New Holland Kobelco E9SR Operation & Maintenance Instruction Manual 6042139100 - PDF DOWNLOAD

Operation and Maintenance Instruction Manual

E9SR

Operation and Maintenance Instruction Manual

E9SR

Print No. 604.21.391.00 English - Printed in Italy

PROVEN PERFORMANCE

PROVEN PERFORMANCE

E9SR OPERATION AND MAINTENANCE INSTRUCTION MANUAL ENGLISH Print No. 604.21.391.00

Edition: 02/2005 English - Printed in Italy Printed by Studio ti - 20905

WARNING

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

WARNING

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

WARNING

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

WARNING

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

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

WARNING

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

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

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

WARNING

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

MACHINE SERIAL NO. ENGINE TYPE

YANMAR 2TNE68

ENGINE SERIAL NO.

NOTES

VALID FOR MODELS

E9SR: PA02-01827~

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

S.p.A.

INDEX Index SECTION I Safety precautions ..........................................................................................................................................1 1.1 General safety information .......................................................................................................................... 2 1.2 Safety precautions ...................................................................................................................................... 2 1.3 Pre-start safety ............................................................................................................................................5 1.4 Safety during operation ............................................................................................................................. 11 1.5 Inspection & maintenance safety .............................................................................................................. 19 1.6 Battery safety ............................................................................................................................................26 1.7 Warning labels & tags ............................................................................................................................... 27 1.8 Prohibited machine operation ................................................................................................................... 31 1.9 End of work shift safety ............................................................................................................................. 33 1.10 Precautions for transportation ................................................................................................................. 34 1.11 Towing the machine .................................................................................................................................35 SECTION II Machine familiarization .................................................................................................................................37 2.1 Foreword ...................................................................................................................................................38 2.2 Identification data ......................................................................................................................................39 2.3 Noise levels (2000/14/EC) ......................................................................................................................... 40 2.4 Basic components of the machine ............................................................................................................ 41 2.5 Operator cab nomenclature ......................................................................................................................42 2.6 Component & controls nomenclature ........................................................................................................ 43 2.7 Storage & others .......................................................................................................................................55 SECTION III Basic machine operation .............................................................................................................................. 57 3.1 Pre-start inspection ...................................................................................................................................58 3.2 Starting and stopping machine engine ...................................................................................................... 65 3.3 Stopping machine engine ..........................................................................................................................69 3.4 Inspection after starting machine engine .................................................................................................. 70 3.5 Machine warm-up......................................................................................................................................72 3.6 Machine operation ..................................................................................................................................... 73 3.7 Practices to improve efficiency .................................................................................................................. 80 3.8 Machine parking ........................................................................................................................................83 3.9 Check & confirmation after work ...............................................................................................................83 3.10 Precautions after operation ..................................................................................................................... 84 3.11 Measures after emergency stop .............................................................................................................. 84 3.12 Locking up with key .................................................................................................................................85 3.13 Emergency measures against sudden failure of machine ...................................................................... 86 3.14 Caution on using rubber crawler shoes ...................................................................................................90 3.15 Machine operation in adverse weather condition .................................................................................... 93 3.16 Precautions when storing the machine for a long period ........................................................................ 95

INDEX SECTION IV Maintenance ..................................................................................................................................................97 4.1 General information ................................................................................................................................... 98 4.2 General safety & precautions .................................................................................................................... 99 4.3 Lubricant, fuel & coolant specifications ...................................................................................................102 4.4 Filters & elements, and bucket ................................................................................................................ 103 4.5 Accessory tools .......................................................................................................................................104 4.6 Torque specifications for capscrews & nuts ............................................................................................. 105 4.7 Torque specifications for joints & hydraulic hoses ................................................................................... 107 4.8 Installing hydraulic hose and pipe joint ...................................................................................................108 4.9 Releasing internal pressure of hydraulic system ..................................................................................... 109 4.10 Pressurizing hydraulic oil tank ...............................................................................................................110 4.11 Bleeding air in fuel system .................................................................................................................... 111 4.12 Replacement of rubber crawler shoe .................................................................................................... 112 4.13 Inspection & maintenance chart ............................................................................................................ 117 4.14 When required .......................................................................................................................................120 4.15 Daily inspection and maintenance ........................................................................................................ 131 4.16 50-hour inspection and maintenance .................................................................................................... 134 4.17 250-hour inspection and maintenance .................................................................................................. 138 4.18 500 hour inspection and maintenance .................................................................................................. 146 4.19 1000-hour inspection and maintenance ................................................................................................ 149 4.20 2000-hour inspection and maintenance ................................................................................................ 151 SECTION V Transportation .............................................................................................................................................161 5.1 Transportation .........................................................................................................................................162 SECTION VI Specifications ..............................................................................................................................................165 6.1 General specifications .............................................................................................................................166 SECTION VII troubleshooting ........................................................................................................................................... 173 7.1 General troubleshooting ..........................................................................................................................174 SECTION VIII Optional equipment .................................................................................................................................... 181 8.1 Operation of hydraulic breaker and nibbler ............................................................................................. 182 8.2 Safety precautions ..................................................................................................................................185 8.3 Periodic inspection and maintenance interval ......................................................................................... 188

Section I SAFETY PRECAUTIONS

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

SECTION I - SAFETY PRECAUTIONS

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

DANGER Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

2

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

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

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

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

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

1.2 SAFETY PRECAUTIONS

WARNING THE PROPER AND SAFE LUBRICATION AND MAINTENANCE FOR THIS MACHINE, RECOMMENDED

BY THE MANUFACTURER, ARE OUTLINED IN THIS MANUAL FOR THE MACHINE. IMPROPER PERFORMANCE OF LUBRICATION OR MAINTENANCE PROCEDURES ARE DANGEROUS AND COULD RESULT IN INJURY OR DEATH. READ AND UNDERSTAND THIS MANUAL BEFORE PERFORMING ANY LUBRICATION OR MAINTENANCE.

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

SECTION I - SAFETY PRECAUTIONS Because of the size of some of the machine components, the serviceman or mechanic should check the weights noted in this manual. Use proper lifting procedures when removing any components. Weight of components table is shown in section “SPECIFICATIONS”.

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, ripper or other attachment is blocked correctly to prevent it from dropping unexpectedly.

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

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

1. Read and understand all Warning plates and decal 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 Operators Compartment.

Remove ignition keys.

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

9. To avoid back injury, use a hoist when lifting components which weigh 20 kg (45 lbs) or more.

Make sure all chains, hooks, slings, etc., are in good condition and are the correct capacity. Be sure hooks are positioned correctly. Lifting eyes are not to be side loaded during a lifting operation.

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

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 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.

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

13. Always use the proper tools that are in good condition and that are suited for the job at hand.

Be sure you understand how to use them before performing any service work.

14. Reinstall all fasteners with the same part number.

Do not use a lesser quality fastener if replacements are necessary.

3

SECTION I - SAFETY PRECAUTIONS 15. Repairs which require welding should be performed only with the benefit of the appropriate reference information and by personnel adequately trained and knowledgeable in welding procedures.

Determine type of metal being welded and select correct welding procedure and electrodes, rods or wire to provide a weld metal strength equivalent at least to that of the parent metal. Make sure to disconnect battery before any welding procedures are attempted.

16. Do not damage wiring during removal operations.

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

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

18. The maintenance and repair work while holding the bucket raised is dangerous due to the possibility of a falling attachment. Don’t 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 stream that will be invisible close to the hose. This oil can penetrate the skin and cause personal injury. Use card-board or paper 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.

4

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 (crawlers). Chips can fly when removing or installing a track (crawlers) pin. Wear safety glasses and long sleeve protective clothing. Tracks (crawlers) can unroll very quickly when separated.

Keep away from front and rear of machine. The machine can move unexpectedly when both tracks (crawlers) are disengaged from the sprockets.

Block the machine to prevent it from moving.

23. Do not breathe dust generating when cleaning parts such as radiators: their inhalation can be harmful for your health.

SECTION I - 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.

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

F1437

OBSERVE ALL SAFETY PRECAUTIONS

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

WARNING Do not wear the working clothes with adhered oil, since it is easy to catch fire.

F1438

WEAR PROTECTIVE CLOTHING

C. READ AND UNDERSTAND THE OPERATION & MAINTENANCE MANUAL Before operating the machine, read and understand this OPERATION & MAINTENANCE MANUAL thoroughly in order to use the machine effectively and safely.

D. KEEP OPERATION & MAINTENANCE MANUAL IN STORAGE Keep this MANUAL in the specified storage located behind the operators seat for quick reference. Should the OPERATION & MAINTENANCE MANUAL become lost or damaged, contact your Dealer to order the OPERATION & MAINTENANCE MANUAL.

F21541

READ MANUAL / KEEP IN STORAGE

5

SECTION I - SAFETY PRECAUTIONS E. DO NOT OPERATE MACHINE EXCESSIVELY 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.

NO!

REFRAIN POOR PHYSICAL CONDITION

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

Prepare beforehand the communication means in case of any emergency, and take note of telephone numbers for emergency contact.

F1440

PREPARE FOR EMERGENCIES

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

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

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

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

6

WORK SITE SAFETY-KNOW THE AREA

LOCK (UP) POSITION

F20387

SAFETY LOCK LEVER

SECTION I - SAFETY PRECAUTIONS I. SIGNS, SIGNALS AND FLAGMEN Install signs on soft shoulders and ground areas, and 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.

F20209

SIGNS, SIGNALS & FLAGMEN

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

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

FUEL

F1475

KEEP FIRE AWAY FROM FUEL AND OIL

K. SURELY INSTALL SAFEGUARD Confirm that all guards and covers are securely and properly installed. If damaged, immediately restore them to proper condition.

Do not operate the machine without guards or covers. Make sure to maintain them in normal condition.

SURELY INSTALL SAFEGUARD

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

CANOPY

CAB

MOUNTING & DISMOUNTING MACHINE

7

SECTION I - SAFETY PRECAUTIONS M. PAY ATTENTION TO WORKING MACHINE Do not approach a working machine. Make sure to make visual contact with the operator before approaching a working machine.

F13237

PAY ATTENTION TO WORKING MACHINE

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

USE PROPER ATTACHMENT

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

F1457

PREVENT FIRES-CLEAN UP SPILLS

P. CONFIRM OPERATING CONTROL PATTERNS Slowly operate the control levers to confirm the operating patterns in advance.

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

HYDRAULIC CONTROL LEVERS CONTROL PROCEDURES

ISO PATTERNS F19190

CONFIRM OPERATING PATTERNS

8

SECTION I - SAFETY PRECAUTIONS Q. 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, handrails, etc.. Make sure to keep all operating controls clean at all times.

KEEP CLEAN AROUND DRIVER'S SEAT

R. HOW TO HANDLE LIFE HAMMER-CAB ONLY A life hammer is provided on the right side of cab. In case of emergency, take the life hammer, break the cab glass, and escape from the cab.

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

CUTTER LIFE HAMMER

HOW TO HANDLE LIFE HAMMER-CAB ONLY

S. 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

DO NOT OPERATE

T. TAG OUT MACHINE DURING MAINTENANCE Before performing any inspection or maintenance procedures to the machine, fill out and post to the operators controls a “DO NOT OPERATE” tag to warn persons not to start the machine. Make sure to inform the supervisor and all operators that the machine is under inspection or maintenance and they will be informed when the machine is ready for normal operation.

"TAG-OUT" MACHINE

9

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

F1439

USE CAUTION NEAR NOISE

V. 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.

F1469

AVOID HOT SURFACES & AREAS

10

SECTION I - SAFETY PRECAUTIONS

1.4 SAFETY DURING OPERATION A. 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

B. STARTING 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.

F15658

DO NOT SHORT CIRCUIT

C. HORN BEFORE STARTING ENGINE Sound the horn before starting the engine to alert people that the machine is being started.

Make sure no one is near the machine.

HORN SWITCH

CAUTION Do not start the engine if the machine has been tagged out.

SOUND HORN BEFORE STARTING

D. CHECK AFTER STARTING ENGINE Make sure to check machine 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 ENGINE

11

SECTION I - SAFETY PRECAUTIONS E. WARM UP MACHINE BEFORE OPERATION Take a sufficient time to warm up the machine, especially at cold season, otherwise the response of machine against the operation of operating lever is delayed which may cause injury and/or machine damage.

RED GREEN

F. CONFIRM 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

G. CONFIRM TRAVEL DIRECTION Make certain of the location of the travel motors before operating travel.

Pay attention that in the case where the travel motors are in the front side, the travel function is reversed.

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

CONDITION WHERE THE TRAVEL DIRECTION IS REVERSED

TRAVEL DIRECTION

TRAVEL MOTOR

KNOW TRAVEL MOTOR POSITION

H. DO NOT HIT CAB WITH ATTACHMENT Check clearence between bucket and cab before operation. Slowly cycle bucket, check for interference with arm and cab, particularly if a lifting eye is welded on bucket bottom. Exercise care when operating the bucket near the cab.

CAUTION FOR INTERFERENCE

DO NOT HIT CAB

12

SECTION I - SAFETY PRECAUTIONS I. 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.

F14394

SLEW / SWING / TRAVEL SAFETY

J. TRAVELING ON SLOPE Use extreme caution when traveling on slopes, machine could turnover or slide causing injury or machine damage.

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

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

K. 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/ turn, 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, it can allow a machine to unexpectedly move. Snow on shoulders or snow drifts can be much deeper than expected. The machine can easily become buried under such conditions. Use extreme caution while operating the machine around or in snow.

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

PAY ATTENTION ON SLOPE

USE EXTREME CAUTION ON FROZEN OR SNOW

L. 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 low to the ground and travel at extremely slow speed.

(12~16in)

TRAVEL POSITION

13

SECTION I - SAFETY PRECAUTIONS M. GROUND STABILITY 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 angle to 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

N. 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.

WARNING Hydraulic excavator whose crawler width can be changed, is dangerous due to losing its side-way stability when the crawler is retracted. The crawler width should always be fully extended during lifting work.

USE PROPER LIFTING DEVICES

O. 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 slew/swing or turn machine around on slopes. Build a level area for the machine to operate. Operate controls carefully to prevent sudden movements which may cause the machine to slide or tip over.

BUILD BANKING FOR SLOPE OPERATION

P. AVOID POWER LINES Serious injury or death can result from contact with electric lines.

In case of works near air electrical lines respect the necessary safety distances: Operation Voltage up to 1000 V from 1 kV to 110 kV from 110 kV to 220 kV from 220 kV to 380 kV unknown

14

Safety distance 1.0 m 3.0 m 4.0 m 5.0 m 5.0 m

KEEP A SAFE DISTANCE FROM UTILITIES

SECTION I - SAFETY PRECAUTIONS Q. WORKING AROUND UTILITY LINES UNDERGROUND At the work around presumable place of laying power, water or gas line under the ground, ask the actual location of them to the organization concerned, give a trial digging, and proceed the work with care after confirmation for nonexistence of them or location of them.

CHECK LOCATION OF UTILITIES

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

If no firm level surface is available, block the crawler and lower bucket and dozer blade to the ground to help prevent machine movement.

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

BUCKET DOZER

BLOCK

PARKING SAFETY

S. RESTRICTED WORK AREAS In work sites with limited height and slew/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 flag man to guide the operator.

USE EXTREME CAUTION AT RESTRICTED AREA

T. DO NOT WORK UNDER PRECIPICES Don't dig under precipices. It causes falling rocks or loosening of the precipice resulting in injury and/or machine damage.

DO NOT DIG UNDER PRECIPICE

15

SECTION I - SAFETY PRECAUTIONS U. WORK WITH SUFFICIENT LIGHTING When working in dark places, turn on the working light. And if required, provide additional lighting facilities to ensure the visual field.

Stop working when it is impossible to ensure the visual field due to fog, snow or rain.

WORK WITH SUFFICIENT LIGHTING

V. SET LIMITS TO WORKING AREA 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.

SAFETY BARRIERS

W. 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 providing caution plates.

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

USE A FLAGMAN WHEN NECESSARY

X. PROHIBITION TO USE 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

16

SECTION I - SAFETY PRECAUTIONS Y. 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 extreme care. Piled up tree leaves or branches also may cause skidding.

PAY ATTENTION AT SLIPPERY SLOPE

Z. STRENGTHEN 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

AA. LOOSENED GROUND AFTER RAIN After raining, there is a possibility of getting into danger of tumbling down or falling down of the machine with vibration and weight of the machine due to loosened shoulder of road.

Pay attention to loosened precipice or shoulder of road, and do not access to such place without care.

PAY ATTENTION TO LOOSENED GROUND

BB. LOOSENED GROUND AFTER EARTHQUAKE OR DYNAMITING Pay attention to the loosened precipice or shoulder of road, and falling rocks. Also pay attention to the unexploded dynamite.

PAY ATTENTION TO LOOSENED GROUND

17

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

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

F14394

SLEW / SWING SAFETY

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

F1463

STABILIZE ATTACHMENTS

18

SECTION I - SAFETY PRECAUTIONS

1.5 INSPECTION & MAINTENANCE SAFETY A. READ CAREFULLY OPERATING / MAINTENANCE PROCEDURES Incorrect maintenance may cause not only damages on the machine, but also injury.

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

READ OPERATING PROCEDURES

B. 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

C. 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.

F1458

CLEANING UP WORKING AREA

19

SECTION I - SAFETY PRECAUTIONS

DO NOT

OPERATE

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

"TAG-OUT" MACHINE

E. 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.

F1479

USE PROPER TOOLS

F. 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.

DOZER BLADE

BUCKET

HYDRAULIC OIL LEVEL CHECK POSITION

G. 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.

F1462

KEEP MACHINE CLEAN

20

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

F14406

F14407

STOP ENGINE / ENGAGE SAFETY LOCK LEVER

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

Never use the fuel for cleaning.

F1475

REFUELING

J. SUPPORT THE MACHINE If it becomes necessary to raise the machine for inspection or maintenance, always support the machine by positioning the machine as shown in the illustration and use safety supports or blocks, with a sufficient capacity rating to support the machine, under the crawler/frame.

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

SUPPORT BLOCK

SUPPORT THE MACHINE

K. 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.

F1471

F3636

CHECKING FOR HIGH PRESSURE LEAKS

21

SECTION I - SAFETY PRECAUTIONS L. PRESSURIZED FLUIDS & LUBRICANTS Always release pressure from hydraulic reservoir, engine coolant, fuel system and all systems containing pressure before removing any caps or components. BE CAUTIOUS OF HOT FLUIDS AND GASSES FROM SYSTEMS ON MACHINES THAT HAVE JUST BEEN STOPPED. ALLOW SUFFICIENT TIME FOR SYSTEMS TO COOL BEFORE PERFORMING ANY INSPECTION OR MAINTENANCE PROCEDURES. F14397

RELEASE HYDRAULIC TANK PRESSURE

M. PAY ATTENTION TO EXHAUST GAS Maintenance for the machine indoor or in the place with poor ventilation may cause poisonning by gas.

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

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

F1446

PAY ATTENTION TO EXHAUST GAS

N. 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 bare fire possible to inflame.

• Provide an appropiate fire fighting equipment such as fire extinguisher.

• Refrain from smoking during maintenance work.

• Put away any flammable materials when grinding work or welding work.

PREVENTIVE MEASURE AGAINST FIRE

O. 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.

F1480

USE APPROVED WORK LIGHTS

22

SECTION I - SAFETY PRECAUTIONS P. DO NOT HEAT HYDRAULIC EQUIPMENT OR PIPING Never apply heat to hydraulic equipment or piping, such as welding, soldering, heating with torch, etc.

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

Q. 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 appropiate equipment, such as ladders or a manlift 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.

DO NOT HEAT HYDRAULIC PIPING

F21544

TAKE CARE AT ELEVATED SPOT

R. 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. Make sure to store all tools properly when the work is completed.

DO NOT DROP OFF TOOLS AND PARTS

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

WHEN REMOVING, REMOVE THE NEGATIVE TERMINAL FIRST

ELECTRICAL SYSTEM PRECAUTION

23

SECTION I - SAFETY PRECAUTIONS T. CAUTION TO MODIFICATION The Manufacturer will not be liable for any injury or damages due to equipment modification without approval.

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

U. AFTER COMPLETION OF MAINTENANCE WORK Always, make sure to check machine for proper functioning when any maintenance 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.

CAUTION TO MODIFICATION

CONFIRM SMOOTH OPERATION

V. 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.

F1478

DISPOSE OF WASTE PROPERLY

24

SECTION I - SAFETY PRECAUTIONS W. 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 temperature below 16 ºC (60 ºF). If needed, preheat surface to hand-touch. In cases where the machine components are extremely cold, it is recommended that the components be brought inside and allow them to warm to 16 ºC ~ 20 ºC (60 ºF ~ 70 ºF) for at least 12 hours prior to welding.

