LONG DIPPER 1.87 m {6’1.62"}

Bucket

0.16 m {0.209 cu•yd}

0.16 m3 {0.209 cu•yd}

3

A

Max. digging reach

5,890 {19’3.89"}

6,190 {20’3.710"}

A'

Max. digging reach at ground level

5,750 {18’10.38"}

6,050 {19’10.19"}

B

Max. digging depth

3,590 {11’9.34"}

3,900 {12’9.54"}

C

Max. digging height

5,210 {17’1.12"}

5,380 {17’7.81"}

D

Max. dumping clearance

3,680 {12’0.88"}

3,840 {12’7.18"}

E

Min. dumping clearance

1,310 {4’3.58"}

1,000 {3’3.37"}

F

Max. vertical wall digging depth

2,810 {9’2.63"}

3,120 {10’2.84"}

G

Min. front slew radius

2,560 {8’4.79"}

2,580 {8’5.5"}

H

Height at min. slew radius

4,070 {13’4.24"}

4,070 {13’4.24"}

J

8-feet level digging depth

3,160 {10’4.41"}

3,510 {11’6.19"}

K

Horizontal digging stroke Stroke at ground level Minimum

2,760 {9’0.66"}

3,190 {10’5.59"}

1,780 {5’10.08"}

1,650 {5’4.96"}

Above

495 {1’7.49"}

495 {1’7.49"}

Below

375 {1’2.76"}

375 {1’2.76"}

L X Y

Dozer strokes

6-13

6. SPECIFICATIONS 6.2.6

MACHINE & COMPONENTS WEIGHT (E50.2SR) UNIT : kg (lbs) ITEM COMPLETE MACHINE

1.

UPPER FRAME ASSEMBLY (Assy of following)

1.1

UPPER FRAME

1.2

CANOPY/CAB

1.3

ENGINE

1.4

HYDRAULIC PUMP

1.5

RADIATOR

1.6

HYDRAULIC RESERVOIR

1.7

FUEL TANK

RUBBER TRACK

STEEL TRACK

CANOPY

CAB

CANOPY

CAB

4,630 {10,210}

4,770 {10,520}

4,730 {10,430}

4,870 {10,740}

2,280 {5,030}

2,420 {5,340}

2,280 {5,030}

2,420 {5,340}

570 {1,257}

m

m

m

85 {187}

220 {485}

85 {187}

220 {485}

* 170 {375}

m

m

m

* 35 {77}

m

m

m

* 5 {11}

m

m

m

* 37 {82}

m

m

m

* 4 {9}

m

m

m

1.8

SWING BRACKET

110 {243}

m

m

m

1.9

SWING CYLINDER

* 39 {86}

m

m

m

1.10

SLEWING MOTOR

* 40 {88}

m

m

m

1.11

CONTROL VALVE

* 35 {77}

m

m

m

1.12

COUNTERWEIGHT

580 {1,279}

m

m

m

1.13

GUARD HOOD

145 {320}

m

m

m

1.14

BOOM CYLINDER

2.

LOWER FRAME ASSEMBLY (Assy of following)

2.1

LOWER FRAME

2.2

SLEWING BEARING

* 58 {128}

m

m

m

1,720 {3,790}

m

1,820 {4,010}

m

545 {1,202}

m

m

m

76 {168}

m

m

m

2.3

TRAVEL MOTOR

* 65 {143} u 2

m

m

m

2.4

LOWER ROLLER

9 {20} u 10

m

m

m

2.5

FRONT IDLER

42 {93} u 2

m

m

m

2.6

IDLER ADJUSTER

30 {66} u 2

m

m

m

14 {31} u 2

m

m

m

225 {463} u 2

m

—

—

STEEL TRACK

—

—

275 {606} u 2

—

SWIVEL JOINT

* 22 {49}

m

m

m

2.11

DOZER BLADE

175 {386}

m

m

m

2.12

DOZER BLADE CYLINDER

* 27 {60}

m

m

m

535 {1,180}

m

m

m

240 {530}

m

m

m

3.1.1 BOOM

165 {364}

m

m

m

3.1.2 DIPPER CYLINDER

* 50 {110}

m

m

m

3.2

2.7

SPROCKET

2.8

RUBBER TRACK

2.9 2.10

3.