• Remove paint from any surface to be heated or welded. Painted surfaces give off unhealthy gasses 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.

Make sure to use plenty soup and water to rinse the surface to be welded, since chemicals will generate unhealthy gasses when heated and/or welded.

WARNING • Provide a fire extinguisher reachable at all times while performing grinding, heating, or welding.

• Make 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.

• Make 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.

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

Refer to Section “MAINTENANCE” for the procedures to adjust the tension on the crawler shoe.

F14399

USE CAUTION WHEN ADJUSTING CRAWLER

Y. PAYING ATTENTION TO BROKEN PIECES WHEN HAMMERING Flying particles may cause injury when hammering tempered parts, such as pin, edge, tooth, bearing, etc..

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

USE CAUTION WHEN HAMMERING PAY ATTENTION TO WELDING WORK

25

SECTION I - SAFETY PRECAUTIONS

1.6 BATTERY SAFETY A. WEAR PROPER PROTECTIVE CLOTHES Wear long sleeve shirt, gloves and approved safety glasses or face shield when working with or around batteries. Battery electrolyte (acid) will cause severe burns if allowed to make contact with clothing, skin or eyes. Should electrolyte (acid) come in contact with clothes, skin or eyes, immediately remove effected clothing, flush area with clean water for 15 minutes and get prompt medical attention.

F1474

WEAR PROPER PROTECTIVE CLOTHES

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

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

Avoid breathing gasses from battery.

F1477

KEEP AWAY FROM FIRE OR FLAMES

D. USING BOOSTER CABLES • If using another machine or vehicle to boost bateries, 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.

E. 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 dispossal.

26

CABLE CONNECTING ORDER CABLE DISCONNECTING ORDER

(RED)

NORMAL BATTERY

DISCHARGED BATTERY

(BLACK)

TO THE ENGINE OF THE TROUBLED MACHINE

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

Connect booster cables using following procedure.

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

2.Connect black booster cable to negative (-) battery terminal of normal battery. Connect other end of booster cable to the engine of troubled machine.

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

SECTION I - SAFETY PRECAUTIONS

1.7 WARNING LABELS & TAGS

NOTICE FOR WARNING LABELS & TAGS • Do not take away the attached warning labels and tags.

• Confirm whether labels can be easily read. If words or illustrations are illegible, clean off or replace the labels.

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

• If labels are damaged, missing or illegible, replace them with new ones. Contact your Dealer for new labels.

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

LOCATION OF WARNING LABELS & TAGS

D

D 7

2

1

5

A

C

3 B

4

VIEW D - D

1

2 4

9

10 VIEW A

VIEW B

VIEW C F19452

27

SECTION I - SAFETY PRECAUTIONS 1. TAG, EQUIPMENT SAFE AREA OF OPERATION Located on the arm.

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

Background: yellow Stripe and graphics: black

F14393

2. TRACK ADJUSTER TAG Located on crawler frame.

It shows that obligation is made to consult the Operation and Maintenance Instruction Manual prior to acting on the track adjust valve.

Danger of severe injuries.

Background: yellow Stripe and graphics: black

F14399

3. PRESSURIZED FLUIDS & LUBRICANTS TAG Located on top of engine radiator.

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

Background: yellow Stripe and graphics: black F14397

28

SECTION I - SAFETY PRECAUTIONS 4. ENGINE STOP TAG Located on engine radiator.

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

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

Background: transparent Stripe and graphics: black

F14407

5. HOT SURFACES TAG Located on engine cover.

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

Background: yellow Stripe and graphics: black F14396

6. BATTERY TAG DANGER WARNING Located on battery box.

Flammable gas (hydrogen gas) is generated in the battery. Do not produce sparks near the battery, and do not put bare flame close to it to avoid the battery from catching fire and explosion.

Background: yellow Stripe and graphics: black

F14400

29

SECTION I - SAFETY PRECAUTIONS 7. TAG, COUNTERWEIGHT SAFE AREA OF OPERATION Located on each side of the rear counterweight.

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

Background: yellow Stripe and graphics: black

F14394

9. BOOSTER CABLES TAG Located on hydraulic tank.

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

Background: yellow Stripe and graphics: black WARNING Electric hazard may cause injury when mishandling the cable.

Read operator manual for safe and proper handling.

F14398

10. ELECTRICAL LINES TAG; SAFETY CONTROLS Located on handrail. It warns about danger in case of work near the electrical lines. It is imperative that should the operator abandon the cab with engine running, even for a very short time, the safety lever must be moved to LOCK position.

Controls are disconnected and any accidental equipment movement is impossible.

Background: white Stripe and graphics: black

WARNING Machine may move suddenly and cause serious personal injury if a control lever is accidentally touched.

Be sure the safety lock lever is in the locked position before exiting the cab.

F14404

30

SECTION I - SAFETY PRECAUTIONS

1.8 PROHIBITED MACHINE OPERATION The following examples of machine abuse and misuse should never be attempted by even the most experienced operator. Such abuse and misuse of this machine and its attachments can result in serious bodily injury, death, severe equipment damage and shortened service life of the machine.

Under no circumstance should any of these operations be attempted. Use common sense and follow proper operation procedures found in this MANUAL while operating this equipment.

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

B. DO NOT USE THE MACHINE’S SLEWING / SWINGING FORCE FOR OPERATIONS. Doing so will exert excessive forces to 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 TRACTIVE FORCE

DO NOT USE SLEWING / SWINGING FORCE

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

DO NOT HAMMER WITH ATTACHMENT

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

USE ONLY FOR INTENDED PURPOSE

31

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

ALLOWANCES

DO NOT OPERATE CYLINDER TO STROKE END

F. DO NOT OVER EXERT THE MACHINE’S CAPACITIES. Know the limitations of the machine and its attachments and operate the machine within those specifications. Do not exceed lift charts.

Never tip or raise the machine to obtain power to move material. This could cause extensive damage to the machine and its components as well as result in serious bodily injury or death.

DO NOT OVER EXERT THE MACHINE

G. CAUTION FOR DOZER BLADE NOT TO HIT OBSTACLES. Pay attention to the dozer blade not to hit any obstacles such as rock lump.

It may cause damages to the dozer blade and cylinder.

DO NOT HIT ROCK, ETC. BY DOZER

H. CAUTION FOR FOLDING UP ATTACHMENT. When the attachment is folded up to travel or transport, pay attention to the bucket not to hit the dozer blade.

DO NOT HIT DOZER BY BUCKET

32

SECTION I - SAFETY PRECAUTIONS I. DO NOT SUPPORT MACHINE WITH DOZER BLADE AT ONE END. When the dozer blade is used as an outrigger, 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

J. CAUTION FOR DEEP EXCAVATION. Pay attention during deep excavation with the dozer blade in front. The boom cylinder could come in contact with the dozer blade.

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

TAKE CARE FOR DEEP EXCAVATION

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

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

B. Lower attachment to the ground.

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

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

E. Thoroughly clean and inspect the machine.

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

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

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

H. Install vandalism guard, if necessary.

END OF WORK SHIFT SAFETY

33

SECTION I - SAFETY PRECAUTIONS

1.10 PRECAUTIONS FOR TRANSPORTATION Use the following general guidelines for loading or unloading the machine to the transportation vehicle: • Loading and unloading of the machine must be carried out on firm leveled areas away from the road shoulder. Do not use the attachments to load or unload the machine from the trailer.

• 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 crawler shoes on the machine, to prevent the machine from side skidding.

• Do not change the traveling direction on the ramp.

When required, back down the machine to the ground, reposition and try it 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" up position.

• Use cable or wire rope with sufficient capacity to secure front and rear of the machine to trailer.

Provide blocks to the machine crawlers, to avoid any movement of the machine.

• Protect wire rope against edges providing pad.

• While transporting, observe legal regulations concerned, keeping the safety in mind.

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

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

TAKE CARE FOR LOADING / UNLOADING

USE RAMP FOR LOADING AND UNLOADING

LOCKED (UP) POSITION

PAD FOR EDGE

PAD FOR EDGE

WIRE ROPE

SECURE FROM MOVEMENT

OVERALL HEIGHT

OVERALL LENGTH

OBSERVE LEGAL REGULATION

34

SECTION I - 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 rope or chain, with the capacity to pull the machine out, to the lower frame axles.

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 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 rope horizontally, 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 rope and crawler frame from any damages.

F15955

TOW MACHINE PROPERLY

NOTES: Do not pull machine utilizing the brackets welded on the lower plates of the carbody. These brackets are provided for pulling lightweight objects. See figure for better reference.

35

SECTION I - SAFETY PRECAUTIONS NOTES:

36

Section II MACHINE FAMILIARIZATION

SECTION II - MACHINE FAMILIARIZATION

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

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

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

Each machine is supplied complete with a copy of this Manual. Descriptions and illustrations herein are not binding. The Manufacturer, provided that the basic characteristics of machine types described and shown in this Manual remain the same, reserves the right to change components, parts and accessories supplied without any commitment to timely update this publication; and this any time it deems it convenient for improvement purposes or due to commercial or manufacturing requirements. For exact information, please consult your Dealer or contact the Manufacturer’s Branch Offices.

DANGER For clarity purposes, some figures in this Manual show the machine with protection panels or covers removed.

Never operate the machine with any protection panels or covers removed.

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

F21361

38

SECTION II - MACHINE FAMILIARIZATION

2.2 IDENTIFICATION DATA

NOTE : The numbers in the illustrations are for explanation only and differ from actual numbers

• ENGINE No.

EXCAVATOR MARKING DECAL 1. Machine technical type 2. Frame identification number 3. Machine total mass 4. Machine manufacturing year 5. Engine power in kW 6. Frame identification number 7. Identification decal: diesel engine type and serial number

39

SECTION II - MACHINE FAMILIARIZATION

2.3 NOISE LEVELS (2000/14/EC) Sound power level Lwa = 88 dB (A) Sound power level guaranteed, determined in compliance with European standard 2000/14/EC. Sound pressure level in the operator’s seat

LWA

88

Lpa = 71 dB (A) Sound pressure level: continuous, equivalent and average (A) measured on an identical machine in compliance with ISO 6396:1992.

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

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

• The weighted average quadratic acceleration value to which the operator’s arms are subjected does not exceed 2.5 m/s2.

• The weighted average quadratic acceleration value to which the operator’s body is subjected does not exceed 0.5 m/s2.

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

40

F21363

SECTION II - MACHINE FAMILIARIZATION

2.4 BASIC COMPONENTS OF THE MACHINE

1

2

41

3 4 5 6

40

7 8 9

39 10 11 38

36

12 13 14

35

15

37

16

34

17

33

18

32 s

31

19 30 29

20 28 21 27

22

26

F19333

23 25

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

Arm cylinder Boom Boom cylinder Left operating lever Travel lever Safety lock lever (right) Right operating lever Adj. crawler frame width/ dozer operating lever Monitor panel Throttle lever Radiator Air cleaner Control valve Reserve tank

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

24

Hydraulic tank Fuel tank Engine Muffler Slewing bearing Swivel joint Slewing motor Hydraulic pump Rubber crawler shoe Travel motor Shoe slide Adj. crawler frame widthcylinder 27. Lower roller 28. Idler adjuster

29.

30.

31.

32.

33.

34.

35.

36.

37.

38.

39.

40.

41.

Idler Swing cylinder Solenoid valve Dozer blade cylinder Dozer blade Battery Safety lock lever (left) Pilot valve Canopy Bucket Bucket link Arm Bucket cylinder

41

SECTION II - MACHINE FAMILIARIZATION

2.5 OPERATOR CAB NOMENCLATURE The operator cab nomenclature, see Figure below, points out locations of operator controls of the Manufacturer hydraulic excavator operator cab (Typical). Study these areas and locate these components on the machine.

Specific information regarding these components are explained on the following pages of this section.

1 18

2

5

3

6

17 19

4

7

16

8 15

9

10 14 13 12

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

Travel speed select switch Left travel lever Right travel lever Right travel pedal Right operating lever Safety lock lever (right) Boom swing operating pedal Adj. crawler frame width/ dozer operating lever Monitor panel (gauge cluster) Throttle lever Starter switch Boom swing lock lever Adj. crawler frame width/ dozer select lever Operator seat Option pedal (nibbler & breaker) Safety lock lever (left) Left operating lever Horn switch Left travel pedal

F19334

* 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).

FRONT

LEFT

TRAVEL MOTOR

42

11

RIGHT

SECTION II - MACHINE FAMILIARIZATION

2.6 COMPONENT & CONTROLS NOMENCLATURE The following information provides a brief description and function of the components and controls of the Manufacturer Hydraulic Excavator. All personnel associated with this machine should read and understand this information BEFORE beginning any work with or on this equipment.

A. MONITOR PANEL (GAUGE CLUSTER) The monitor consists of the following: A.1 METERS A.2 WARNING LAMPS A.3 INDICATOR

(1) (4) (5) (A.1) METERS

(A.2) WARNING LAMPS

(6)

(2)

(7)

(A.3) INDICATOR

(3)

F19453

A.1 METERS (1) COOLANT TEMPERATURE METER This indicates the temperature of RED the engine coolant water, and operates when the starter switch is WHITE turned to the “ON” position.

BLUE The temperature is normal in the WATER TEMP F15992 white range. If the indicator enters the red range, let the engine run in low idle until the temperature cools down and the indicator moves back into the white range.

(2) FUEL METER This indicates the amount of fuel.

WHITE F: Full tank is about 9 liters (2.4 gal).

The gauge indicates the residual volume of fuel in the fuel tank. Make RED sure to refuel when the indicator is F15993 FUEL approaching to the “E” point. Refill

the fuel tank with diesel fuel only. Normally the gauge takes time to move up to the apropiate leve after turning the key switch to the ON position.

(3) HOUR METER The hour meter indicates the total time the engine has run.

Even if the machine is not moving, HOUR METER the meter continues to count as F15994 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.

43

SECTION II - MACHINE FAMILIARIZATION A.2 WARNING LAMPS CAUTION CAUTION When any of warning lamp is lightened, immediately stop the work. Then investigate the cause for it, and carry out appropriate inspection and maintenance referring to the section “MAINTENANCE.”

(4) 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 the section “BASIC MACHINE OPERATION”).

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

(5) BATTERY CHARGE LAMP (RED) This is to warn an abnormality in the battery charging system during engine running. This indicator will illuminate when the starter switch is turned to the “ON” position, and should turn off after the engine is started.

Check the charging system if this indicator does not turn off after the engine is started. See Section 4 “Maintenance” for details.

(6) COOLANT TEMPERATURE LAMP (RED) If the coolant temperature rises abnormally, this warning lamp lights.

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

44

The engine may suffer sever damage if the machine is operated with the engine temperature lamp illuminated.

NOTES: 1. If the engine is overheating, stop operation immediately and let the engine run at idling 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 section “MAINTENANCE” for details.

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.

A.3 INDICATOR LAMPS These lamps indicate the working conditions.

(7) 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”.

SECTION II - MACHINE FAMILIARIZATION B. SWITCHES

3 2

1

F19335

1.

2.

3.

Starter switch Travel speed select switch Horn switch

B.1 STARTER SWITCH This is used to start or stop the engine.

HEAT:When engine start up is difficult due to cold climate, turn the key to this position to activate the pre-heating and the glow lamp indicator will illuminate. 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.

B.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 the machine in LOW speed on slopes and at loading/unloading the machine on a truck/trailer.

Sudden change of the machine travel speed may cause the machine to roll over.

LOW (1st) speed

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 to the section “SPECIFICATIONS” for speed.

Set to HIGH when travellin on flat, hard ground.

See to the section “SPECIFICATIONS” HIGH (2nd) speed for speed.

45

SECTION II - MACHINE FAMILIARIZATION B.3 HORN SWITCH Depress this switch, provided on the top of left operating lever, to sound the horn.

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

46

SECTION II - MACHINE FAMILIARIZATION C. LEVERS AND PEDALS

1

9

3

3

8

2

1 2 6

4

F19336

5

1.

2.

3.

4.

5.

6.

7.

8.

9.

7

Safety lock levers Right/ Left operating levers Travel levers with pedals Throttle lever Crawel width/ Dozer selector lever Crawel width/ Dozer operating lever Slewing (swing) lock lever Boom swing operating pedal Option pedal (Nibbler & Breaker)

C.1 SAFETY LOCK LEVER (EQUIPPED LEFT LEVER ONLY IN CAB SPEC.) The safety lock lever is provided to prevent any unexpected operation due to involuntary movement of the operator’s control levers.

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

• Note that even when the safety lock lever is set in the locked (up) position, the functions for dozer and boom swing are still activated.

For the machine with canopy, the operation of either safety lock lever is effective for locking and unlocking.

47

SECTION II - MACHINE FAMILIARIZATION * LOCKING HYDRAULIC SYSTEM When the safety lock lever is set in the “LOCKED(UP) Position” the hydraulic system is shut down, except the dozer blade and the boom swing functions. * UNLOCKING HYDRAULIC SYSTEM When the safety lever is set to the “UNLOCKED (DOWN) Position” all hydraulic functions are active.

NOTE: When the safety lock lever is set to the “LOCKED” (UP) position, the function of the r.h. and the l.h. control levers is stopped. Each attachment and swing motor are locked simultaneusly.

LOCKED (UP) POSITION

UNLOCKED (DOWN) POSITION

C.2 OPERATING LEVERS (ISO OPERATING PATTERN) C.2.A STANDARD OPERATION These two levers activate each operation as illustrated in the right.

WARNING • Confirm for safety around the working area. Also ensure that each lever operation is in accordance with the operating pattern indicated on the labels.

• If labels do not match the operator’s control pattern, replace them immediately to avoid accidents and/or injury.

SLEWING

BOOM

ARM

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

All functions can be activated simultaneously.

BUCKET

ISO OPERATING PATTERN

48

LH OPERATING LEVER

RH OPERATING LEVER

5. ARM OUT

1. BOOM DOWN

6. ARM IN

2. BOOM UP

7. SLEWING LEFT

3. BUCKET IN

8. SLEWING RIGHT

4. BUCKET ON

SECTION II - MACHINE FAMILIARIZATION C.3 TRAVEL CONTROL LEVERS The travel levers are located in front of operator seat. They are used to move the left or right track of the machine either forward or backward. These controls have 2 basic operational functions: PEDAL

WARNING Use caution to avoid coming in contact with other machine functions while travelling.

Make sure to know the location of the travel motors before operating the travel function.

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

FORWARD

(A): Push both levers forward to travel Forward.

(B): Pull both levers back to travel in Reverse.

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

Refer to the Section “BASIC MACHINE OPERATION” for changing travel direction.

C.4 THROTTLE LEVER The throttle control lever is located to the right side of the operator’s seat and it is used to control the engine speed.

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

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

C.5 ADJUSTABLE CRAWLER FRAME WIDTH/DOZER SELECTOR LEVER This lever is located on the front lower side of the operator’s seat and it is used to select the dozer operation or adjust the crawler frame width.

Usually, this lever is to be set to (C) position (dozer side). Only when changing the machine width (crawler frame width), this lever is set to (D) position (crawler frame side) to allow the adjusting crawler frame width with the adjustable crawler frame width/dozer operating lever, by actuating cylinder.

30~40 cm 12~16 in DOZER BLADE TRAVEL MOTOR

THROTTLE LEVER

(A)

(B)

F15519

ADJUSTABLE CRAWLER FRAME WIDTH

(D)

(C) WARNING

REVERSE

DOZER F19337

• The frame width/dozer function is active at all times, even with the safety lever in the lock (up) position.

• Do not touch the frame width/dozer control lever unless one of these functions need to be activated, severe injury could occur.

49

SECTION II - MACHINE FAMILIARIZATION C.6.a DOZER OPERATING LEVER This lever is to control the dozer up or down function.

(E): Dozer down (Push the lever forward.)

(F): Dozer up (Pull the lever back.)

DOZER OPERATION

(F)

(E)

DOZER BLADE

(F)

(E) C.6.b ADJUSTING CRAWLER FRAME WIDTH This lever is to change the machine width (crawler frame width).

(G): Push the lever forward to widen the width of crawler frame: 750 mm (2’ 5.5”).

(H): Pull the lever back to narrow the width of the crawler frame: 980 mm. .

F15520

ADJUSTABLE CRAWLER FRAME WIDTH

(G)

(H)

NOTE: It is recommended to operate the machine with wider width to make the machine more stable during operation. Use the narrower width only when the job site space is limited. Refer to section “BASIC MACHINE OPERATION” for the procedures to change the machine width (crawler frame width).

H G F19338

C.7 SWING LOCK LEVER This lever is located on the front lower side of the operator’s seat, and it is used to lock the machine’s upper frame for transportation. The upper frame can be locked in two different positions, forward or backward.

CAUTION Do not operate the swing function when the upper frame is locked, damage to the machine could occur.

50

UNLOCK

LOCK

F19339

SECTION II - MACHINE FAMILIARIZATION C.8 BOOM SWING OPERATING PEDAL The boom swing control pedal is located to the right of the travel levers, and it is used to operate the boom swing function.

(A) (B)

(A) (B)

WARNING Lock the boom swing control pedal when this function is not operated, failure to do so may cause serious accidents.

F19340

(A) : Depress the pedal to the right to activate the boom Right-Swing function.

(B) : Depress the pedal to the right to activate the boom Right-Swing function.

C.9 (OPTION PEDAL) NIBBLER & BREAKER This pedal, located to the left side of the travel control levers, is used to operate the optional attachment such as the Nibbler & Breaker.

OPTION PEDAL

WARNING Lock the optional pedal while this function is not operated, failure to do so may cause serious accidents.

F19341

Refer to section IX“OPTIONAL EQUIPMENT”, for the operation of hydraulic nibbler & breaker.

Pedal lock device This is the lock device for nibble & breaker optional operating pedal. The lock is realised if the lock pin of the pedal is pushed forward.

LOCK

UNLOCK F19342

51

SECTION II - MACHINE FAMILIARIZATION D. GUARD WITH LOCKING DEVICE & COVER

UNLOCK

WARNING Make 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.

RELEASE

LOCK

D.1 Opening 1. Insert the key.

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

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

ROD

D.2 Locking 1. Return the rod to the original position, and fix it into the holder.

2. Close the cover.

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

GUARD (R/H) ENGINE GUARD

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

CAUTION Always, make sure to use the open door lock rod to secure the engine covers whenever they are in the open position.

ROD F19344

GUARD (L/H)

E. SEAT FRONT TO BACK ADJUSTMENT a. Pull the seat adjustment lever to right side. b. Move the seat forward or backward to desired position. c. Release the lever to lock the seat in position.

ADJUST POSITION LOCK LEVER

52

SECTION II - MACHINE FAMILIARIZATION F. ELECTRICAL EQUIPMENT F.1 WORKING LIGHT SWITCH A working light is provided on the boom to improve the visual field during poor lighting conditions.

To turn ON or OFF the working light, use the switch provided on the back of the working light lamp.

SWITCH

F19345

F.2 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.

10A 30A 10A 20A 20A

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

1.

2.

3.

4.

5.

10A 30A 10A 20A 20A

Horn Timer, Relay Monitor panel (Gauge cluster) Working light Lever lock switch

FUSE F19346

Red Red, Blue White, Green Red, White Yellow

NOTE: (a) When replacing a fuse, replace it with one of the same capacity. (b) The spare fuses are stored in the back side of fuse box cover.

F.3 SOCKET OF 12V POWER SOURCE Open the cap and connect the socket for the car accessories.

NOTE: It can be used for the cigarette lighter.

SOCKET

53

SECTION II - MACHINE FAMILIARIZATION G.1 REPLACING PROCEDURES

CAUTION When a new fuse is blown within a short time of service or frequent replacement for fuses are required, it may be caused by troubles in electric sequence. Consult with an authorized Distributor for the repair or replacement.

MAIN FUSE BOX

The main fuse box covered by the fuse box cover is provided under the seat.

1. Place the bucket to the ground.

2. Set the safety lock lever to the locked position.

3. Set the starter switch to “OFF” to stop the engine.

4. Open the cover under the seat.

5. The fuse box cover is locked at its one side.

Release the lock and remove the cover.

6. When any fuse is blown as shown in the right, replace it to the spare fuse stored in the fuse box.

7. After the replacement of fuse, make sure to set the cover with a click.

F19348

FUSE BOX COVER

F19349

WARNING Never replace a faulty fuse with a higher amperage fuse. Never use a “jumper” in place of a fuse. Never splice accessories directly into fuse terminals.

G.2 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.

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 as an ordinary fuse.

F19350

54

SECTION II - MACHINE FAMILIARIZATION

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

F21542

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

Refer to Section “MAINTENANCE” for the details of the tools.

55

SECTION II - MACHINE FAMILIARIZATION NOTES:

56

Section III BASIC MACHINE OPERATION

SECTION III - BASIC MACHINE OPERATION

3.1 PRE-START INSPECTION A. DAILY INSPECTION OF MACHINE 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).

5

7

2,3 6 1

4

F19351

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

1.

2.

3.

4.

58

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

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

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

Check the travel system, such as the crawler, idlers, and sprockets, for any damage or wear, and the cap screws for looseness.

5.

6.

7.

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

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

Repair and tighten capscrews as required.

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

SECTION III - BASIC MACHINE OPERATION B. INSPECTION BEFORE OPERATION The following items should be inspected before starting machine operation: 1. CHECK COOLANT LEVEL

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.

WARNING Never remove radiator cap when engine is hot. Allow engine to cool down before removing radiator cap.

The radiator reserve tank is provided on the right side of the engine compartment.

1. Check the coolant level with cold engine.

2. Open engine cover to check the coolant level in the radiator reserve tank. The coolant level should be between the lines of FULL and LOW.

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

Maintain coolant level at the full mark with engine cold.

Refer to section IV “MAINTENANCE” for engine coolant specifications.

3. Open radiator expansion tank cap (A) to refill with proper coolant mixture.

Check the radiator coolant level when the coolant level in the reserve 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. Remove the radiator cap (B), and check for proper coolant level.

5. Refill radiator with proper coolant mixture.

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

F14396

(A)

FULL LOW

F14397

(B)

RADIATOR

RADIATOR RESERVE TANK F19352

F19208

59

SECTION III - BASIC MACHINE OPERATION 2. CHECK COOLANT LEAKAGE If the coolant level in the radiator reserve 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 with your Dealer for advise and/or repairs. Make sure to repair leakages before resuming operation.

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

• Always make sure to check engine oil level before starting the engine.

• Keep the engine to a standstill for at least 30 minutes, when checking engine oil level after working.

1. Use the ignition key to unlock and open engine covers.

2. Pull out engine oil dipstick (G), 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 Section “MAINTENANCE” for oil specifications.

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

Make sure to check the oil level again after refilling.

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

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

4. CHECK HYDRAULIC OIL LEVEL

WARNING Never perform maintenance or inspection on a machine that has just finished working. Allow sufficient time to the machine to cool off. Release hydraulic tank pressure before working with any hydraulic component.

WARNING F14396

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.

60

SECTION III - BASIC MACHINE OPERATION 4.1 Check 1. Move the machine to firm level ground and set it in the hydraulic oil level check position.

2. Check the oil level through sight level gauge provided on the side of the hydraulic tank.

Hydraulic oil level should be between H and L. Oil level varies depending on oil temperature.

Check the oil level referring to the 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)

HYDRAULIC OIL LEVEL CHECK POSITION

DOZER BLADE

BUCKET

NOTE: Avoid overfilling. It causes damages on hydraulic equipment or oil spouting.

4.2 Refill with oil when the level is below “L.” Refer to the section “MAINTENANCE” for the recommended oil to be used.

1. Refer to section “MACHINE FAMILIARIZATION” to open the cover.

2. Make sure the temperature of hydraulic oil is around 40˚C (104˚F), before refilling.

3. Release hydraulic tank pressure as instructed on section “MAINTENANCE”.

4. Remove plug (A) completely.

5. Refer to section “MAINTENANCE” for hydraulic oil specifications.

6. Install the plug (A), the seal (K) and tighten securely.

7. Star t the engine and operate each cylinder evenly 5 to 10 times with no load.

Reset the machine to the hydraulic oil level check position and stop the engine.

8. Check the oil level again, and correct as needed.

9. Pressurize the hydraulic oil tank, referring to section “MAINTENANCE” for the procedures.

HYDRAULIC TANK

OIL FILLING PORT

LEVEL GAUGE

F19353

(A) (K)

F19354

LEVEL GAUGE

F19355

61

SECTION III - BASIC MACHINE OPERATION 5. CHECK FUEL LEVEL

WARNING • Make sure to use diesel fuel only, and stop engine before refilling.

• Be careful not to overflow fuel at refilling. Clean up all spilled fuel to prevent fire.

• Dispose of hazardous waste according to environmental laws and regulations.

1. Turn ignition 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 the Section “MAINTENANCE” for fuel specifications.

Fuel tank capacity: 15 liter (4.0 gal) 4. Do not remove fuel tank strainer (4) for refilling to avoid contamination.

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

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

F16499

F14396

OFF HEAT

ON START

FUEL

We recommend to refuel at the end of the workshift. 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.

(3) (4)

NOTE: If the machine runs out of fuel during operation, air may get mixed in the fuel lines. Proceed to bleed the air out of the fuel system as indicated in the Section “MAINTENANCE”.

(4)

F19357

6. CHECK FOR FUEL LEAKAGE Check and repair any fuel leakage. Do not operate a machine leaking fuel. Fuel leakage may be caused by faulty drain plug (A), crack on hose in fuel line, loosened hose clip, etc.

Make sure to stop the engine immediately if any fuel leakage is found. Repair fuel leakage before resuming operation.

WATER SEPARATOR

FUEL HOSE

(A)

62

F19358

SECTION III - BASIC MACHINE OPERATION 7. CHECKING BELT

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 10 Kg (22 lb) to the center of belt between pulleies, and measure the belt deflection.

F14407

10 kg (22 lb) GENERATOR 10kg

Deflection Belt Fan: 8-10mm (0.31-0.39in) See the section IV “MAINTENANCE” (EVERY 250 HOURS), for details on the inspection and adjustment procedure for the belt.

PULLEY F15549

63

SECTION III - BASIC MACHINE OPERATION C. CONFIRMATION BEFORE STARTING MACHINE ENGINE 1. CHECK WARNING LAMPS

RED: WARNING LAMP

1

YELLOW: INDICATION LAMP

2 WARNING

3

Careless movement of any operating levers may cause sudden movement of the machine. Make 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 lever on the “LOCKED” (up) position.

Before starting the engine, check the warning lamps and indicator lamps according with the following procedures: 1. Make sure the safety lever is in the “LOCKED” (up) position.

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

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

4. Do not operate the machine under faulty conditions. Consult with your Dealer. Refer to the section II “COMPONENT & CONTROLS NOMENCLATURE” and make sure all warning lights and indicators function properly. Repair any mal functioning before resuming operation.

OFF

ON

HEAT

START

4 5

F15550

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

OFF → HEAT

OFF → ON

Lamp

Pre-Heating

Before Start

Just

1

Battery Charge Lamp

Light OFF

Light ON

Light OFF

2

Engine Oil Pressure Lamp

Light OFF

Light ON

Light OFF

3

Engine Coolant Temp. Lamp

Light OFF

Light OFF

Light OFF

4

2nd Speed Travel Lamp

Light OFF

Light OFF

Light OFF

Key Operation

2. CHECK WORKING LIGHT While the key position in the starter switch is being “ON” position, turn on the working light switch to check the lightening of working light. If it does not lighten, presumably the light bulb is burned out or electrical wire is broken. Repair it referring to the Section “MAINTENANCE”.

START → ON After

WORKING LIGHT

F19359

64

SECTION III - BASIC MACHINE OPERATION

3.2 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.

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

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

4. Turn the ignition key (3) to the START position to start the engine and release after starting the engine.

Release the ignition key immediately after the engine starts.

The key will return to the “ON” position by itself.

LOCKED (UP) POSITION

(2)

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 make sure to sound horn before starting the engine.

F15553

NOTE: (a) Do not increase the engine speed (high idling) with cold engine. (b) Do not hold the ignition key in the START position for more than 15 seconds. If the engine does not start, return the key switch to the OFF position, wait 30 seconds, and then try again.

65

SECTION III - BASIC 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 preheater to start the engine easily under these conditions.

THROTTLE LEVER

1. Perform steps (1) - (3) mentioned in STARTUP UNDER NORMAL CONDITIONS shown on the previous page.

F15555

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

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

HEAT START ENGINE START

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

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

66

SECTION III - BASIC 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 hard hat, approved safety glasses or face shield, 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.

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

Use the booster cables and clips without any damages or corrosion.

F14398

CAPSCREW

BATTERY

67

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

WARNING • Erroneous connection of booster cables may cause explosion of the batteries. Pay special attention to connect and disconnect the booster cables.

• The electrical system of this machine works with 12V DC.

1. Set the key switch to “OFF” for both normal vehicle and troubled machine.

2. Refer to the section “MACHINE FAMILIARIZATION” and remove the left side cover. Then open the cover under the operator’s seat.

3. Remove the cover from the battery terminals.

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

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

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

7. Finally, connect the clip from the other end of the negative (-) booster cable (black) to the engine body (hook, etc.) of troubled machine, away from the battery.

WARNING Do not connect the negative (-) booster cable to the machine carbody (lower structure).

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

9. Start the engine of troubled machine.

10. After starting the engine of troubled 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 troubled machine.

68

BATTERY F21364

RUBBER COVER

-

+

F19504

CABLE CONNECTING ORDER CABLE DISCONNECTING ORDER

(RED)

NORMAL BATTERY

DISCHARGED BATTERY

(BLACK)

TO THE ENGINE OF THE TROUBLED MACHINE

SECTION III - BASIC MACHINE OPERATION

3.3 STOPPING MACHINE ENGINE THROTTLE LEVER

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

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

F15562

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

2. Make sure to place the safety lock lever in the “LOCK” (up) position before leaving the cab.

3. Push the throttle lever 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 key to OFF to stop the engine.

5. Remove the ignition key.

OFF HEAT

ON START

STARTER KEY F15563

69

SECTION III - BASIC MACHINE OPERATION

3.4 INSPECTION AFTER STARTING MACHINE ENGINE Check and ensure the following items after starting the engine: A. EXHAUST GAS COLOR, ABNORMAL SOUND & SMELL While operating the engine, check the following items.

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

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

2. Stop operation immediately when any abnormal sound exists during the machine operation. Check the cause of the abnormal sound, and repair as needed.

3. Avoid the 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 par ts may be damaged due to vibration.

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

EXHAUST GAS COLOR

SOUND

SMOKE

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

NOTE: • Do not apply any heavy load on 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 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 reach oil to every part of the engine.

70

• Careless contact with any operating lever will cause unexpected sudden machine movement. Standing or shift body position of the operator after securely setting the safety lock lever at “LOCK” (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 make sure to sound horn before starting operation.

SECTION III - BASIC MACHINE OPERATION B. CHECK EACH SWITCH & LEVER After warming up the engine, check 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.

* 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/ width 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.

LOCKED

NOTE: When any abnormalities are found, immediately stop the engine, proceed with the appropiate 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. Confirm that engine temperature gauge and fuel level gauge work properly.

(3) (1) (2) (4)

HOUR METER

F19361

71

SECTION III - BASIC MACHINE OPERATION

3.5 MACHINE WARM-UP A. ENGINE WARM-UP

THROTTLE LEVER

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 the 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. Set the throttle lever in the “MIDDLE SPEED” position.

2. Set the safety control lever in the “UNLOCK” (down) position.

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

4. Operate the bucket control lever to retract it or extend it completely against relief. Hold this position for one minute, then release lever 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 warm-up operation.

WARNING In extremely cold climate 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 adecuate lubrication to hydraulic components; thus, reducing the life expectancy of the machine.

72

RIGHT OPERATING LEVER BUCKET OUT BUCKET IN

UNLOCKED (DOWN)

F19362

SECTION III - BASIC MACHINE OPERATION

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

(12~16in)

UNLOCKED

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 make 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.

1. FORWARD/REVERSE TRAVEL 1. Make sure the safety control lever is in the “UNLOCK” down position. Operate the boom, arm, 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.

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

3. COUNTER ROTATING MACHINE 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.

(FORWARD / REVERSE TRAVEL)

FORWARD

FORWARD

REVERSE

REVERSE

(PIVOT TURN)

FORWARD

(SPIN TURN)

FORWARD

REVERSE

73

SECTION III - BASIC MACHINE OPERATION 4. TRAVEL SPEED SHIFTING (1ST/2ND) 1. For fast travel speed, depress and release the travel speed selector switch once before operating the travel controls. The fast lamp indicator (A) will illuminate in the cluster gauge.

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

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 key switch is turned to the “OFF” position.

B. STOP TRAVELING

(STOP TRAVELING)

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

STOP

STOP

STOP

STOP

1. Put the travel levers of left and right at neutral position to stop the machine travel.

Avoid to stop the machine travel suddenly.

Stop the machine travel as slowly as possible.

C. TRAVEL PRECAUTIONS

CONDITION WHERE THE TRAVEL DIRECTION IS REVERSED

WARNING TRAVEL DIRECTION

• Use a flag-man when traveling on the shoulder of a road or in confined areas.

• Never allow persons to ride on the machine.

1. Make certain the travel motor location is known before performing any travel operation. Travel with travel motors in 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.

74

TRAVEL MOTOR

SECTION III - BASIC MACHINE OPERATION 5. When traveling on rough ground, use low (1st) speed to reduce the shock to the machine.

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

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

8. For loading/unloading at the transport, remove any mud clogged in the crawler shoes to prevent the machine from side skidding on the ramps.

Refer to the section “TRANSPORTATION” for the usage of ramps, etc.

LOW IDLING POSITION

LOW SPEED (1st)

D. CARE ON UP/DOWN SLOPE

WARNING • Never take such traveling manner as changing direction on a slope or crossing a slope. Once get down to a flat ground and take a detour, keeping in mind the safety traveling.

• Raise the bucket 30 to 40 cm (12~16in) above the ground level, while traveling. And do not get down the slope with reverse traveling.

• When the machine is skidded, immediately get down the bucket and take braking.

• The slewing on a slope may cause the machine turning over due to losing balance on the machine.

It is quite dangerous to slew to down side of the slope with full of loading in the bucket. When such work is inevitable, make the ground level on the slope to secure the flat working area.

• Never travel on the slope of more than 30˚ gradient.

• When parking on the slope is inevitable, make sure to apply skids to the crawlers and get down the bucket to the ground.

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

2. While getting down slope, slowly operate the travel levers.

3. Travel slope with low speed (1st speed).

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

(12~16in) (12~16in)

75

SECTION III - BASIC MACHINE OPERATION 5. When the engine is stalled 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.

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

7. When parking the machine on a slope, even if it is a short time of period, place all attachments on the ground, place each operating lever in the neutral position, set the safety control lever to the “LOCK” (up) position and block the crawlers.

BUCKET DOZER

BLOCK

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.

SHOE SLIDE SLEWING BEARING

(A) F21365

1. Where a river bed is flat and water flow is slow, the machine may be operated in a water-depth to the shoe slide (A).

2. Operate the machine in the water with care checking river bed conditions with bucket, etc. And never enter into the water of the depth beyond.

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

4. After traveling in seawater, thoroughly wash up the machine to remove salt.

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 purges.

76

GREASING POINT

SECTION III - BASIC MACHINE OPERATION F. GETTING OUT OF SOFT GROUND If possible, avoid traveling 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: 1. ONE CRAWLER SHOE GETS CAUGHT IN MUD When either side of crawler shoes gets caught in the mud, lay logs or boards on the mud to form a base. Operate the boom and arm to form an angle between boom and arm 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.

2. BOTH CRAWLER SHOES GET CAUGHT IN MUD When both sides of crawler shoes 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 its crawler is stuck in mud, sand or gravel on the soft ground, take each crawler off the ground by pushing the boom and arm 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 crawler back and forth.

CAUTION Operate the machine at the operator’s seat.

Do not allow any person to come near the machine.

77

SECTION III - BASIC MACHINE OPERATION G. SLEWING OPERATION

SLEWING PATTERN (ISO) LEFT OPERATING LEVER

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.

• Build a level area for the machine to operate.

• Use a flagman to guide the operator.

78

SLEWING LEFT

F19455

SLEWING RIGHT

SECTION III - BASIC MACHINE OPERATION H. CHANGING MACHINE WIDTH (CRAWLER FRAME WIDTH)

CAUTION • Change the machine width on a flat and hard ground without any obstacles.

• Make sure to lift the machine body up to change the crawler width. Otherwise, the crawler frame and width adjusting cylinder may be damaged.

(A)

1. Lift up the machine body as shown in the sketch 2. Set the crawler/dozer shifting lever to (A) position (crawler frame width side).

F19365

3. Expanding: move the adjustable crawler frame width/ dozer lever to (B) position (crawler frame width expansion) to expand the machine width (crawler frame width).