ATTACHMENT ASSEMBLY (Assy of following)

3.1

BOOM ASSEMBLY

180 {397}

m

m

m

3.2.1 DIPPER (STD.)

115 {254}

m

m

m

3.2.2 BUCKET CYLINDER

* 27 {60}

m

m

m

13 {29}

m

m

m

3.2.4 IDLER LINK

4 {9} u 2

m

m

m

3.3

BUCKET ASSEMBLY (STD.)

112 {247}

m

m

m

4.

FLUIDS (Assy of following)

95 {210}

m

m

m

4.1

HYDRAULIC OIL

45 {99}

m

m

m

4.2

FUEL

44 {97}

m

m

m

4.3

COOLING WATER

6 {13}

m

m

m

DIPPER ASSEMBLY

3.2.3 BUCKET LINK

* MARKS SHOW DRY WEIGHT

6-14

7. OPTIONAL EQUIPMENT

7-1

7. OPTIONAL EQUIPMENT

7-2

7. OPTIONAL EQUIPMENT

7.1

OPERATION OF HYDRAULIC HAMMER AND SHEARS

7.1.1

SELECTION OF HYDRAULIC HAMMER AND SHEARS

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.

7.1.2

BEFORE OPERATING HAMMER OR SHEARS

Consult your Dealerfor the piping when installing the hydraulic hammer.

REPLACE THE HYDRAULIC RETURN FILTER ACCORDING TO THE REPLACEMENT SCHEDULE TABLE LISTED. 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 hammer during operation.

7.1.3

HYDRAULIC OIL LEVEL CHECK AND CONTAMINATION PREVENTION

When the hydraulic hammer is not installed on the machine, attach blanking plugs to the tube end on the dipper 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.

7.1.4

BASIC OPERATION

CAUTION

A

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

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

B

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

3. Using boom, dipper and bucket controls set the hammer or shears to desired position.

4. Release control pedal lock rod (1).

5. Make certain hammer or shears are in desired position and against material to be broken.

1

6. Place left foot on pedal and depress with heel to activate breaker.

7. Operate hammer for 30 sec. than release pedal.

B

WARNING •

OPERATION OF HAMMER OR SHEARS LONGER THAN 30 SEC. INTERVALS COULD CAUSE PREMATURE WEAR OR DAMAGE TO THE ATTACHMENT AND THE MACHINE. IF MATERIAL IS NOT BREAKING, REPOSITION HAMMER OR SHEARS AND REPEAT OPERATION IN 30 SEC. INTERVALS.

•

NEVER LEAVE THE OPERATOR’S CAB WITH ENGINE RUNNING.

7-3

A

7. OPTIONAL EQUIPMENT A. CONTROL PEDAL Release pedal lock on the left front side of operator’s seat to operate pedal.

CAUTION •

•

Precaution for pedal operation.

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

A

Do not put foot on the pedal except during operation. If you put your foot on the pedal and mistakenly step on it, the machine may move suddenly to cause a serious accident.

B

Hydraulic hammer Foot pedal depressing section

Operating condition

Pedal in neutral position.

Hammer stops operating.

Depress heel section. (B)

Hammer starts operation.

Shears Foot pedal depressing section

Operating condition

Depress toe section. (A)

Shears close.

Depress heel section. (B)

Shears open.

WARNING NEVER LEAVE THE OPERATOR CAB WITH ENGINE RUNNING.

B. PEDAL LOCK DEVICE This is a device to lock the pedal.

CAUTION

1

Make sure to set the pedal lock in "LOCKED" position while the hammer or shears are not used. Careless contact with UNLOCKED position of pedal may cause severe accident and injury.

B

1. PEDAL LOCK PIN A. LOCK POSITION B. UNLOCK POSITION

7-4

A

7. OPTIONAL EQUIPMENT 7.1.5

SETTING SELECTOR VALVE

For machines to shear and hammer specification, the selector valve (1) installed on the main control valve is required to be switched to the position corresponding to the specification.