RETRACTING

4. Retracting: move the adjustable crawler frame width/ dozer lever to (C) position (crawler frame width retracting) to contract the machine width (crawler frame width).

I. CHANGING DOZER WIDTH If required, the width of dozer blade can be extended by setting the additional plate as follows.

1. Pull the pin off, and remove the plate.

2. Set the plate outside, and align the pin bores.

3. Insert the pin to set it.

EXPANDING

PIN

F19368

79

SECTION III - BASIC MACHINE OPERATION

3.7 PRACTICES TO IMPROVE EFFICIENCY

WARNING • Swinging on a slope may cause the machine to become unstable or unbalanced. Do not swing down side of the slope with a full bucket. When working in slopes, build a level area for the machine to operate safely.

• Make certain the swing area of the machine is clear of people and obstacles before swinging.

A. DIGGING 1. Use Arm In Action Operate the bucket at shallow depth, use the arm 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 arm 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 the machine will be digging, and operate the bucket at shallow depth, 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, especially sudden stops during dropping, of the boom as this creates unnecessary stress on the machine and its components.

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

NOTE: Other than showing in the below sketches, wider range of the machine application is obtainable by means of utilizing the optional attachments. Refer to the section “MAINTENANCE” for changing the bucket.

80

SHALLOW

DIGGING DIRECTION

SECTION III - BASIC MACHINE OPERATION 1. DITCH DIGGING The working efficiency is much improved by means of setting the bucket suitable for trench digging and setting the machine in parallel to the trench to be digged.

For wide ditch digging, dig both sides portions at first, then dig the center portion.

2. USING THE DOZER 1. The dozer is used to push the soil back to digged ditch, or for ground leveling.

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. OFFSET DIGGING

WARNING Carefully operate the attachment paying attention to the surrounding conditions, since the boom swing operating range is wide.

The boom swings to the left and to the right enabling side digging in narrow spaces, by depressing the left and right sides of the swing pedal.

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

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

81

SECTION III - BASIC MACHINE OPERATION B. LOADING 1. The working efficiency is improved, if the dump truck is set at the position so that the slewing angle becomes minimum keeping a good visual field of the operator.

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 loading from the side.

C. WORKING IN NARROW SPACE The position is available for slewinging in narrow spaces.

D. MINIMUM SLEWING POSITION 1. Extend arm cylinder and bucket cylinder to maximum length, and fold bucket.

2. Extend boom cylinder to maximum length.

3. Swing boom by depressing boom swing pedal provided on right side.

4. Handle operating lever to swing boom.

NOTE: Use care to protect attachment from interference.

* MINIMUM SLEWING RADIUS Model Boom At swing (Minimum slewing radius) Not swing (Minimum slewing radius)

E9SR 970 mm (3’ 2.2”) (Boom Swing-Left 80°) 1250mm (4’ 1.2”)

NOTE: Dimensions shown in the above table are specifield for Standard/Long Arm.

82

SECTION III - BASIC MACHINE OPERATION

3.8 MACHINE PARKING

WARNING

BUCKET

• Always park the machine on a firm, level surface.

• Avoid parking on a slope. When parking on a slope is inevitable, make sure bucket teeth are digged in the ground, rest the dozer blade on the ground, and block the crawlers.

• Make 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.

DOZER

BLOCK

1. Place both travel levers (1) in the “NEUTRAL” position.

2. Set the throttle lever (2) to “LOW IDLING” position.

3. Place the bucket on the ground.

4. Place the dozer blade on the ground.

5. Block the crawlers.

6. Set the safety lock lever (3) to the “LOCKED” (up) position.

LOCKED

BUCKET

DOZER

3.9 CHECK & CONFIRMATION 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 trouble is 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 the “INSPECTION & MAINTENANCE CHART” for details on preventive maintenance.

WATER TEMP

FUEL

83

SECTION III - BASIC MACHINE OPERATION

3.10 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., adhered to the traveling components.

3.11 MEASURES AFTER EMERGENCY STOP 1. Avoid emergency stops 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 (to disipate heat), before stopping the engine.

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

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

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

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

84

SECTION III - BASIC MACHINE OPERATION 1. Even if the engine ceases its operation, keep the safety lock lever in the “LOCKED” (up) position.

2. When the emergency stop is done without placing the bucket on the ground, support it with safety blocks under the attachment or the bucket, and block the crawlers.

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

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

5. Consult with 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.

BUCKET DOZER

BLOCK

DO NOT OPERATE

SKID

➘

➘

SKID

3.12 LOCKING UP WITH KEY Make sure to use the ignition key to lock the following items: (a) Engine guard

KEY CYLINDER

(b) Storage box KEY CYLINDER

F19373

85

SECTION III - BASIC MACHINE OPERATION

3.13 EMERGENCY MEASURES AGAINST SUDDEN FAILURE OF MACHINE A. RELEASING LOCK FOR 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 on the travel motors, etc., it is possible to temporarily move the machine by means of releasing lock for the travel motor with removing the spool in the counter balance valve of the travel motor.

SAFETY BLOCK

CAUTION When di/re-assembling the travel motor, pay special attention not to allow invasion of foreign particles and dust into the travel motor.

1. Remove the shoes in accordance with “REPLACEMENT OF RUBBER CRAWLER SHOE”.

2. Apply safety blocks under the lower frames of left and right (travel motor side), and get down the machine which has been lifted up, then stop the engine.

3. Remove the travel motor cover (1) on the lower frame with loosening three capscrews (2).

4. Provide a container to receive draining oil under the travel motor, then disconnect the hoses. Since the draining oil comes out from the hoses and oil, receive it in the container.

Put a stopper plug to all openings on the hoses.

NOTE: To avoid erroneous connection of hoses, put a mark, such as the port name, on each hose at their disconnecting.

5. Remove the socket capscrews (3) to remove the travel motor from the lower (crawler) frame. Gradually loosen the capscrews paying attention not to drop off the travel motor.

8-Socket capscrew (3): M10x20 6. Remove the plug (4).

Plug (4): 27 mm of hex. size.

86

SAFETY BLOCK PLUG

CONTAINER

SECTION III - BASIC MACHINE OPERATION 7.Remove the spool (5). Be careful not to damage the spool during removal. Place spool (5) and loose parts (6) and (7) in a clean container with clean oil to protect them from rust and contamination.

8.Install plugs (4) to prevent contamination.

9. Remove 7-socket capscrew (12), and separate the bodies (10) and (11) from assembly.

• Make sure to contain oil spillage and dispose of all hazardous waste in accordance with local government regulations.

10. Remove 10-spring (13) for parking brake.

11. Temporarily reassemble bodies (10) and (11) in without springs (13).

12. Install the travel motor to the lower (crawler) frame and reinstall hydraulic lines.

13. Repeat steps 3 through 12 on the opposite track side to remove the other travel motor.

14. Install track chains in accordance with “INSTALLATION OF RUBBER CRAWLER SHOE” in the Section “MAINTENANCE”, and move the machine to a safe place to proceed with repairs.

By removing the spools and springs, the travel motors are released from locked condition.

Move the machine to a safe place.

NOTE: After all repairs are made, reinstall the counter balance spools and brake springs on both travel motors. Make sure hydraulic oil level is to specifications. Refer to “MAINTENANCE” section for proper oil and capacities.

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.

87

SECTION III - BASIC 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 excersized since the weight of the bucket will tend to move the bucket abruptly when the lines are disconnected.

Make 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), disconnect hose (H) side. Conversely, when the bucket is in dump position (B) (bucket cylinder completely retracted), disconnect the hose (R) side.

F15615

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

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.

88

SECTION III - BASIC MACHINE OPERATION C. LOWERING ARM & BOOM

WARNING

STEP1

STEP2

• This procedure is to be used only as an emergency to lower the position of attachment. Extreme caution should be excersized since the weight of the attachments will tend to drop them abruptly when the lines are disconnected.

• Make 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 blockage.

• Do not enter into the area under attachments, while lowering them.

1. Lowering Arm (Step1) Gradually loosen the hose of rod side connected to the arm cylinder.

2. Lowering Boom (Step2) Gradually loosen the hose of head side connected to the boom cylinder.

ARM (R)

BOOM (H)

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 advise and/or repairs.

D. SLEWING UPPER SLEWING STRUCTURE The upper slewing structure has no braking system. Therefore, it is possible to slew the upper slewing structure by means of pushing the attachment with a few persons.

89

SECTION III - BASIC MACHINE OPERATION

3.14 CAUTION ON USING RUBBER CRAWLER SHOES A. PROPER USAGE The rubber crawler shoe offers excellent features which a steel crawler shoe does not possess.

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

Comparison between rubber and steel crawler shoes: Rubber shoe Steel shoe Less vibration Smooth run Low noise Harmless for paved road Easy handling Not damageable Large traction force = Excellent

= Good

= Ordinary

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

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

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

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

90

* Although the rubber crawler shoe displays many advantages because of its material properties, it has disadvantages in terms of strength. It is therefore necessary to get fully familiar with the characteristics of the rubber crawler shoe and observe what are prohibited and cautioned against, in order to extend the service life of the rubber crawler shoe and have it fulfill its advantages to a maximum possible extent. Read throughly the section III “CAUTIONS ON USING RUBBER SHOES” before use. * GUARANTEE OF RUBBER CRAWLER SHOE Guarantee does not cover such damages done to the rubber crawler shoe 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, ferroconcrete debris, metal scraps and others which may tear off the rubber crawler shoe, and neglect to observe prohibited operations.

SECTION III - BASIC MACHINE OPERATION 4. Do not enter such hot places as an open-air fire, and steel plate left in the open sun.

Do not work in asphalt levelling.

5. When storing the machine for long periods (more than three months), keep it indoors which will not be exposed to direct sunshine and rain. Refer to the section III “PRECAUTIONS WHEN STORING THE MACHINE FOR A LONG PERIOD”.

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

TRAVEL

C. CAUTIONS ON USAGE Use care of the following when working: 1. Rubber shoes slip easily on icy surfaces Take the necessary safety precautions, such as not driving on snowy/icy slopes.

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

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

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

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

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

91

SECTION III - BASIC MACHINE OPERATION 7. If the machine is operated in salty or corrosive places, the adhesion of the core metal of the shoe will get loose. Refrain from using the shoe, or wash it with water after use.

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

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

9. Avoid changing direction of the machine on ground with difference in level (about 20cm/8in). 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.

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

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

92

(8in)

SECTION III - BASIC MACHINE OPERATION

3.15 MACHINE OPERATION IN ADVERSE WEATHER CONDITION 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.

1. FUEL AND OIL Use fuel and oil of high quality and low viscosity for each system. See section IV, “LUBRICANT, FUEL & COOLANT SPECIFICATIONS” for details.

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 allseason-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 oveloading. Keep a close watch on the cluster gauge 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.

3. BATTERY When the ambient temperature lowers, the charging performance goes down or the battery may freeze. Keep the charging rate as close as possible to 100%. Cover the battery with insulation material.

Perform test on the battery. We recommend the test be performed at romm 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

0°C

20°C

(14°F)

(32°F)

(68°F)

100%

1.28

1.27

1.26

90%

1.26

1.25

1.24

80%

1.24

1.23

1.22

75%

1.23

1.22

1.21

Charging rate

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.

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.

• 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.

93

SECTION III - BASIC MACHINE OPERATION B. OPERATION AT SEASHORE OR SALTY CLIMATE 1. BEFORE OPERATION • Check all mounting hardware for proper tightness. Torque to proper value to aid in preventing salt from entering the machine systems.

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

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 during rain. The electrical components (relays, fuses, etc.) are installed at the operator’s seat of the machine.

Never expose the operator’s seat to water.

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

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

3. FUEL Be careful not to let contamination in the fuel when refueling. Inspect the elements and filters at adequate interval.

4. ELECTRICAL EQUIPMENT Clean the starter and generator especially, at adequate interval, to prevent dust from accumulating. See “MAINTENANCE” section for details.

94

SECTION III - BASIC MACHINE OPERATION

3.16 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

Action

Washing machine

Wash the machine thoroughly.

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

Lubricate every required part.

Lubrication

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

Replenish if necessary, and change if contaminated.

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

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

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

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 wood 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 wood block 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.

• Get down the bucket to the ground and set the skids to the crawler.

Periodical operation for lubrication (during storage)

If the oil film on the parts is insufficient and rust occurs, 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.

• Before starting the engine, check the engine oil and coolant level, and replenish if insufficient.

• Wipe off the rust inhibiter from the cylinders and piston rod thoroughly.

• Apply rust inhibiters to the cylinder rods after the above operation.

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

• Ensure proper ventilation during warming-up operation.

Operation after long term storage

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

• Fully wipe off the rust inhibiters from the cylinders and piston rods.

• Refill fluids to proper levels and lubricate as required.

95

SECTION III - BASIC MACHINE OPERATION NOTES:

96

Section IV MAINTENANCE

SECTION IV - MAINTENANCE

4.1 GENERAL INFORMATION

WARNING Read, understand and follow all safety precautions contained in this manual before performing any inspection or maintenance procedures on this machine, its systems or components.

• Store the vessels and containers indoor for the oils, fluids and greases, taking suitable measures to prevent them from invading dust, water, etc.

NOTE: Make sure to consult with your Dealer for the adjustment, disassembling and repair.

A. It is recommended by the Manufacturer, that an inspection and maintenance schedule be developed and maintained on a regular basis for this machine. Developing and maintaining such a schedule, helps to keep the machine in optimum operating condition.

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. Use only original 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.

98

F1478

SECTION IV - MAINTENANCE

4.2 GENERAL SAFETY & PRECAUTIONS Do not carry out any other inspection and maintenance procedures than specified in the manual. Carry out them parking the machine at 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 “INSPECTION & MAINTENANCE CHART” for better reference.

Proceed with any maintenance as required.

HOUR METER

F15632

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 injury. If it is inevitable to operate the engine for the inspection or maintenance, carry out the work with a pair of two persons. And either person makes the engine ready to stop at any time at the signal of the partner.

DO NOT OPERATE

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 fully understanding the contents of safety precautions indicated on the machine decals.

F15635

99

SECTION IV - MAINTENANCE F. HOT SURFACES & FLUIDS Use cautions 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.

WARM ENGINE OIL Engine oil should have a temperature of between 20~40˚C (68~104˚F) before the oil is changed.

If necessary run engine until the oil is warm within the recommended oil change temperature.

G. 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 the section IV “RELEASING INTERNAL PRESSURE OF HYDRAULIC SYSTEM”.

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

I. INSPECT WASTE OILS AND FILTERS Before disposal, inspect all waste oils, fluids and filters for debris and foreign material. It is recommended to cut open the oil filters to determine any abnormal wear.

J. CAUTION FOR OIL FILLING When a strainer is provided on the filling port, do not remove it at refilling fuel, oil or fluid.

100

SECTION IV - MAINTENANCE K. 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.

L. KEEP THE MOUNTING FACE CLEAN After removing the O-ring or gasket, clean the installing face, and replace with a new one.

When installing the O-ring or gasket, apply a thin layer of oil to the seal, and install securely.

OLD

NEW

M. PROVIDING LOCKING DEVICE When the inspection or maintenance is carried out under the attachment, provide proper support or blocks to secure the attachment.

N. CAUTION AT 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 must be carried out visually.

O. DUSTY CIRCUMSTANCES When the machine is operated in dusty circumstances, take the precaution of doing as follows.

• Frequently check the alarm lamp for the air cleaner clogging. Clean up the air cleaner element more frequently than the specified interval.

• Clean up the radiator core more frequently than the specified interval to prevent it from clogging.

• Clean up and replace the fuel filter element more frequently than the specified interval.

• Clean up the electric equipment, especially for starter and generator, not to allow deposit of dust on them.

101

SECTION IV - 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

Hydraulic oil tank

Type of lubricant

Capacities (When changed)

Climate Zone -22˚ -4˚ 14˚ 32˚ 50˚ 68˚ -30˚ -20˚ -10˚ 0˚ 10˚ 20˚

ISO VG46 Total system

15 liters (4.0 gal)

Slewing motor

Automatic circulation of the above oil

Engine oil pan --------------

H level: 1.7 liters (0.45 gal)

Engine oil

L level: 0.7 liters (0.18 gal)

ISO VG32

SAE 40 SAE 30 SAE10W

Travel motor ---------------- 330 cc (20cu•in)x2

Diesel fuel

9 liters (2.4 gal)

ASTM D-975 No.1

Radiator

Coolant

Radiator 1.1 liters (0.29gal)

30% LLC mixture

Total volume 2.2 liters (0.58gal)

75 cc (4.6 cu•in) X 6

Lower rollers

50% mixture EXTREME GEAR OIL SAE #90

Gear oil Idlers Attachment and dozer pin Swing cylinder pin Slewing bearing

30 cc (1.8 cu•in) X 2

1 places

Idler adjuster

2 places

Operating lever & pedal

As required

Slewing gear

Grease

ASTM D-975 Grade 2-D ASTM D-975 Grade 1-D (If commercial coolant is used, the mixing rate should conform with the specified.)

A. P. I. classification for "service GL-4"

EXTREME GEAR OIL SAE #90

19 places

Grease

A. P. I. classification for "service CD"

SAE10-30 ASTM D-975 No.2

Fuel tank

Specified lubricant

ISO VG68

Tank 10 liters (2.6 gal) Hydraulic oil

86˚ 104˚F 30˚ 40˚C

70 g

Note: Machines are shipped from factory with *marked oil.

Extreme pressure Multipurpose grease NLGI No.2 Lithium base grease EP type Cartridge Pail can

N.L.G.I No.2 Lithium base with MoS2 grease F21369gb

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 case that you do use BIO OIL, it is required to flush the hydraulic system that was filled with mineral oil three times.

3. If you use BIO OIL, slewing and propel travel brake performance will be reduced, because of the lower friction factor of BIO OIL compared to that of mineral oil (This item is not applied for the small size machine).

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

102

SECTION IV - MAINTENANCE

4.4 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.

A. FILTER AND ELEMENT LIST No.

Items enclosed in parenthesis { } are the parts to be changed at the same time.

Qty Parts Name Replacement Interval

Device

After 50 hours (first change) (1)

Return filter {O-ring}

Hydraulic oil tank

1 Every 500 hours (from 2nd. change)

(2)

Hydraulic oil tank

Suction strainer {O-ring}

1

Every 2000 hours

(3)

Air cleaner

Element

1

Every 500 hours

(4)

Engine oil filter

Cartridge

1

After 50 hours (first change) Every 250 hours (from 2nd.change) (5)

Fuel filter

Element {O-ring}

1

Every 500 hours

(6)

Water separator

Element {O-ring}

1

When required

B. BUCKET

(7)

BUCKET

Side Cutter

2

When required

(8)

BUCKET

Tooth

3

When required F21370gb

(3) (7)

(8) (1) (2) (5) (4) (6) F19376

103

SECTION IV - MAINTENANCE

4.5 ACCESSORY TOOLS No.

TOOL NAME

REMARKS

1

SPANNER

SIZE 10 mm - 12 mm

2

SPANNER

SIZE 13 mm

3

SPANNER

SIZE 14 mm - 17 mm

4

SPANNER

SIZE 19 mm - 22 mm PLUS/MINUS REPLACEABLE

5

DRIVER

TYPE

6

WRENCH

FOR ENGINE OIL FILTER

7

ADJUSTABLE WRENCH

8

PLIER FOR GREASE

9

BOW-WRENCH

NIPPLE OF IDLER ADJUSTER

11 LABEL (WARNING TAG)

104

do not operate

10 TOOL CASE

SECTION IV - 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. Retighten the loose bolt and install new ones when ever lost.

For the new machine, checking and retightening of bolts an nuts must be carried out at the first 50 hours operation. When replacement is needed, make sure to use the same size of the Manufacturer genuine parts.

Refer to the table below for proper tightening of capscrews.

• The table below is not applicable for the capscrews holding plastic covers, etc.

For proper tightening of such capscrews, consult with your Dealer. Over-tightening may cause damages on the parts to be fixed.

• In case that the tightening torque is specified in the manual, use such torque values regardless to the table below.

• Numerical indication on the capscrew head shows the classification for strength (e.g., 7 = 7 T). No indication is provided for smaller size of capscrews, M 5 or less.

CLASSIFICATION

105

SECTION IV - MAINTENANCE

1. Metric Coarse Thread Standard Tightening Torque Values. Make certain to tighten all Capscrews & Nuts to proper torque values.