1

1. SELECTOR VALVE 2. COVER NOTE: • Inappropriate switching of the selector valve may cause decrease of work efficiency and operating speed due to inferior operation, and also cause damage to the machine.

Positively switch the selector valve.

•

2

Be sure to switch selector valve one or two times a month periodically.

A. SETTING PROCEDURE NOTE: To switch the selector valve, be sure to stop the engine and lower the attachment to the ground making the machine at stable conditions.

3

1

2

1. SELECTOR VALVE (Main circuit)

4

2. ALLEN KEY (5 mm) 3. SOCKET BOLT 4. WRENCH (24 mm Hex)

1. Use an Allen key (2) to loosen and remove the socket bolt (3).

2. Use a wrench (4) to turn the selector valve (1) to the proper position.

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

4. Markings of the selector valve (1) are shown below.

B: Hammer N: Shears Selector valve shifting position A

(A) USE BREAKER (B) USE NIBBLER

7-5

B

7. OPTIONAL EQUIPMENT 7.1.6

SETTING STOP VALVE

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

1

Stop (A) : Hydraulic oil stops flowing.

Free (B) : Hydraulic oil flows.

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

2

1

1. PLUG 2. DIPPER A. STOP POSITION B. FREE POSITION C. 19 mm (Hex)

C A

7-6

B

7. OPTIONAL EQUIPMENT

7.2

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

NO PASSENGERS PROTECTIVE EQUIPMENT When operating attachments that produce flying debris, it is highly recommended to procure and install protective guards on the machine and close all windows 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.

USE FOR INTENDED PURPOSE Use the attachment only for its intended purpose. If not used in accordance with the manufacturers instructions, the excessive pressure exerted on the boom, dipper and frame structure of the machine will cause premature failure of the components.

7-7

7. OPTIONAL EQUIPMENT CYLINDERS Do not operate boom, dipper or bucket cylinders to full stroke when using a hammer attachment.

Doing this can cause undue stress on the cylinder rods and result in damage.

AVOID CONTINUOUS OPERATION Operate the hammer/shears in 30 sec. intervals.

Operation for longer than 30 sec. at a time can cause high oil temperatures and damage the accumulators, cylinder seals and possibly result in pump damage.

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

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

7-8

7. OPTIONAL EQUIPMENT DO NOT USE SLEW/SWING FORCE Never use the slew/swing force of the machine for pushing or sliding objects. This will cause premature failure of the attachment and other machine components.

DO NOT PRY AND BREAK FORCIBLY Do not use the hammer to pry and break rock and concrete. This may damage the hydraulic hammer, and also boom, dipper and cylinder.

DIPPER IN VERTICAL POSITION The dipper should not be operated in the vertical position to prevent the dipper cylinder from vertical shocks.

This may damage the rod packing and piston and cause the oil leaking from those sections.

DO NOT LIFT Never use an optional attachment to lift or transport objects or material. Doing so can cause extensive damage to the attachment, the machine structures or cause injury or death due to slipping or dropping of load due to improper attachment.

7-9

7. OPTIONAL EQUIPMENT WORKING RANGES

C

WARNING

C

The balance of the machine becomes unstable at the position shown in the right figure involving a possibility of the machine turning over. Never carry out the hammer work with this position.

A. FRONT OK B. REAR OK C. LATERAL WORK PROHIBITED NOTE: • Refer to this SECTION for the work with an attachment other than the hydraulic hammer, too.

•

B

A

NEVER OPERATE AN OPTIONAL ATTACHMENT OVER THE SIDES OF THE MACHINE. ONLY OPERATE OVER THE FRONT OR REAR OF THE MACHINE.

Use the reinforced dipper for the work with the hydraulic hammer, etc. The use of standard dipper for such work may cause damages on the dipper.