Classification

4.8 T

7T

10.9 T

NOMINAL SIZE NO LUBRICATION OIL LUBRICATION NO LUBRICATION OIL LUBRICATION NO LUBRICATION OIL LUBRICATION M6

P=1

M8

P=1.25 1.09 0.11(7.9 0.8) 0.92 0.09(6.6 0.7) 2.4 0.2(17.3 1.4)

M10 P=1.5

0.45 0.05(3.2 0.4) 0.38 0.04(2.7 0.3) 0.98 0.1(7.1 0.7) 0.83 0.08(6.0 0.6) 1.77 0.18(12.8 1.3) 1.5 0.15(10.8 1.1)

2.2 0.2(15.9 1.4) 1.83 0.18(13.2 1.3)

2.0 0.2(14.4 1.4)

4.3 0.4(31 2.9)

3.6 0.4(26 2.9)

4.7 0.5(34 3.6)

4.0 0.4(29 2.9)

8.5 0.9(61 6.5)

7.2 0.7(52 5.1)

M12 P=1.75

3.7 0.4(27 2.9)

3.2 0.3(23 2.2)

8.1 0.8(59 5.8)

6.8 0.7(49 5.1)

M14 P=2

5.9 0.6(43 4.3)

5.0 0.5(36 3.6)

12.8 1.3(93 9.4)

10.8 1.1(78 7.9)

M16 P=2

9.0 0.9(65 6.5)

7.6 0.7(55 5.1)

19.5 2(140 14.4) 16.4 1.6(118 11.5)

M18 P=2.5

12.4 1.2(90 8.7)

10.5 1.0(76 7.2)

M20 P=2.5 M22 P=2.5

17.5 1.7(126 12.3) 14.7 1.4(106 10.1)

14.6 1.5(105 10.8) 12.3 1.2(89 8.7) 23 2(166 14.5)

19.5 1.9(140 13.7)

35 4(252 29)

29 3(209 22)

27 3(195 22)

23 2(166 14.5)

49 5(354 36)

41 4(296 29)

38 4(274 29)

32 3(231 22)

68 7(491 51)

57 6(412 43)

23 2(166 14.5)

19.6 2(142 14.5)

51 5(368 36)

43 4(310 29)

92 9(665 65)

77 8(557 58)

M24 P=3

30 3(217 22)

24 3(173 22)

65 7(470 51)

53 5(383 36)

118 12(852 87)

93 10(673 72)

M27 P=3

44 4(318 29)

36 3(260 22)

96 10(694 72)

78 8(563 58)

173 17(1250 123) 140 14(1010 100)

M30 P=3.5

60 6(433 43)

50 5(361 36)

131 13(948 94)

110 11(796 79)

235 24(1700 174) 198 20(1430 145)

M33 P=3.5

81 8(585 58)

68 7(491 51)

176 18(1270 130) 148 15(1070 110) 317 32(2290 230) 266 27(1920 195)

105 10(758 72)

88 9(636 65)

227 23(1640 170) 190 19(1370 140) 409 41(2960 300) 343 34(2480 250)

M36 P=4

TORQUE VALUE UNIT-kgf•m (lbf•ft)

2. Metric Fine Thread Standard Tightening Torque Values. Make certain to tighten all Capscrews & Nuts to proper torque values.

Classification

4.8 T

7T

10.9 T

NOMINAL SIZE NO LUBRICATION OIL LUBRICATION NO LUBRICATION OIL LUBRICATION NO LUBRICATION OIL LUBRICATION M8

P=1.0

1.15 0.11(8.3 0.8) 0.97 0.1 (7.0 0.7) 2.5 0.2 (18.0 1.4) 2.1 0.2 (15.2 1.4)

4.5 0.4 (33 2.9)

3.8 0.4 (27 2.9)

8.9 0.9 (64 6.5)

7.5 0.7 (54 5.1)

M10 P=1.25 2.3 0.2 (16.6 1.4) 1.91 0.19(13.8 1.4) 4.9 0.5 (35 3.6)

4.2 0.4 (30 2.9)

M12 P=1.25 4.0 0.4 (29 2.9)

3.4 0.3 (25 2.2)

8.7 0.9 (63 6.5)

7.3 0.7 (53 5.1) 15.7 1.6 (114 11.6) 13.2 1.3 (95 9.4)

M16 P=1.5

7.9 0.8 (57 5.8)

20 2 (144 14.5) 17.2 1.7 (124 12.3)

M20 P=1.5

9.4 0.9 (68 6.5)

19 1.9 (137 13.7) 15.8 1.6 (114 11.6) 41 4 (296 29)

37 4 (268 29)

31 3 (224 22)

34 3 (246 22)

74 7 (535 51)

62 6 (448 43)

58 6 (420 43)

126 12 (911 87)

105 10 (759 72)

M24 P=2

32 3 (231 22)

27 3 (195 22)

M30 P=2

65 6 (470 43)

54 5 (391 36)

142 14(1030 100) 118 12 (852 87) 255 26 (1840 188) 212 21 (1530 150)

M36 P=3

109 11 (788 79)

91 9 (658 65)

238 23(1720 166) 198 20 (1430 145) 428 43 (3100 310) 357 36 (2580 260)

70 7 (506 51)

TORQUE VALUE UNIT-kgf•m (lbf•ft) F17003gb

106

SECTION IV - MAINTENANCE

4.7 TORQUE SPECIFICATIONS FOR JOINTS & HYDRAULIC HOSES

A. SLEEVE TYPE TUBE FITTINGS Tube size

Spanner

Tightening

ODXThickness (mm)

size (mm) 19 27 32 36 41 55

torque kgf•m(lb•ft) 4.5 ± 0.5 (33 ± 4) 15 ± 2.0 (110 ± 14) 18 ± 2.0 (130 ± 14) 22 ± 2.0 (160 ± 14) 28 ± 3.0 (200 ± 22) 45 ± 4.5 (330 ± 33)

10 x 1.5 15 x 2.0 18 x 2.5 22 x 3.0 28 x 4.0 35 x 5.0

B. JOINTS FOR PIPING (O-RING SEALING TYPE) Nominal screw

Spanner

Tightening

size (PF) 1/8 1/4 3/8 1/2 3/4 1

size (mm) 14 19 22 27 36 41

torque kgf•m(lb•ft) 1.7 ± 0.2 (12 ± 1) 3.7 ± 0.2 (27 ± 1) 7.5 ± 0.5 (54 ± 4) 11.0 ± 1.0 (80 ± 7) 16.5 ± 1.0 (119 ± 7) 26.0 ± 1.0 (188 ± 7)

O-RING

C. HYDRAULIC HOSES Nominal screw

Spanner

Tightening

size (PF) 1/8 1/4 3/8 1/2 3/4 1

size (mm) 17 19 22 27 36 41

torque kgf•m(lb•ft) 1.5 ± 0.2 (11 ± 1) 3.0 ± 0.5 (22 ± 4) 5.0 ± 0.5 (36 ± 4) 8.0 ± 0.5 (58 ± 4) 12.0 ± 1.0 (87 ± 7) 14.0 ± 1.5 (101 ± 11)

UNION NUT

NOTE: All torque values are subject to a dry condition.

107

SECTION IV - MAINTENANCE

4.8 INSTALLING HYDRAULIC HOSE AND PIPE JOINT

A. METAL JOINT SEAT FACE

ELBOW

The following two types of joint are used on the joint part of hose piping.

A. Metal joint (30° Flare type) Sealing is performed with metal compression of the opening of connector (tee, elbow) and hose. Use cautions to disassemble and assemble it to protect the damage on the seat surface.

B. O-ring seal joint Hose fitting is equipped with O-ring which seals the oil pressure on the joint and protects it from oil leakage.

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 hydraulic unit. * O-RING 1. At reassembling, be sure to replace the Oring with a new one.

2. Where the union is loosened and oil is leaked, 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 a specified causes oil leakage and shor t life of hydraulic equipment, because the material and hardness differ even if they are the same size. * JOINT 1. Care must be exercised not to damage hose, pipe and O-ring groove face and seal face (dent, etc.) of hydraulic equipment. The use of a damaged parts causes oil leakage.

2. Use care to prevent contamination.

Fitting with foreign materials inside causes oil leakage.

108

HOSE UNION NUT SEAT (HOSE SIDE)

SEAT (CONNECTOR SIDE)

B. O-RING SEAL JOINT HOSE

UNION NUT CONNECTOR

O-RING

O-RING

O-RING FILETTATO

* 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 install the joints.

Lubricants on threads shall be wiped off prior to install the joints.

SECTION IV - MAINTENANCE

4.9 RELEASING INTERNAL PRESSURE OF HYDRAULIC SYSTEM Release the internal pressure of hydraulic system before carrying out maintenance work such as hydraulic oil change, return filter change, suction strainer cleaning, cylinder repair.

Pressurize the hydraulic oil tank after maintenance and releasing air in the system.

HYDRAULIC OIL LEVEL CHECK POSITION

BUCKET

DOZER BLADE

A. RELEASING HYDRAULIC SYSTEM AND TANK 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 tank 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 TANK

LEVEL GAUGE F19384

FUEL TANK

1. Place the machine in the “hydraulic oil check position” as shown in the right figure.

Fully retract the arm 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, arm, bucket, swing) stop the engine then operate the control levers to release pressure of each line.

AIR PLUG

F19385

NOTE: The internal pressure of the hydraulic system can be released only by the above method.

3. Set the safety lock lever to “LOCKED” position.

4. Make sure the hydraulic oil temperature is below 40°C (104°F).

5. Slowly loosen the air plug on the upper side of the hydraulic oil tank to release internal pressure.

NOTE: Remove the AIR PRESSURE CAP after the engine has cooled down to touchable with a hand. Slowly loosen the cap to release the inside pressure. Remove the AIR PRESSURE CAP after all pressure is released.

6. Temporarily install plug until completion of the inspection and maintenance procedures.

7. In case of Manual operating lines (Travel, Swing, Dozer, Service), operate each control levers to release pressure of each line after stopping engine.

Now inside pressure in the hydraulic oil tank is fully released. Proceed the inspection and maintenance procedures for the hydraulic system.

109

SECTION IV - MAINTENANCE B. BLEEDING AIR IN HYDRAULIC SYSTEM

1.

2.

3.

4.

Bleed the air contained in the hydraulic circuit after performing maintenance to the hydraulic system.

Start the engine, and operate the engine at low idle for around 5 minutes. Then proceed as follows: With the engine running in low idle, extend and retract each cylinder 4 - 5 times. However, do not extend and/or retract each cylinder to the end of its stroke yet.

Repeat extending and retracting each cylinder 2 - 3 times but now to the end of is stroke.

Air bleeding for the hydraulic circuit has been completed. Stop te engine and let it set for more than 5 minutes to dissipate the air bubbles in the hydraulic oil tank.

ALLOWANCES

NOTE: If engine speed is at high idle during the bleeding, the piston and packings may be damaged due to the air contained in the cylinder.

4.10 PRESSURIZING HYDRAULIC OIL TANK After having performed maintenance to the hydraulic system, make sure to pressurize the hydraulic tank as follows; 1. Start the engine and keep low idling under the condition where the air plug on the hydraulic oil tank is open.

2. Slowly and gradually extend each cylinder to its stroke end to obtain the "Hydraulic Oil Tank Pressurization Position".

3. Tighten plug Tightening torque : 3.0 +- 0.3 kgf•m (22 +2 lbf•ft) 4. Ensure that the tank is free from oil leakage, and close the tank cover. Operate the attachments and retract the cylinder rods to pressurize the hydraulic tank.

HYDRAULIC OIL TANK PRESSURIZATION POSITION

BUCKET CYLINDER

ARM CYLINDER

BOOM CYLINDER SWING CYLINDER DOZER CYLINDER

AIR PLUG

NOTE: If the hydraulic oil tank is not pressurized, the hydraulic pump could be damaged. Make sure to pressurize it.

F19385

110

SECTION IV - MAINTENANCE

4.11 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. Set the safety lock lever at “LOCKED” position, and stop the engine.

2. Make sure to fill the fuel tank.

3. Ensure that the handle of fuel filter and water separator are set in “OPEN” position.

4. Move the priming lever at the side of fuel injection pump up and down to feed fuel while the engine is stopped.

5. Turn starter switch for engine cranking. During cranking, the fuel is fed and the fuel injection starts, and the engine starts immediately after air is bled.

FUEL FILTER

HANDLE

CLOSE

OPEN F19387

NOTE: Don’t operate the starter continuously for 15 seconds or more.

If it is necessary to crank for 15 seconds or more, stop cranking once, and start cranking again by setting it at “START” position after approx. 30 seconds.

(1) 15 SEC. OR LESS (2) 30 SEC. APPROX.

By moving the priming lever at the side of fuel injection pump up and down, the fuel is fed while the engine is stopped.

Therefore, release the air beforehand, and the worktime is shortened.

FUEL FEED PUMP PRIMING LEVER

111

SECTION IV - MAINTENANCE

4.12 REPLACEMENT OF RUBBER CRAWLER SHOE

WARNING • This work must be carried out by two people. The operator operates the machine in accordance with the signal of the partner. The rubber crawler shoe replacement is carried out lifting the machine body.

Erroneous falling of the machine body during the work on the crawler shoe is quite dangerous. Do not operate any other attachments than the crawler.

• Grease in track tensioning mechanism is under extreme high 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 crawler shoe, ensure 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 “REMOVING OF RUBBER CRAWLER SHOE” below. If the tension on the crawler shoe is not released, consult with your Dealer for its repair.

A. REMOVING RUBBER CRAWLER SHOE 1. Operate boom, arm, 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 safety supports.

3. Slowly loosen the grease nipple (1) on the grease cylinder to allow to discharge the grease and release tension.

4. Slowly loosen the grease nipple less than one turn.

5. Engage some steel pipes into the rubber crawler shoe, then slowly rotate the sprocket backward. When the rubber crawler shoe floats from the steel pipes, slide the shoe to the side to remove it.

F14399

SUPPORT

DIRECTION OF ROTATION

STEEL PIPE

112

SECTION IV - MAINTENANCE B. INSTALLING RUBBER CRAWLER SHOE 1. Operate boom, arm, 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, etc.

3. Engage the rubber crawler shoe with the sprocket and hang it on the idler.

4. Slowly rotate the sprocket backward and push the rubber crawler shoe into its position, then stop the rotation.

5. Engage a steel pipe into the rubber crawler shoe, and rotate the sprocket backward again to securely engage the rubber crawler shoe with the idler.

6. Stop the rotation of sprocket to ensure that the rubber crawler shoe is securely engaged to the sprocket, idler and lower rollers.

7. Referring to the next Item “C”, carry out the check and adjustment of tension on rubber crawler shoe.

8. After confirming the engagement of rubber crawler shoe to the sprocket, idler and lower roller, and also the proper tension on the rubber crawler shoe, place the machine on the ground.

SUPPORT

DIRECTION OF ROTATION

STEEL PIPE

LOWER ROLLER RUBBER SHOE

METAL CORE

LUG STEEL CORD IDLER

TRAVEL MOTOR

SPROCKET

F15740

113

SECTION IV - MAINTENANCE C. CHECK AND ADJUSTMENT OF TENSION ON CRAWLER SHOE An appropriate adjustment of tension on the rubber crawler shoe is important not only for prolonging the service life of the rubber crawler shoe and machine but also preventing the rubber crawler shoe from coming out of place.

WARNING RUBBER CRAWLER SHOE

Since checking and adjustment for the tension on the rubber crawler shoe is carried out with the machine lifted, it is quite dangerous if the machine is erroneously dropped to the ground. Never move the machine while checking and adjusting it. Work has to be performed be two people, and the operator must operate the machine in accordance with the signal of the partner.

RUBBER CRAWLER SHOE Since the abrasion of the rubber crawler shoe 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 crawler shoe, there is an initial stretch. Therefore, frequently check crawler tension during the first 30 hours on a new machine or new tracks.

1. CHECK 1. Move the rubber crawler shoe so that the jointing part (M mark) comes to the upper center position.

2. Slewing the upper structure to place it at 90˚ (right angle) to the crawler frame. Operate boom, arm, and bucket to set the attachment on the ground. Slowly and gradually lower the boom to lift one side of the machine.

3. Measure the clearance (A) between the lower face of crawler frame and the upper face of crawler shoe at the center position of crawler frame. Proper value (tension) (A) mm: 45~55 mm (1.8~2.2 in).

4. If the tension is not proper, adjust it referring to the section IV “ADJUSTMENT”.

JOINT MARK

SUPPORT

LOWER ROLLER

CRAWLER FRAME

NOTE: The machine operation with loosened rubber crawler shoe causes the rubber crawler shoe to come out of place and wear prematurely.

RUBBER CRAWLER SHOE

114

SECTION IV - MAINTENANCE 2. ADJUSTMENT It is required to adjust the tension on the crawler shoe depending on the working place of the machine. When working at the place with a lot of gravel or round stones, 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 your Dealer for assistance.

2.1 MAKING TENSION STRONGER Provide a grease gun.

1. Feed grease to the grease nipple (1) with the grease gun so that proper tension on the crawler shoe is obtainable.

2. Move the machine forward and backward to equalize the tension on both crawler shoes of left and right.

3. Again check the tension on the crawler shoes, and repeat the adjustment to obtain the proper tension on both crawler shoes.

F14399

PRESSURE

NOTE: When the tension on the crawler shoe is still loose even grease is supplied to the grease nipple, it is presumable that some faulty conditions may exist on the seal in the cylinder or machine body. Request the repair to your Dealer.

GREASE CYLINDER

GREASE GUN

115

SECTION IV - MAINTENANCE 2.2 MAKING TENSION LOOSER

LOOSEN

WARNING Grease in track tensioning mechanism is under extreme high 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.

1. Gradually loosen the grease nipple (1) to discharge grease.

Do not loosen the grease nipple (1) more than one turn.

2. Move the machine (crawler shoe) forward and backward, when grease does not be discharged adequately.

3. Tighten up the grease nipple.

Tightening torque: 6 ± 1kgf•m(43 ± 7 lbf•ft) Move the machine forward and backward to ensure the correct tension on the crawler shoes.

Again check the tension, and if it is not correct, adust it again.

116

GREASE

GREASE

SECTION IV - MAINTENANCE

4.13 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.

Components

Interval Item

Engine oil

Engine oil filter

When re- Daily quired

WARNING Read, understand and follow all safety precautions found in this manual before performing inspection & maintenance.

Symbols and their meanings: Necessary regular inspection item to hour meter. * Only first replacing performed.

Inspection and / or maintenance is needed.

50h

Check level

Lubricant, etc.

(Replacing part)

Engine oil

Change

* (First)

Change

* (First)

Water separator Drain / Clean

250h 500h 1000h 2000h

Cartridge Element

Clean Element

Fuel filter

ENGINE

Change

Air cleaner element

Check / Clean

Element

Change Check level

Radiator coolant Change

Tap water

Check leakage Check Fan belt Adjust F19553gb

117

SECTION IV - MAINTENANCE

Components

Interval Item Radiator core

Clean

Radiator cap

Clean

When re- Daily quired

50h

250h 500h 1000h 2000h

Lubricant ,etc.

(Replacing part)

FUEL SYSTEM

ENGINE

Hoses in cooling Check / system Change Check color, sound, smell of exhaust gas Valve clearance Check / Adjust Compression pressure

Check / Adjust

Injection timing

Check / Adjust

Starter and generator

Check / Adjust

Fuel Fuel tank

Drain water and deposits Check leakage

HYDRAULIC SYSTEM

Hydraulic oil

Check level

Hydraulic oil

Change Hydraulic Suction Clean / tank strainer Change Return filter

Change

Strainer

*

(First)

Element

Check oil leakage and damage of pipings and hoses Check oil leakage and damage of cylinders, etc.

Line filter Inline filter

UPPER FRAME

Check level

Clean

Slewing bearing Grease

Grease

Grease in slewing grease bath

N.L.G.I No.2 Lithium base MoS2 grease

Change

F17005gb

118

SECTION IV - MAINTENANCE

Components

Interval Item

LOWER FRAME

Travel reduction Oil motor Change

When re- Daily quired

50h

250h 500h 1000h 2000h

*

(First)

Lubricant ,etc.

(Replacing part) Gear oil

Check/Adjust tension of rubber/steel shoe Check crawlers and links of rubber shoe Check Roller Idler

Change

Gear oil

Check oil leakage and wear of sprocket/travel reduction motor Bucket Grease

ATTACHMENT

Grease for pins Boom&Arm cylinder Change Bucket Adjust mount gap

ELECTRICAL EQUIPMENT

Check wear and damage of tooth and side cutters Check damage of electrical wirings

Battery

Check electrolyte level Measure specific gravity

Check function of warning lamps Check switches / levers Change working light(Lamp)

OTHERS

Distilled water

12V 55W Halogen lamp

Check abnormal deformation and damage of machine exterior Check looseness and missing of capscrews and nuts Check Operating lever Lubricate

Grease F21965gb

119

SECTION IV - MAINTENANCE

4.14 WHEN REQUIRED Thoroughly read and understand the section “SAFETY PRECAUTIONS” of this MANUAL before operating or servicing the machine.

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.

F14396

A. CLEANING RADIATOR CORES

CAUTION Direct contact of yourself with compressed air, steam and high pressure water causes injury. Make 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 section “MACHINE FAMILIARIZATION” “Open/Close Guard Cover” 2. Check the radiator fins for clogging with dust and mud.

3. Remove the dust and mud on the radiator cores and fins with compressed air.

NOTE: To avoid damages on the fins, take some distance between the spray nozzle of compressed air and the fins. If the fins gets some damages, it causes water leakage resulting in overheating.

120

F19389

SECTION IV - MAINTENANCE 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.

F14397

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.

CAUTION If the tightness of cap is insufficient, it may cause danger of getting burned due to spouting out of hot water or steam during operation.

121

SECTION IV - MAINTENANCE C. REPLACEMENT OF WORKING LIGHT A light bulb of 23 W 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 is adhred on it.

When replacing the light bulb, hold it at the flange portion not touching with its glass portion.

When the working light is not lightened even though the switch for working light is turned on, the light bulb or fuse may be burned out.

If there is no trouble on the light bulb, check the fuse referring to the section “MACHINE FAMILIARIZATION”.

The following is the description for the changing procedures of light bulb.

1. Place the attachment on the ground, and set the safety lock lever to “LOCKED” position, then stop the engine.

2. Disconnect the connector, then remove the working light with spanner from the boom.

3. Remove the screw (1) (3 pieces) then remove the rim (2) and lens (3) from the housing (4).

4. Remove the light bulb (6) from the reflector (5), and install a new bulb.

5. Assemble the working light in reverse order of the above.

NOTE: Pay attention not to break the light bulb at the replacement. Hold the lens at removing the screw (10), otherwise, the lens falls off.

BOLT ON OF

F

(150mm)

WASHER NUT F19390

(1)

(2) (3) (6) (5)

ON OF

F

(4) F19391

122

SECTION IV - MAINTENANCE D. CHECK FOR ABRASION/DAMAGES ON TOOTH POINT & SIDE CUTTER

DANGER When replacing the tooth point and side cutter, apply a safety block to the bottom face of the bucket.

Check the tooth point and side cutter for their worn-out condition. The tooth point holed or cracked must be replaced before the abrasion on the adapter. And the worn-out side cutter is also to be replaced earlier.

If the replacement is too late, the bucket body will be damaged.

TOOTH POINTS

2-3 mm (0.08-0.12 in)

REPLACEMENT OF TOOTH POINT & SIDE CUTTER: Consult with an authorized Distributor for the replacement of tooth point and side cutter.

8-10 mm (0.31-0.39 in)

SIDE CUTTER

WORN OUT

CRACK

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

123

SECTION IV - MAINTENANCE 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. Make sure to align them visually.

F17301

1. REMOVAL OF BUCKET 1. Slightly operate the boom and the arm to remove load from the pins.

2. Roll O-rings (1) onto the bucket boss.

After installing the pins, get them back to the original position.

3. Remove the spring lock ring (2) and lock pin (3), then remove the pins (4) and (5) to remove the bucket (6).

NOTE: • Pay attention not to adhere any sand or dust to the pins removed.

• Pay attention not to damage the dust seals (9) which are installed in both ends of the arm (7) and bucket link (8).

SECTION A-A

124

SECTION IV - MAINTENANCE 2. INSTALLING BUCKET 1. Clean each pin and pin hole and grease sufficiently.

2. Move the bucket cylinder to match the pin bores of the bucket (6) and bucket link (8) with each other; then insert the pin (4) installing the shims (10).

3. Raise the boom up to lift the bucket slightly from the ground.

4. Move the arm (7) to match the pin bores of the bucket (6) and arm (7) with each other; then insert the pin (5) installing the shims (10).

5. Insert the lock pin (3) into pin (4) and (5), and attach the spring lock rings (2).

6. Fit O-ring (1) to the normal position.

Apply grease to the bucket link from the grease nipples sufficiently.

NOTE: Replace the O-ring (1) showing cracks or losing elasticity with a new one.

3. ADJUSTING BUCKET MOUNT GAP

WARNING Unexpected movement of attachment, while adjusting the bucket mounting gap is quite dangerous. Place the bucket on the ground in a stable condition, and set the safety lock lever to “LOCKED” position, then stop the engine.

WARNING

O-RING

SECTION B-B

If the clearance of the bucket is not properly adjusted, galling may occur on the contact faces of the bucket and arm, resulting in abnormal noise and damage of the shaft and O-ring.

An adjusting device is provided to adjust the clearance between the bucket and the arm.

When the clearance becomes large, adjust the clearance as follows.

Standard clearance of the bucket in total of both clearances Normal

0.5 mm (0.02 in)

BUCKET CLEARANCE ADJUSTING MECHANISM

1. Lower the bucket to the ground to stabilize.

Slightly lift boom to remove load from bucket pin connections to properly adjust bucket clearance.

125

SECTION IV - MAINTENANCE 2. Roll the O-ring (1) from its normal position to the bucket boss to avoid damage.

3. Slightly swing to the left direction to slightly push the arm end to the bucket left side (where no adjusting mechanism of clearance is equipped). By contacting the arm and bucket, total clearance is obtained on one place.

4. Set the safety lock lever to the “LOCKED” position; then stop the engine.

5. Measure the total clearance “X” between the arm and bucket boss. The clearance is the existing total clearance. Exact clearance is gotten easily by using a thickness gauge.

6. If the measurement value is 1 mm (0.04in) or more, decrease the clearance.

Remove shims (3) to recondition the clearance “X” after loosening 3-capscrew (2) with washer (4).

The clearance decreases by extruding the bushing (5), depending on the thickness of removed shims.

NOTE: Thickness of shim is 0.6 mm (0.02in). 6-shims on the average are provided on one capscrew (2).

BUCKET BOSS

SECTION C-C

BUCKET CLEARANCE ADJUSTING MECHANISM

LOCKED (UP) POSITION

Example: When X = 2 mm Remove 3-shim (0.5 x 3 = 1.5 mm) Remained clearance = 2 - 1.5 = 0.5 mm Tightening torque; 5.6 kgf•m (41 lbf•ft)

7. Tighten the 3-capscrew (2) with washer (4) equally to the specified tightening torque.

8. Return the O-ring (1) to the normal position.

(Groove between the arm and bucket bosses.)

BEFORE ADJUSTMENT

2.0 mm (0.08 in) AFTER ADJUSTMENT

0.5 mm (0.02 in)

126

1.5 mm (0.06 in)

SECTION IV - MAINTENANCE F. INSPECTING RUBBER CRAWLER SHOE Repair or replace rubber crawler shoe if it falls into the following condition.

Contact your Dealer for repair or replacement of rubber crawler shoes.

1. HEIGHT OF LUG 1. If the lug of height (A) wears off, traction force decreases. Replace the shoe with a new one if (A) decreases below 5 mm (0.2in).

LOWER ROLLER

RUBBER CRAWLER SHOE

LUG

METAL CORE

STEEL CORD

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

STEEL CORD

2. BREAKAGE OF STEEL CORD If the steel cords of the rubber crawler shoe are broken by more than one half of one side row, replace the shoe with a new one.

BREAKAGE OF STEEL CORD

3. CRACK OF RUBBER CRAWLER SHOE If a crack which has developed to about 60 mm (2.4in) length is seen between the lug of rubber shoe, repair the shoe.

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

NOTE: For repairs or replacement of rubber crawler shoes, contact your Dealer.

FOR 60mm(2.4in) OR OVER, REPAIRS IS NEEDED REPAIR IS NEEDED REPAIR IS NOT YET NECESSARY

127

SECTION IV - MAINTENANCE 4. PEELING OFF OF METAL CORE ON RUBBER CRAWLER SHOE Depending on the usage of rubber crawler shoes, there may occasionally happen a peeling off of metal core on the rubber shoes (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.

LOWER ROLLER INTERFERENCE WITH ROLLER METAL CORE

STEEL CORD

NOTE: 1. The metal core starts peeling with the prohibited usage of the rubber crawler shoe.

2. Fully understand the prohibited usage of the rubber crawler shoe referring to section III “Basic machine operation” “Using rubber crawler shoes.”

3. Note that the warranty is not applicable for any damages due to the prohibited usage of the rubber crawler shoe or the use of it with improper tension on it.

RUBBER

PEELING OFF OF METAL CORE

1. The rubber crawler shoe on which the peeling off of metal core shows even at one place must be replaced with a new one.

2. The cracked rubber crawler shoe by which the metal core comes to the surface must be replaced with a new one.

3. The cracked rubber crawler shoe on the contacting portion of the metal core with the roller is not required to repair.

128

CROPPING OUT OF METAL CORE

CRACK

SECTION IV - MAINTENANCE 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.

RUBBER BOOT

OPERATING LEVER

1. Move the machine to firm and level ground, set the attachment on the ground, place the safety control lever to “LOCKED“ positon, then stop the engine.

2. Carefully raise up the rubber boot on the troubled operating lever with hand paying attention not to give any damages to 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.

APPLY GREASE UNIVERSAL JOINT SOCK.HEAD CAPSCREW

5. Check the pilot valve for any looseness, and if loosened, retighten the socket bolt.

H. CHECKING ELECTRICAL WIRING AND FUSES

WARNING • When a frequent replacement is required for the fuses or there are any traces of short circuiting on the electrical wiring, consult with your Dealer.

• Before checking the electrical system, make sure to disconnect the battery cable of negative (-) side.

Erroneous short circuiting may cause fire.

129

SECTION IV - MAINTENANCE REPLACING PROCEDURES

CAUTION When a new fuse is blown within a short time of service or frequent replacement for fuses are required, it may be caused by troubles in electric sequence. Consult with an authorized Distributor for repairs The main fuse box covered by the fuse box cover is provided under the seat.

MAIN FUSE BOX F19386

1. Place the bucket to the ground.

2. Set the safety control lever to the lock position.

3. Turn the starter switch to “OFF“ to stop the engine.

4. Open the cover under the seat.

5. The fuse box cover is locked on one side.

Release the lock and remove the cover.

6. When any fuse is blown as shown in the right, replace it with the spare fuse stored in the fuse box.

7. After replacing the fuse, make sure to set the cover with a click.

FUSE BOX COVER

F19395

WARNING Never replace a faulty fuse with higher amperage fuse.

Never use a “jumper“ in place of a fuse. Never splice accessories directly into fuse terminals.

1.

2.

3.

4.

5.

10A 30A 10A 20A 20A

Horn Timer, Relay Monitor panel (Gauge cluster) Working light Lever lock switch

Red Red, Blue White, Green Red, White Yellow

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 wires and fuse link. Replace the fusible link if needed.

FUSE 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 as an ordinary fuse.

F21479

130

SECTION IV - MAINTENANCE

4.15 DAILY INSPECTION AND MAINTENANCE Thoroughly read and understand the section, “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 SECTION “BASIC MACHINE OPERATION” IN THE FOLLOWING ITEMS FOR INSPECTION AND MAINTENANCE: • Check Coolant Level • Check Coolant Leakage • Check Fuel Level • Check Fuel Leakage • Check Belt • Check Hydraulic Oil Level • Check Engine Oil Level • Check Warning Lamps • Check Working Light • Check Exhaust Gas Color, Abnormal Sound and Smell • Check each Switch and Lever A. CHECK EXTERNAL CONDITIONS OF MACHINE A dent or distortion which apparently seems not to be severe damage, may be abnormal contact on internal parts or hoses.

Consult with your Dealer for advise and/or for repairs.

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 tighten.

Likewise, check and make sure all hose clamps are properly tighten.

The abnormal sound during operation may cause leakage or fire. Use torque values.

NOTE: Use the tools suitable for the work referring to Section IV “ TOOLS”.

131

SECTION IV - MAINTENANCE C. CHECK EACH CYLINDER, PIPING AND HOSE FOR LEAKAGES AND DAMAGES

WARNING Hydraulic line is always highly pressurized. Make 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.

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.

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. Set the safety lock lever to “LOCKED” position, then stop the engine.

2. To check the location of leakage, take a time to allow getting the temperature on each portion of the machine down to around 40˚C(104˚F). Make sure to wear the protective glasses and gloves for the check.

3. Press the rubber cap of the air breather on the top of the hydraulic oil tank several (five to seven) times to release the internal pressure of the tank.

NOTE: When any abnormalities happen on the machine, immediately stop operation, and ask for repairs as needed.

When the volume becomes insufficient for the engine coolant or oil due to leakage, an warning lamp is illuminated.

132

F16499

F14396

AIR PLUG HYDRAULIC TANK

FUEL TANK

F19397

SECTION IV - MAINTENANCE D. CHECK TRAVEL SYSTEM FOR LEAKAGE AND ABRASION 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 the machine and check for any abnormal sound.

NOTE: Consult with your Dealer for advise and/or repairs as needed.

A. B. C. D. E. F.

Travel Sprocket Lower roller Crawler shoe Shoe slide Idler

133

SECTION IV - MAINTENANCE

4.16 50-HOUR INSPECTION AND MAINTENANCE Thoroughly read and understand the section, “SAFETY PRECAUTIONS” of this MANUAL before operating or servicing the machine.

Perform together with 8-hour (daily) inspection and maintenance.

A. ADJUSTING CRAWLER TENSION Proper adjustment of the rubber crawler tension is essential for extending service life of the crawler and the travel system, and prevention of coming off of crawler due to insufficient tension.

F14399

WARNING The inspection of the crawler shoe tension is carried out with one side of machine lifted. It is quite dangerous if the machine is erroneously dropped. Never operate the machine during the inspection. Make sure to carry out the work with the help of another person. The operator operates the machine in accordance with the signal of the partner.

RUBBER CRAWLER SHOE

Refer to this Section for the check and adjustment of rubber crawler shoe tension.

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.

2. Clean the grease fittings before greasing.

Replace the grease nipple with a new one, if damaged.

3. Lubricate with a grease gun thruogh the grease fittings with arrows and the table below.

4. Properly wipe off any grease squirted out around the pin connection.

GREASING POSITION

BUCKET

DOZER BLADE

CAUTION Dispose of all hazardous waste in accordance with government environmental regulations.

134

No. 1 2 3 4

Greasing points Bucket cylinder rod pin Idler link/Arm connecting pin Bucket link pin Arm/Bucket connecting pin

Q.ty 1 1 1 1

SECTION IV - MAINTENANCE C. DRAINING WATER FROM WATER SEPARATOR AND CLEANING If the red ring (D) in the water separator sinks down to bottom of the case (F), no water is mixed in. When the ring (D) is floating, water is mixed in up to the level of the ring. Drain the mixed water in accordance with the following procedures.

WARNING

WATER SEPARATOR

(A)

CLOSED

Fuel oil adhered periphery may cause fire. Wipe it off thoroughly.

(B) 1. Set the safety lock lever to “LOCKED” position, then stop the engine.

2. Open the engine guard. After cooling down each portion, push the handle (A) of the water separator upward to the “CLOSE” position.

3. Loosen the ring (H) to remove the case (F), and drain the water out

(H)

OPEN

(D) WATER

(F) F19398

(C)

NOTE: Pay attention not to lose the red float (D) and spring (C).

CAUTION Dispose of all hazardous waste in accordance with government environmental regulations.

Check the water drained for its contamination.

And when it is dirty, clean up the element (B) and inside of the case (F).

4. Remove the element (B), and clean it with diesel fuel.

5. Replace the O-ring (E) with a new one.

6. Install the element (B) to the water separator body.

7. Set the O-ring (E) to the case (F), then tighten it up with ring (H).

8. Push the handle downward to set at “OPEN” position.

9. After draining water, make sure to bleed out the air releasing for the fuel system.

F15790

NOTE: Do not clean up the element with gasoline.

135

SECTION IV - MAINTENANCE D. DRAINING WATER AND DEPOSITS FROM FUEL TANK FUEL TANK

WARNING • Make sure to stop the engine when discharging fuel from the fuel tank.

• Thoroughly wipe up the spilled fuel.

(A) 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.

1. Swing the upper structure of the machine so that the drain plug (A) under the fuel tank comes to midway between the crawler shoes of left and right.

2. Place an empty container under the drain plug to catch the fuel discharged.

3. Slowly loosen the drain plug to drain water mixed in and deposits together with the fuel.

4. When pure fuel begins to discharge, tighten up the drain plug (A).

Tightening torque for drain plug: 3 ± 0.4 kgf•m (22 ± 3 lbf•ft)

F19399

(A) F21480

NOTE: Check for fuel leakage after tightening up the drain plug.

Consult it with your Dealer for advise and repairs if needed.

Make sure to contain any fuel spillage.

If the leakage appears on the drain plug (A), check the flange portion.

5. Remove the drain plug (A) to fully discharge fuel inside the fuel tank.

Tank volume; 9 liters (2.4 gal) 6. Check the packing (B) for any damages. If damaged replace it with a new one.

Remove the flange (E). Check the O-ring (F) for any damages. If damaged, replace it with a new one.

7. After the replacement, install the flange and drain plug to the tank in reverse order of the above.

Tightening torque for Bolt (C): 0.98 ± 0.1 kgf•m (7.1 ± 0.7 lbs•ft) 8. Refill the tank with fuel.

136

FUEL WATER DEPOSIT

(F) (E) (B) (A)

(C) F21481

SECTION IV - MAINTENANCE E. CHECK BATTERY FLUID LEVEL AND SPECIFIC GRAVITY The battery fluid easily decreases with high ambient 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 the battery fluid level periodically, and if insufficient, refill the battery with distilled water before starting the engine (before charging battery).

F14398

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.

• Battery fluid has strong acidity. It corrodes metal very rapidly. If it adheres on skin or enters into eys, it causes a burn or blindness.

At such cases, immediately wash skin or eye with lots of water, and ask a doctor to treat it as soon as possible.

INDICATOR INDICATIONS GREEN

BLUE GOOD

RED

RED

WHITE REFILLING REQUIRED

RED CHARGING REQUIRED

Check the indicator (A) on the battery, and always keep it at green color. Red color means insufficient battery fluid or charging.

1. Set the safety lock lever to “LOCKED” position, then stop the engine.

2. Referring to the section II “ GUARD WITH LOCKING DEVICE & COVERS”, remove the left guard and open the cover under the seat. The battery is located under the left operating control panel.

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 (1015 mm (0.4-0.6 in) above the plate).

5. Make sure the air vent holes on the caps (1) are clean and securely tighten caps (1).

6. If the terminal (2) are dirty, wash it with warm water, then install it to the position applying grease or spraying rust preventive solution.

If the terminal is oxidized, polish it with a wire brush or sand paper.

When it is difficult to obtain enough cranking speed at the 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 (20˚C or 68˚F).

For the specific gravity of battery fluid at cold climate or other specific conditions, refer to section “BASIC MACHINE OPERATION”, and make the charging rate around 100%.

AIR VENT HOLE

UPPER LIMIT LOWER LIMIT

PLATE (ELECTRODE)

BATTERY

If it is difficult even after re-charging is carried out, replacement of the battery with 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 with your Dealer for advise and/or repairs as needed.

137

SECTION IV - MAINTENANCE

4.17 250-HOUR INSPECTION AND MAINTENANCE Thoroughly read and understand the section, “SAFETY PRECAUTIONS” of this MANUAL before operating or servicing the machine.

Perform together with daily and 50-hour inspection and maintenance.

GREASING POSITION

BUCKET

A. GREASING ATTACHMENT AND DOZER PINS

NOTE: In ordinary operation, apply grease every 250 hours of operation or every six months, but under special conditions, observe the following lubrication intervals: 1) When operating the machine with a special attachment, apply grease every day before starting work.

2) For underwater digging operation, apply grease to the areas to be immersed in water every day before and after work.

3) Where the machine is stored for more than one month, apply grease before working.

138

DOZER GREASING POINTS

DOZER BLADE

SECTION IV - MAINTENANCE 1. Move the machine to a firm level area and place the attachment in the oil check position.

2. Make sure to clean the grease fittings before the greasing. Replace the grease fittings with a new one, if damaged.

3. Use table below to lubricate all connections through grease fittings unil grease purges out.

4. Properly wipe off any grease oozed out around the pin connection.

NOTE: Since the dozer foot pin (3) is supported by an iron bushing, frequent greasing is required for it when the dozer is frequently used at the work.

And when greasing the attachment, make sure to grease to dozer foot pin (3), too.