7-10

7. OPTIONAL EQUIPMENT

7.3

PERIODIC INSPECTION AND MAINTENANCE INTERVAL

A. REPLACEMENT INTERVAL Contamination and deterioration of hydraulic oil will cause malfunctioning of the control valves, early wear and seizure of the hydraulic pump and consequential failure of the entire hydraulic circuit. Operation of the hammer hastens deterioration of hydraulic oil comparing with normal operation, using a bucket. Replace filters and hydraulic oil, referring to the following table : INSPECTION/ MAINTENANCE

LOCATION

HYDRAULIC OIL REPAIR KIT

REPLACEMENT INTERVAL FIRST

2nd REPLACEMENT

REGULAR

Hydraulic reservoir

—

—

Every 600 h

Hydraulic reservoir

50 h

250 h

Every 200 h

B. MAINTENANCE RECORD SHEET (EXAMPLE) DATE

HRS

FILTER REPLACEMENT

7-11

HYD. OIL CHANGE

7. OPTIONAL EQUIPMENT

7-12

8. TROUBLESHOOTING

8-1

8. TROUBLESHOOTING

8-2

8. TROUBLESHOOTING

8.1

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 an approved Dealer for assistance.

SYS

PROBLEM 1. All operating speeds are slow or power is lost.

PROBABLE CAUSE

POSSIBLE REMEDY

a. Low hydraulic oil level

Fill oil to specified level

b. Air leaking into the suction pipe

Tighten suction pipe hose clamp or replace hose

c. Hydraulic pump is damaged

Repair or replace

d. Pilot gear pump is damaged

Repair or replace

e. Main relief valve is not adjusted correctly

Adjust or replace

f. Pilot relief valve is not adjusted correctly

Adjust or replace

OPERATING

Repair or replace 2. A specific cylinder func- a. Cylinder seal is damaged tions improperly or los- b. Control valve or overload valve functions incorrectly Repair or replace/Rees power. or there are signs of air in the cylinder move air from cylinder c. Pilot valve is damaged

Repair or replace

d. Pilot valve piping is loose

Retighten

3. The cylinder position a. Cylinder seal is scored will not hold with operat- b. Control valve or overload valve is damaged ing lever in neutral. c. Overload valve is not operating d. Pilot valve is damaged

Repair or replace Repair or replace Repair or replace Repair or replace

4. Machine does not slew. a. Hydraulic motor (slewing) is not working or slewing Repair or replace gear is damaged

5. Slewing speed is slow.

b. Slewing bearing is damaged

Repair or replace

c. Pilot valve is not working

Repair or replace

d. Slewing reduction unit is damaged

Repair or replace

e. Solenoid valve is not working

Repair or replace

f. Control valve is not working

Repair or replace

g. Lever lock Sol. V. is not working

Repair or replace

a. Control valve is not working

Repair or replace

b. Hydraulic motor (slewing) is not working

Repair or replace

c. Hydraulic pump is not working

Repair or replace

d. Pilot valve is not working

Repair or replace

6. Abnormal sound occurs a. Insufficient lubrication of slewing gear and bearings Grease when slewing. b. Pilot valve is not working Repair or replace c. Control valve is not working

TRAVEL

1. Machine does not travel a. Too much track tension smoothly. b. Dirty or clogged tracks

Repair or replace Adjust crawler tension Clean crawlers

c. Brake valve is not working

Repair or replace

d. Travel reduction unit is damaged

Repair or replace

e. Control valve is not working

Repair or replace

f. Travel motor damaged

Repair or replace

g. Main relief valve pressure is set incorrectly

Adjust or replace

h. Swivel joint is damaged

Repair or replace

8-3

8. TROUBLESHOOTING SYS

PROBLEM

TRAVEL

2. Travel power is insufficient.

PROBABLE CAUSE a. Hydraulic pump is damaged

POSSIBLE REMEDY Repair or replace

b. Poor engine performance

Repair or replace

c. Main relief valve pressure is set incorrectly

Adjust or replace

d. Low hydraulic oil level

Fill to proper level

e. Hydraulic motor (travel) is not working

Repair or replace

f. Brake valve is not working

Repair or replace

g. Seal in swivel joint is scored or oil is leaking

Repair or replace

3. Machine does not travel a. Unequal tensions on tracks in a straight line. b. Set pressures of main relief valves unbalanced

Adjust tension.

Adjust.