No. Greasing points

CYLINDER GREASING POINTS

ATTACHMENT GREASING POINTS

Q.ty

1

Dozer cylinder rod pin

1

2

Dozer cylinder foot pin

1

3

Dozer foot pins

2

4

Boom foot pin

1

5

Boom cylinder foot pin

1

6

Boom cylinder rod pin

1

7

Arm cylinder foot pin

1

8

Arm cylinder rod pin

1

9

Boom/Arm connecting pin

1

10

Bucket cylinder foot pin

1

11

Bucket cylinder rod pin

1

12

Swing cylinder foot pin

1

13

Swing cylinder rod pin

1

14

Swing bracket/frame connecting pin

2

SLEWING MOTOR

SWING BRACKET GREASING POINTS

139

SECTION IV - MAINTENANCE B. OIL CHANGE FOR ENGINE

WARNING • Do not carry out the oil change just after stopping the engine which is kept at high temperature at every portion. 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.

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.

Container to receive drained oil: 2 liter (0.53 gal) or more capacity Oil volume to be refilled: 1.7 liter (0.45 gal) 1. Place an empty container to receive the drain oil under the drain plug (1) located at the bottom of engine.

2. Remove the bottom cover (4) under the drain plug.

3. Slowly loosen the drain plug (1) so that the oil does not splash over yourself.

Make sure to contain any oil spillage.

4. Check drained oil. In case that lots of metal par ticles and/or foreign materials are contained in it, consult with your Dealer for advise and/or repairs.

5. Securely tighten the drain plug (1).

6. Open the engine guard, and remove the filler port cap (Yellow) (2). Refill the engine with the specified oil.

Refer to this Section for the recommended oil.

7. Start the engine, operate it for several minutes at idling, and shut it down.

Check the oil level and make sure it is between the “H” and “L” marks on the dipstick (3) referring to the section II “CHECK AND REFILL-UP OF ENGINE OIL”.

140

F14396

SECTION IV - MAINTENANCE C. GREASING TO SLEWING BEARING WARNING Never slewing the machine, while feeding grease to the slewing bearing.

Feed grease to the swing bearing, slewing the machine and place it in 4 different positions (90˚ apart), until grease oozed out. Only one grease nipple is provided for the slewing bearing. Properly wipe off any grease squirted out around the swing bearing seal.

D. ADJUSTMENT FOR BELT TENSION WARNING Make 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 proper tension, wear conditions and damages. Make sure to adjust tension properly.

Provide a lever (such as bar, wrench or handle) and a wooden piece.

F14407

NOTE: • There may be big differences among individuals on the adjustment for the belt tension with a lever causing too much or too little belt tension. Make sure to check for deflection and tensile force after the adjustment.

• Use the lever with the length of 300-400mm (1216in) suitable for the adjustment work.

E. ADJUSTMENT FOR FAN BELT 1. Apply the lever between the alternator (4) and the cylinder block, and fix it on the alternator.

At that time, insert a wooden piece between the generator and the lever to avoid damaging the alternator. Select the wooden piece of suitable thickness for the clearance between the alternator (4) and the lever.

2. Loosen the adjusting capscrew (5) and the fixing capscrew (6).

3. Apply the lever to the wooden piece, and pulling it with hands to give tension on the belt, tighten the fixing capscrew (6).

4. Tighten the adjusting capscrew (5).

5. After adjustment, start the engine and operate it at low idling for around 5 minutes, then stop the engine to confirm the belt tension (deflection and tensile force).

LEVER BLOCK

141

SECTION IV - MAINTENANCE F. REPLACEMENT OF ENGINE OIL FILTER

WARNING Every portion of the engine is kept at high temperature just after stopping the engine. Take time to allow cooling down the engine for inspection and maintenance.

WARNING F14396

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.

NOTE: • The oil filter is of a cartridge type which can not be reused nor cleaned with the filter disassembling.

Replace it as a unit.

• Replace it at 50 hours operation for the first use of new machine.

• The filter wrench provided on the machine is used for removing.

The filter wrench provided on the machine is used for dismantling filter cartridge. And it must be replaced with a new one at 50 hours operation for the first use of new machine.

1. Stop the engine, open the engine guard, and remove the under cover.

2. Apply the filter wrench (B) to the filter cartridge (A), and turn the wrench with spanner to counter clock wise to remove it.

3. Wipe off any dust on the seal face of filter base, and avoid contamination.

4. Thinly apply clean engine oil to the packing of new filter cartridge, and install and tighten it up with hand. Then retighten it by about 2/3 turns.

5. Start 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.

• When some metal particles are adhered on the element removed, consult it with your Dealer.

142

SPANNER

APPLY ENGINE OIL

CAUTION Dispose of all hazardous waste in accordance with government environmental regulations.

SECTION IV - MAINTENANCE G. CLEANING ENGINE FUEL FILTER WARNING Each unit is hot immediately after the machine has been operated.

Change the filter after the temperature has cooled down.

Clean up all spilled fuel to avoid a fire.

WARNING F14396

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.

Prepare empty container.

1. Stop the engine, and open the engine guard.

2. Set the handle (A) of fuel filter at “CLOSE” position. And remove the retaining ring (B), and take out the cup case (D) and element (C).

3. Drain dust and water accumulated on the bottom of cup case (D) of fuel filter in the empty container, and clean the fuel filter.

4. Wash and clean the element (C) with diesel fuel, and use compressed air, 2~3kgf/cm2 (28~43psi) from the inside to remove dust.

FUEL FILTER

(A) CLOSE

(B) OPEN

(D)

F19403

NOTE: It is strictly prohibited to wash and clean element with gasoline.

5. Replace O-rings (E) and install the fuel filter in reverse order shown in the item (2).

6. Bleed air referring to the section IV “BLEEDING AIR IN FUEL SYSTEM”.

7. Ensure that the filter installing face is free from possible fuel leakage, after running engine at idling for several minutes.

BODY

(E) (C) (D) SPRING

CAUTION Dispose of all hazardous waste in accordance with government environmental regulations.

(B) F19830

143

SECTION IV - MAINTENANCE H. CHECKING RADIATOR HOSE 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.

RADIATOR RESERVE TANK

FULL LOW F19405

I. REPLACING RADIATOR HOSE

WARNING

Danger of highly pressurized steam is 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 a good enough time to allow cooling down the coolant temperature.

1. Loosen the radiator cap slowly. Ensure that pressure has been released. Push the cap down and hold it down while turning to remove.

2. Drain the coolant from the drain cock until the coolant level becomes below the hose to be replaced.

3. Loosen the hose clamp and disconnect the damaged hose; then replace it with a new one.

4. Install the drain cock.

5. Fill the radiator with coolant, then fill the reserve tank with coolant, too. Refer to section III “PRE-START INSPECTION”.

6. After the fill-in, tighten securely the radiator cap (1).

144

F14397

RADIATOR CAP

CAP

DRAIN HOSE F19406

SECTION IV - MAINTENANCE J. CHECKING/CLEANING/REPLACING AIR CLEANER ELEMENT

WARNING Wear protective glasses or goggles when using compressed air.

NOTE: Stop the engine before inspecting or cleaning the air cleaner element. This will prevent the engine from getting damaged due to dust.

F14407

1. CHECK ELEMENT When black smoke is discharged from the exhaust outlet, check the air cleaner element, and clean or replace if needed.

(1)

2. CLEANING ELEMENT NOTE: Do not reuse the element with damaged folds, gasket and/or seal.

Do not heavily tap the element nor hit it to anything else for cleaning.

1. Open the engine guard and the cover under the seat.

2. Remove the wing nut (1) which holds the air cleaner housing.

3. Pull out the left side of element only, toward this side, holding the hose side of exhaust port by right hand.

4. Loosen the wing nut (2) on the housing by hand, then take out the element (3).

5. Use a clean cloth or adhesive tape to cover the engine air intake port on the housing in order to avoid contamination. Then clean the inside of the air cleaner housing.

6. Use compressed air to clean the element from inside along the folds. Use compressed dry air lower than 3kgf/cm2 (43psi). And blow it off from outside. Then again blow it off from inside.

7. After cleaning element, put a light bulb inside the element, and visually inspect for small cracks on the element meshes. A faulty element on the screen and/or packing must be replaced with a new one.

F19407

WING NUT (2)

ELEMENT (3)

WASHER

AIR CLEANER HOUSING F19408

F19409

145

SECTION IV - MAINTENANCE 8. Remove the cloth or tape covering the engine air intake port.

9. Install the cleaned element into the air cleaner housing, and securely tighten it with the wing nut (2) by hand.

10.Fix the air cleaner housing to the frame with the wing nut (1).

NOTE: The element is reusable up to 6 times of cleaning or for one year, after that it must be replaced with a new one.

AIR INLET

AIR CLEANER HOUSING

AIR OUTLET F19410

ADHESIVE TAPE

4.18 500 HOUR INSPECTION AND MAINTENANCE Thoroughly read and understand the section, ”SAFETY PRECAUTIONS” of this MANUAL before operating or servicing the machine.

Perform together with daily to 250-hour inspection and maintenance.

A. REPLACEMENT OF AIR FILTER 1. Open the engine guard and the cover under the seat.

2. Remove the wing nut (1) which is fixing the air cleaner housing.

3. Loosen the wing nut (2) on the housing with fingers, then take out the element (3).

4. Use a clean cloth or adhesive tape to cover the engine air intake port on the housing in order to avoid contamination.

Take clean the inside of the air cleaner housing.

5. Install a new element and secure it with the wing nut (2) by hand.

Do not use any tools to tighten the wing nut (2).

6. Fix the air cleaner housing to the frame with the wing nut (1).

AIR CLEANER HOUSING

WASHER

146

SECTION IV - MAINTENANCE B. REPLACEMENT OF HYDRAULIC RETURN FILTER The return filter keeps the hydraulic oil clean by removing any foreign matter 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 F14396

• Never change oils or filters on a machine that has just finished working. Allow machine to cool first until oils and fluids are warm, not hot.

• Release hydraulic tank pressure, before working with any hydraulic component, 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 DOZER BLADE

BUCKET

AIR PLUG

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.

1. Move the machine to firm level ground, place the attachment in the oil check position, and stop the engine.

2. Open the engine guard and the left side cover.

Then remove the left operating box upward.

3. Make sure to clean the hydraulic oil tank surface to avoid contamination.

4. Slowly loosen the air plug (2) to release inside pressure in the hydraulic oil tank.

5. Loosen 4 capscrews (3) with 4 lock washers (4) to remove the cover (5). At that time, the cover (5) may jump out due to spring force on the spring (6). Remove the capscrews (3) holding the cover (5) downward.

6. Remove the spring (6) and valve (7), then remove the element (8) out of the tank.

7. Make sure to clean all parts properly.

8. Install the new element into the tank.

9. Set the valve (7) and spring (6) on the return filter.

10. Replace the O-ring (9) on the fixing face of cover with a new one together with the return filter (8).

F19385

(3) (4)

(5) (9) (2) (6)

F19414

(6) (7) (8)

F19415

147

SECTION IV - MAINTENANCE 11. Set the cover (5), and holding it against spring force, install it with the capscrew (3) and the lock washer (4).

Tightening torque for capscrew (3): 4.7 +- 0.5 kgf•m(34 +- 4 lbs•ft) 12. Extend each cylinder up to their stroke ends, and pressurize the hydraulic oil tank.

13. Install the cover.

NOTE: For the machine with the breaker, the deterioration of hydraulic oil is increased 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 intervals for them to Section IX “OPTIONAL EQUIPMENT”.

C. REPLACEMENT OF FUEL FILTER F14396

WARNING

FUEL FILTER

• 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 fire.

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.

Provide an empty container to receive the fuel.

1. Stop the engine and open the engine guard.

2. Put fuel container under the fuel filter.

3. Set the handle (A) of fuel filter at “CLOSE” position. And remove the retaining ring (B), and take the element (C) out of the cup case (D). At this time, care must be exercised not to miss the spring which is placed in the cup case.

For the sake of safety and in order not to make the ground dir ty, make sure to discharge the fuel into the container and make the around clean.

4. Replace element (C) and O-ring (E) with new ones.

5. Install them in reverse order shown in the item (3).

6. Bleed air referring to the section IV “BLEEDING AIR IN FUEL SYSTEM”.

7. Run the engine in low idle for several minutes to ensure that the filter fitting section is free from possible fuel leakage.

148

(A) CLOSED

(B) OPEN

(D)

F19416

BODY

SPRING

CAUTION Dispose of all hazardous waste in accordance with government environmental regulations.

SECTION IV - MAINTENANCE

4.19 1000-HOUR INSPECTION AND MAINTENANCE Thoroughly read and understand the section, “SAFETY PRECAUTIONS” of this MANUAL before operating or servicing the machine.

Perform together with daily to 500-hour inspection and maintenance.

CAUTION • The anti-freeze agent is inflammable and detrimental to human body. Keep away from flames and sparks.

• Pay attention not to adhere the anti-freeze agent on skin or enter into eye. If it adheres on skin or enters into eye, immediately wash skin or eye with lots of clean water, and ask a doctor to treat it.

A. REPLACEMENT OF COOLANT

WARNING Danger of highly pressurized steam is 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.

• Allow sufficient time to cool down the engine before servicing.

Use of soft water with less impurities as base coolant. Use the “Long Life Coolant” mixing it in the coolant 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 the section IV “LUBRICANT, FUEL & COOLANT SPECIFICATIONS”.

Provide an empty container to receive the coolant drained.

1. Stop the engine. Open the engine guard.

Start the servicing with the coolant cooled down enough.

2. Loosen the radiator cap slowly. After ensuring that the pressure has been released, push the cap down and hold it down while turning to remove.

3. Discharge the coolant through the drain hose into the empty container.

4. After discharging, close the drain plug, and fix the hose to the original position. Then fill the cooling line with the mixture of water and cleaning solvent (radiator cleaner).

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 open the radiator drain cock. Flush the radiator with tap water until the water draining becomes clean.

F14396

F14397

RADIATOR CAP

CAP

DRAIN HOSE F19417

THROTTLE LEVER

149

SECTION IV - MAINTENANCE 7. Close the radiator drain cock. Fill the radiator with tap water in which LONG LIFE COOLANT has been mixed (30% or more) up to the radiator cap. Rotate the engine for a while to fully release air from the cooling system.

8. Stop the engine. Check the coolant level (the reserve tank water level should be between FULL and LOW). Refer to section III “PRESTART INSPECTION”. Make sure level is to specifications.

9. After checking for leakage, close the engine guard.

RADIATOR RESERVE TANK

FULL LOW F19419

NOTE: When the “Long Life Coolant” is not used, replace the coolant two times a year in spring and autumn.

NOTE: The following works require a professional skill because they are the inspection and maintenance inside the engine. Since the adjustment also requires special knowledge and skill, consult them with your Dealer.

B. CHECK 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 color, noise and so on.

C. CHECK AND ADJUSTMENT FOR STARTER AND GENERATOR (DYNAMO) There is a possibility of warn-out brush and/or lack of grease lubrication on bearing.

This is of the adjustment to get good start ability and power generation.

D. CHECK AND ADJUSTMENT FOR FUEL INJECTION TIMING This is to adjust the fuel injection timing to optimize the engine performance.

E. CHECK 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.

150

F19420

SECTION IV - MAINTENANCE

4.20 2000-HOUR INSPECTION AND MAINTENANCE Thoroughly read and understand the section, “SAFETY PRECAUTIONS” of this MANUAL before operating or servicing the machine.

Perform together with daily to 1000-hour inspection and maintenance.

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.

F14396

BUCKET

A. OIL CHANGE IN HYDRAULIC OIL TANK AND CLEANING OF SUCTION STRAINER

DOZER BLADE

DRAINING OIL RECEIVING CONTAINER

WARNING Danger of highly pressurized fluid with high temperature exists in the hydraulic oil tank just after the machine operation. Do not start the fluid change immediately.

Start it after the fluid cooled down. When loosening the air plug, loosen it slowly to release inside pressure.

NOTE: When loosening the drain plug (1), pay attention not to pour the fluid over yourself.

OIL FILLING PORT (F)

HYDRAULIC TANK

LEVEL GAUGE

F19421

(4)

(

Container to receive discharged fluid: 17 liter (4.5 gal) or more capacity.

Volume to be filled in: 11.3 liter (3.0 gal).

1. Slew the machine so that the drain plug on the hydraulic oil tank comes to midway between the both crawlers.

2. Referring to the section IV “REPLACEMENT OF HYDRAULIC RETURN FILTER”. Items (2) through (4), proceed the work in accordance with the same procedures.

3. After releasing inside pressure from hydraulic oil tank, remove the plug (4) of oil filling port with a wrench.

4. Using an oil suction pump, discharge the oil from the oil filling port (F) into a container to receive the drained oil.

5. The remaining oil in the tank is drained from the drain plug (1). Set up a container to receive the drained oil under the drain plug on the bottom of hydraulic oil tank. Then remove the drain plug with a spanner (27 mm) to drain up the remaining oil.

6. Check the O-ring (5) for any scores or other damages and replace it with a new one, if necessary.

AIR PLUG

(F)

F19422

SUCTION PUMP

(5) (1)

F19423

DRAINING OIL RECEIVING CONTAINER

151

SECTION IV - MAINTENANCE 7. After draining up the remaining oil, install the drain plug (1) and O-ring (5) to the tank, and tighten it up.

Then inspect the suction filter after removing it from the hydraulic oil tank.

8. Loosen the clip (6) for hydraulic piping, and disconnect the hose (7) from the flange (12) on hydraulic oil tank. Loosen the capscrews (8) with lock washers (9) (4pcs.each), and take out the suction strainer (10).

9. Remove dust and other contamination on the strainer (10), then clean it with diesel fuel or cleaning oil. Replace the strainer (10) with a new one if it is damaged.

10. Replace the O-ring (11) with a new one.

11. Install the suction strainer (10) in reverse order of the above [8].

Suction strainer (10) tightening torque : 12±1 kgf•m(87±7 lbf•ft) capscrew (8) tightening torque : 2.4±0.2 kgf•m(17±1 lbf•ft) 12. Fill the hydraulic oil tank with the specified hydraulic oil of the specified volume. Check if the oil level on the level gauge being between “H” and “L”. Dot not fill the oil beyond the “H” level.

13. Install the cap (4) and tighten securely.

14. After the completion of hydraulic oil change and cleaning of suction strainer, carry out the air releasing in the hydraulic line.

15. After the air bleeding, return the machine attachment to the hydraulic oil check position.

16. Stop the engine, and again check the oil volume, and if insufficient, refill with the oil again.

17. Pressurize the hydraulic oil tank.

18. Check for any leakages. Thoroughly wipe off the fluid spilled over.

NOTE: If the air bleeding is insufficient or the engine is started up with insufficient oil in the hydraulic line, it leads to short service life of the hydraulic equipment, and may cause severe damage to it as well.

CAUTION Dispose of all hazardous waste in accordance with government environmental regulations.

152

LEVEL GAUGE

F19355

HYDRAULIC OIL TANK PRESSURIZATION POSITION BUCKET CYLINDER

BOOM CYLINDER

DOZER CYLINDER

ARM CYLINDER

SWING CYLINDER

SECTION IV - 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 tank, depress rubber cap on the tank several times (5 to 7 times).

• Make sure to clean any spillage to avoid fire.

The (P) ports of right and left pilot valves and solenoid valve are equipped with connector with filter. Dust, etc. that adheres on the filter will decrease oil flow. If dust, etc enter in the valve it may cause trouble.

Take out and clean filter, periodically.

PILOT VALVE

(P) O-RING

(A)

(B)

(C) (C) F15927

1. Move the machine to firm level ground, place the attachment in the oil check position, and stop the engine.

2. Carry out the air releasing for the hydraulic line referring to the section IV “RELEASING INTERNAL PRESSURE OF HYDRAULIC SYSTEM”.

3. Loosen 2 bolts (C) on the operating box to remove the cover.

4. Disconnect the hose (A) connected to "P port" on the pilot valve at first, then remove the elbow (B).

After the removal, put a blinding plug to the bore to prevent it from invasion of foreign matter.

5. Dust tends to accumulate on the inside elbow (B) (dented portion). Make sure to properly clean parts to avoid contamination (projected portion).

6. Check the O-ring for damages, and replace it with a new one, if damaged.

7. After cleaning, install it to the original position in reverse order of the above (3) and (4).

Refer to paragraph the tightening torque for the adapter hose.

Then the in-line filter of solenoid valve is removed for cleaning.

8. Remove the floor mat and floor plate.

O-RING FILTER

(B)

F15928

FLOOR MAT

FLOOR COVER

SOLENOID VALVE

153

SECTION IV - MAINTENANCE 9. Prior to removing the in-line filter assembly, remove the hose (D). Use caps and plugs on the hose to avoid contamination.