HYDRAULIC

c. Performances of hydraulic travel motor has deterio- Repair or replace. rated Repair or replace.

e. Unbalanced discharge from hydraulic pump

Repair or replace.

f. Unbalanced flow from brake valve

Repair or replace.

g. Unbalanced flow between RH swivel joints

Repair or replace.

1. Temperature rise in the a. Oil cooler core clogged hydraulic oil temp. b. Engine fan belt slipping

1. Engine oil pressure is too low.

GAUGE CLUSTER DISPLAY

d. Unbalanced flow from control valve

2. Abnormal rise in the coolant temperature.

3. Battery charge.

1. Starter does not turn or turns slowly which does not start the engine.

Adjust or replace

c. Low hydraulic oil level

Refill to specified level

d. Wrong type hydraulic oil used

Replace with correct, new oil

e. Hydraulic pump is not working

Repair or replace

a. Engine oil level low

Fill to specified level

b. Oil leaking

Repair & fill to proper level

c. Wrong oil viscosity

Replace with proper oil

a. Low coolant

Fill to proper level

b. Coolant leaking

Repair & fill to proper level

c. Loose radiator cap

Tighten

d. Radiator core clogged

Clean cooling system

e. V-belt loose or damaged

Tighten to proper tension

f. Rust or scale in coolant

Flush system/fill to level

g. Faulty thermostat

Replace

a. Battery terminals disconnected, loose, or corroded Clean and connect b. Low battery electrolyte

Replenish

c. Slipping of V-belt or damaged

Adjust or replace

d. Battery service life has run down

Replace

a. Battery disconnected

Connect

b. Battery discharged

Charge

c. Battery terminals disconnected, loose, or corroded Clean and connect d. Ground cable disconnected

ENGINE

Clean

e. Engine oil viscosity too thick (Cold Weather) 2. Starter turns but engine a. Insufficient fuel does not start. b. Improper starting procedure

Connect Change to proper oil Refuel Refer to "chapter 3. MACHINE OPERATION"

c. Air in fuel line

Remove (See 4-19)

d. Clogged fuel filter

Replace element

e. Clogged air cleaner

Replace elements

f. Air heater circuit malfunctioning

Check circuit

8-4

8. TROUBLESHOOTING SYS

PROBLEM

PROBABLE CAUSE

3. Engine tends to stop at a. Low idling RPM low speed b. Fuel filter clogged

4. No power

ENGINE

5. Engine overheats.

POSSIBLE REMEDY Serviceman Replace element

c. Air cleaner clogged

Replace elements

d. Improper valve clearance

Serviceman

a. Fuel filter clogged

Replace element

b. Air cleaner clogged

Replace element

c. Improper valve clearance

Serviceman

d. Loose clamps on the air inlet hose

Tighten clamps

e. Cracked air inlet hose

Replace hose

a. Insufficient coolant

Refill coolant

b. Clogged radiator

Clean cooling components

c. V-belt to loose or damaged

Adjust or replace belt

d. Faulty thermostat

Replace

6. Engine exhaust is black.

a. Air cleaner clogged

Replace elements

b. Improper valve clearance

Serviceman

7. Poor fuel consumption

a. Fuel leak

Serviceman

b. Air cleaner clogged

Replace elements

c. Loose clamps on suction hose

Tighten clamps

d. Cracked suction hose

Replace w/ new hose

e. Engine oil level is too high 8. Excessive oil consump- a. Improper oil tion. b. Oil leak

9. Engine oil pressure does not rise.

10 Battery dies often. .

Reduce to specified level Replace with correct oil Serviceman

c. Improper oil replacement intervals

Change at correct interval

d. Improper warming-up operation

Refer to 3-11

a. Low oil volume

Fill to specified level

b. Oil leak

Serviceman

c. Improper oil viscosity

Replace with proper oil

a. Battery terminals disconnected loose, or corroded

Clean & tighten terminals

b. Low battery electrolyte

Fill cells w/ distilled water

c. V-belt loose or damaged

Adjust or replace belt

d. Defective battery

Replace battery

8-5

8. TROUBLESHOOTING

8-6