10. Remove the adapter on the elbow (E) which is connected to the solenoid valve.

Use a plastic cover on the elbow oil port.

11. Remove the adapters (2) and (4), then remove the filter (3).

12. Dust and rubbish are accumulated outside the filter (3). Make sure to clean properly to avoid contamination.

13. Check the O-rings (1) and (6) for damages, and replace them with new ones, if damaged.

14. After cleaning, assemble the filter (3) with the adapter (4), then install the assembly to adapter (2).

After the removal, put a plug to the bore to prevent it from entry of foreign matter.

15. Remove plug from elbow (E) of the solenoid valve, install the adapter assembly.

16. Removing plastic plug from the hose (D), install it to the elbow (5). Attach the floor plate and floor mat, then pressurize the hydraulic line.

NOTE: Consult with an authorized Distributor, when the boom, arm, bucket, boom swing, and dozer are not activated against the operation of each operating lever, or the locking function does not work against setting the safety control lever to the "LOCK" position.

154

(E) ADAPTER ASSEMBLY

(D)

SOLENOID VALVE F19427

1

2

3

4

6

F19428

F19429

5

SECTION IV - MAINTENANCE C. OIL CHANGE FOR TRAVEL SPEED REDUCTION UNIT

WARNING • The oil is very hot just after the machine operation.

Start the servicing after getting down the oil temperature.

• Remaining some residual pressure in the travel motor may cause flying out of plug or spouting out of oil at loosening the plug.

Slowly loosen the plug with care.

F17301

Container to receive discharged oil: 330 cc (20 cu.in) or more capacity Oil volume to fill in: 330 cc (20 cu.in) -LH/RH each.

(2)

Change the oil at 500 hours operation for the first use of new machine.

1. Set the machine on a level ground so that the DRAIN (discharge) port (1) comes just to the bottom.

2. Provide a container under the DRAIN port (1) to receive the discharged oil.

3. Slowly remove the plug of LEVEL (filling) port (2) with an allen wrench key.

Then remove the plug of the DRAIN port (1) to discharge oil into the container.

4. Apply sealing tape on the thread of plug of the DRAIN port (1), and securely tighten it.

5. Slowly remove the plug of LEVEL (charge) port (2) with a hexagonal wrench key.

6. Slowly fill in oil through the LEVEL port (2), up to overflowing of oil from the port.

See the section IV “LUBRICANT, FUEL & COOLANT SPECIFICATIONS” for the applied gear oil.

7. Apply sealing tape on the thread of plug of the LEVEL port (2), and securely tighten it.

Thoroughly wipe off oil spilled over.

8. Ensure no oil leakages traveling the machine slowly.

GL

(1) F19430

F19431

NOTE: Check the waste oil. If any metal particles are mixed in it, consult it with your Dealer.

F19432

155

SECTION IV - MAINTENANCE D. GEAR OIL CHANGE FOR LOWER ROLLER AND IDLER

WARNING Highly pressurized grease is contained in the grease cylinder of truck spring. When loosening the grease nipple for the tension adjustment of crawler shoes or disassembling, gradually loosen the grease nipple within one turn to slowly release the pressurized grease.

The lower roller and idler have to be removed from the crawler frame to change the gear oil for each of them. The following is to describe the procedures to remove/reinstall, and the gear oil change for each of them. Refer to the section IV “LUBRICANT, FUEL & COOLANT SPECIFICATIONS” for the oil and grease to be used and required volume.

1. LOWER ROLLER 1. Loosen the rubber crawler shoe of the side to change the gear oil referring to the section IV “REPLACEMENT OF RUBBER CRAWLER SHOE”.

2. The fixing capscrews (1) of lower roller is a bit loosened in advance (around one turn).

3. Start up the engine, and lift up the oil filling 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, 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) .

6. Remove the feeding port plug (4) with an allen wrench, and discharge the old gear oil.

7. Fill in the prescribed volume (60cc or 3.7 cu•in) of gear oil through the feeding port.

8. Apply sealing tape to thread on the plug (4), and securely tighten it. Throughly wipe off oil adhered to periphery.

156

A. B. C. D. E. F.

Idler Idler Adjuster Shoe slide Rubber crawler shoe Lower roller Crawler frame

SUPPORT

(4)

(2) (1)

(1) (2)

(3)

F19433

SECTION IV - MAINTENANCE 9. Apply Loctite # 262 to thread on the capscrews (1), and temporarily install the lower roller (3) to the crawler frame.

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: 11.7 ± 0.2 kgf•m(85 ± 1 lbf•ft) 11. Again lift up the machine to adjust the crawler shoe tension referring to the section IV “REPLACEMENT OF RUBBER CRAWLER SHOE”.

157

SECTION IV - MAINTENANCE 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 require 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 work for rubber crawler shoe.

1. Remove the rubber crawler shoe referring to the section IV “REPLACEMENT OF RUBBER CRAWLER SHOE”. Make sure to apply the safety support, etc.

Stop the engine.

2. Pull off the idler (1) and idler adjuster (2) from the crawler frame.

Weight of Idler + Idler Adjuster = approx. 12 kg (26 lb) 3. Remove the feeding port plug (3) with an allen wrench to discharge the old gear oil.

4. Fill in prescribed volume (30 cc or 1.8 cu•in) of gear oil through feeding port.

5. Apply sealing tape to thread on the plug (3), and securely tighten it. Throughly wipe off oil adhered to periphery.

6. Apply grease to the sliding face 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 are facing to outside.

8. Install the rubber crawler shoe referring to the section IV “REPLACEMENT OF RUBBER CRAWLER SHOE”.

9. Adjust the tension on the rubber crawler shoe referring to the section IV “REPLACEMENT OF RUBBER CRAWLER SHOE”.

After confirming the engagement of rubber crawler shoe with the idler and the conditions for tension, get down the machine to the ground removing the safety support, etc.

158

F14399

GREASING POINTS

IDLER

SECTION IV - MAINTENANCE E. REPLACEMENT OF GREASE IN SLEWING GREASE BATH If a bit water is mixed in grease, it may become muddy into white color. 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 damages on the pinion gear of slewing motor and internal gears of slewing bearing. Consult with your Dealer for the judgement for the replacement of grease.

NOTE: The following works require a professional skill because they are the inspection and maintenance inside the engine. Since the adjustment also requires special knowledge and skill, consult them with an authorized Distributor.

SHOE SLIDE SLEWING BEARING

F19843

GREASING POINTS

SLEWING MOTOR SLEWING CYLINDER

SLEWING MOTOR PINION GEAR INTERNAL GEAR

GREASE

COVER

159

SECTION IV - MAINTENANCE NOTES:

160

Section V TRANSPORTATION

SECTION V - TRANSPORTATION

5.1 TRANSPORTATION A. WHEN PREPARING TRANSPORTATION PLANS • Before preparing to transport the machine, refer to the section “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.

B. LOADING/UNLOADING THE MACHINE

WARNING • Slow speed traveling is necessity to load and unload the machine.

• It is dangerous to use the attachment for loading and unloading the machine. Do not take such manner.

• Do not operate other operating levers than the traveling lever on the ramp.

• Pay attention to the sudden transferring of the center of gravity of the machine on the border between the truck/trailer and the ramp. * USE OF RAMP Refer to the section I “PRECAUTIONS FOR TRANSPORTATION” for cautions at loading/ unloading the machine. * USE OF PLATFORM OR EARTH BANKING 1. Make the width of the earth banking (raising the ground level) enough to the machine width.

2. Make the earth banking strong enough in order not to turn over the machine during loading/unloading due to broken side slope of 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 truck/trailer.

4. At loading the machine, climb up to the truck/trailer from front end of the machine for the case of the machine with attachment, and from back end for the machine without attachment.

5. Set the machine at the prescribed position on the truck/trailer.

162

or less

SECTION V - TRANSPORTATION

NOTE: To prevent the bucket cylinder from damages during transport, apply a wooden block to the edge of bucket link in order not to get down it to the floor.

1. Pull up the safety lock lever and set to the “LOCKED” position.

2. Turn OFF all switches and pull out the starter key.

Lock all the caps and the door (CAB SPEC.).

3. Apply the blocks to both the front and rear of the crawler and fix them with a wire rope of sufficient strength. This will prevent the machine from moving forward/backward or rolling due to vibration from the truck/trailer.

OVERALL LENGTH

OVERALL HEIGHT

C. SECURING THE MACHINE After the machine is loaded and positioned, fix the machine by the following procedures.

1. Get down the dozer.

2. Fully extend the bucket and arm cylinders, then slowly get down the boom.

LOCKED (UP) POSITION

PAD FOR EDGE

PAD FOR EDGE

WIRE ROPE

163

SECTION V - TRANSPORTATION D. LIFTING PROCEDURES FOR THE MACHINE COMPLETE

WARNING • The wire ropes to be used for lifting the machine should have sufficient strength against the machine weight.

• Improper lifting method and/or rope rigging manner might cause for a movement or slip of the machine while it is being lifted, resulting serious injury or damages on the machine.

• Do not impose a load suddenly on the wire ropes and slings.

• When the lifting work is carried out in cooperation with other people, make sure to check every situations by exchanging signals with each other.

• During the lifting work, keep any persons away from the lifted machine, especially under the machine.

Carry out the lifting work at a level ground.

1. Manipulate each operating lever to take the machine a position as shown in the figure.

2. Operate the boom swing pedal to face the boom direct front.

3. Stop the engine, and make the safety lock lever to “LOCKED” position. Then take off the machine after ensuring for no abnormalities around the operator’s seat.

4. Rope the wires to the shackles under the floor mat. Location is this side of slewing lock lever and crawler frame width/dozer selector lever.

5. Slightly lift the machine to ensure the balance, then lift up the machine.

F16499

BOOM 12°

FULL EXTENDED

SHACKLES

164

F19437

Section VI SPECIFICATIONS

SECTION VI - SPECIFICATIONS

6.1 GENERAL SPECIFICATIONS A. MACHINE DIMENSIONS - E9SR (LONG ARM)

(3.5˝)

RET. EXT.

(3´2.6˝)

(1 ´7 .3˝ )

(1´6.7˝)

(2´5.5˝)

(1´8.7˝)

(11.0˝)

Unit: mm (ft·in)

RET. EXT.

(7.9˝)

(7.1˝) (2´5.5˝) (3´2.6˝)

(7´3.0˝) (9´5.0˝)

• Dimension does not include height of grouser Shoe lug: 18mm (0.7in)

166

(3´3.8˝) (4´4.8˝) (2´11.0˝)

TOTAL LENGTH EXCLUDING DOZER

(9.4˝)

(6.1˝)

(7.5˝) (1.3˝)

(4´9.9˝)

(2´5.5˝)

SECTION VI - SPECIFICATIONS B. ATTACHMENT WORKING RANGES (LONG ARM/STANDARD BUCKET)

Unit: mm (ft-in) Model

E9SR

Attachment Arm Item Bucket A Max. digging reach A' Max. digging reach at ground level B Max. digging depth C Max. digging height D Max. dumping clearance E Min. dumping clearance F Max. vertical wall digging depth G Min. front slew radius H Height at min. slew radius Stroke K Horizontal digging Minimum L stroke at ground level Above X Dozer strokes Below Y

Long 925 mm (3´-0.4˝) Standard 0.022 m3(0.029 cu.yd) 3300 (10´-9.9˝) 3210 (10´-6.4˝) 1750 (5´-8.9˝) 3160 (10´-4.4˝) 2320 (7´-7.3˝) 740 (2´-5.1˝) 1460 (4´-9.5˝) 1390 (4´-6.7˝) 2240 (7´-4.2˝) 1520 (4´-11.8˝) 1060 (3´-5.7˝) 190 (7.5˝) 240 (9.4˝) F21486gb

167

SECTION VI - SPECIFICATIONS C. BOOM WITH ARM CYLINDER

Model

E9SR 1440 X 515 X 220 (4´-8.7˝ X 1´-8.3˝ X 8.7˝)

L X H X W mm (ft-in) Weight w/Arm cyl.kg(lb)

45 (99) F21487gb

D. LONG ARM & STANDARD BUCKET Model

E9SR

L X H X W mm (ft-in)

1535 X 265 X 350 (5´-0.4˝ X 10.4˝ X 1´-1.8˝)

Weight kg(lb)

58 (128) F21488gb

E. ARM Model

E9SR

L X H X W mm (ft-in)

1150 X 255 X 175 (3´-9.3˝ X 10.0˝ X 6.9˝)

Weight kg(lb)

42 (93) F21489gb

F. STANDARD BUCKET

Model Heaped capacity

E9SR m3

(cu·yd)

L X H X W mm (ft-in) Weight kg (lb)

0.022 (0.029) 380 X 355 X 350 (1´-3.0˝ X 1´-2.0˝ X 1´-1.8˝) 16.5 (36.4) F21490gb

G. DOZER

W/o cylinder weight Model L X H X W Ret/Ext mm (ft-in) Weight kg(lb)

E9SR 660 X 195 X 750/980 (2´-2.0˝ X 7.7˝ X 2´-2.5˝) 42 (93) F21533gb

168

SECTION VI - SPECIFICATIONS H. CRAWLER SHOE

Type

Model

Shoe width mm (in)

E9SR

180 (7.1)

Total crawler width mm (ft-in)

Ground pressure kgf/cm2 (psi)

Rubber shoe

Retracted: 750 (2´-6˝) 0.25 (3.6)

Extended: 980 (3´-2.6˝)

F21536gb

I. BUCKET TYPE

Heaped capacity m3 (cu·yd)

Outside width of bucket mm (ft-in)

Number of teeth

Weight kg (lb)

Remarks

0.022 (0.028)

350 (1'-2")

3

16,5 (36)

Standard

0.018 (0.023)

300 (1'-1.2")

3

15,5 (34)

Optional

0.014 (0.018)

250 (1'-1")

3

14,5 (32)

Optional F21535gb

169

SECTION VI - SPECIFICATIONS J. PERFORMANCE SPECIFICATIONS

1. SPEED AND GRADEABILITY E9SR

Model Item Slewing Speed Travel Speed Gradeability % (degree)

Rubber crawler shoe 9.0 rpm Low (1st) 2.0 km/h (1.2 mph)

High (2nd) 3.5 km/h (2.2 mph) 58 % (30˚)

2. SIDE DIGGING & DOZER Type Right Left Stroke of Dozer(above/below) mm(in) Boom Swing Angle

Boom swing by hydraulic cylinder 50˚ 80˚ 190 / 240 (7.5 / 9.4)

3. ENGINE Model Type Number of cylinders-Bore x Stroke Total Displacement Output Rating Maximum Torque Starting Motor Generator

YANMAR 2TNE68 Vertical, 4-cycle,Water cooled, diesel engine 2 - 68 mm X 72 mm (2.68 in X 2.83 in) 0.52 liters (31.7 cu.in) 4.2 PS / 2000 rpm (5.7kW / 2000 min-1) 3.1 kgf•m / 1500 rpm (34lbf•ft/1500 rpm) 12V / 0.9 kW 12V / 20 A

4. HYDRAULIC COMPONENTS Hydraulic Pump Hydraulic Motor Hydraulic Motor w/Reducer (Travel) Control Valve Cylinder (Boom, Arm, Swing, Bucket, Dozer, Frame width) Return Filter

Variable displacement axial piston + gear pump Orbit motor Axial piston, 2-Speed motor 9-spool multiple control valve Double action cylinder Safety valve containing/Filter Type (30 )

F21537gb

170

SECTION VI - SPECIFICATIONS K. MACHINE & COMPONENTS WEIGHT Unit: kg (lb)

MODEL

E9SR

COMPLETE MACHINE(LONG ARM)

950

(2090)

UPPER FRAME ASSEMBLY (ASSY OF FOLLOWINGS) UPPER FRAME ENGINE RADIATOR HYDRAULIC PUMP HYDRAULIC TANK FUEL TANK CONTROL VALVE SLEWING MOTOR SWING BRACKET SWING CYLINDER COUNTER WEIGHT

426 75 65 2.8 10 16 1.4 17 15 16 15 46

(939) (165) (143) (6.2) (22) (35) (3.1) (37) (33) (35) (33) (101)

377 120 17 17 33 X 2 17 X 2 3.8 X 6 4.5 X 2 5.2 X 2 2.8 X 2 42 8 7.5 122 35 25 17 7 9 7 25 15 liters 2.2 liters 1.7 liters 9 liters

(831) (265) (26) (37) (73 X 2) (37 X 2) (8.4 X 6) (9.9 X 2) (11.5 X 2) (6.2 X 2) (93) (18) (17) (269) (77) (55) (37) (15) (20) (15) (55) (4.0 gal) (0.58 gal) (0.45 gal) (2.4 gal)

TRAVEL SYSTEM (ASSY OF FOLLOWINGS) LOWER FRAME SWIVEL JOINT SLEWING BEARING RUBBER CRAWLER SHOE TRAVEL MOTOR LOWER ROLLER IDLER SPROCKET IDLER ADJUSTER DOZER DOZER CYLINDER CRAWLER WIDTH CYLINDER HOE ATTACHMENT (ASSY OF FOLLOWINGS) BOOM ARM(LONG) BUCKET BOOM CYLINDER ARM CYLINDER BUCKET CYLINDER FLUIDS HYDRAULIC OIL COOLING WATER ENGINE OIL FUEL

F21538gb

171

SECTION VI - SPECIFICATIONS NOTES:

172

Section VII TROUBLESHOOTING

SECTION VII - TROUBLESHOOTING

7.1 GENERAL TROUBLESHOOTING This troubleshooting information covers the components and systems as described in this MANUAL. Should in depth troubleshooting, repair or replacement of components or adjustment of valves be required, contact your Dealer for assistance.

OPERATING Problem

Probable cause

Possible remedy

All operating speeds are slow or power is lost.

Low hydraulic oil level.

Fill oil to specified level.

Air leaking into the suction pipe.

Tighten suction pipe hose clamp or replace hose.

Hydraulic pump is damaged.

Repair or replace.

Pilot gear pump is damaged.

Repair or replace.

Main relief valve is not adjusted correctly.

Adjust or replace.

Pilot relief valve is not adjusted correctly.

Adjust or replace.

Cylinder seal is damaged.

Repair or replace.

Control valve or overload valve functions incorrectly or there are signs of air in the cylinder.

Repair or replace/Remove air from cylinder.

Pilot valve is damaged.

Repair or replace.

Pilot valve piping is loose.

Retighten.

Cylinder seal is scored.

Repair or replace.

Control valve or overload valve is damaged.

Repair or replace.

Overload valve is not operating.

Repair or replace.

Pilot valve is damaged.

Repair or replace.

Hydraulic motor (slewing) is not working or slewing gear is damaged.

Repair or replace.

Slewing bearing is damaged.

Repair or replace.

Pilot valve is not working.

Repair or replace.

Slewing reduction unit is damaged.

Repair or replace.

Solenoid valve is not working.

Repair or replace.

Control valve is not working.

Repair or replace.

A specific cylinder functions improperly or loses power.

The cylinder position will not hold with operating lever in neutral.

Machine does not slew.

174

SECTION VII - TROUBLESHOOTING OPERATING Problem

Slewing speed is slow.

Abnormal sound occurs when slewing.

Probable cause

Possible remedy

Lever lock Sol.V. is not working.

Repair or replace.

Control valve is not working.

Repair or replace.

Hydraulic motor (slewing) is not working.

Repair or replace.

Hydraulic pump is not working.

Repair or replace.

Pilot valve is not working.

Repair or replace.

Insufficient lubrication of slewing gear and bearings.

Grease.

Pilot valve is not working.

Repair or replace.

Control valve is not working.

Repair or replace.

175

SECTION VII - TROUBLESHOOTING TRAVEL Problem

Probable cause

Possible remedy

Machine does not travel smoothly.

Too much crawler tension.

Adjuster crawler tension.

Dirty or clogged crawler shoes.

Clean crawlers.

Brake valve is not working.

Repair or replace.

Travel reduction unit is damaged.

Repair or replace.

Control valve is not working.

Repair or replace.

Travel motor damaged.

Repair or replace.

Main relief valve pressure is set incorrectly

Adjust or replace.

Swivel joint is damaged.

Repair or replace.

Hydraulic pump is damaged.

Repair or replace.

Poor engine performance.

Repair or replace.

Main relief valve pressure is set incorrectly.

Adjust or replace.

Low hydraulic oil level.

Fill to proper level.

Hydraulic motor (travel) is not working.

Repair or replace.

Brake valve is not working.

Repair or replace.

Seal in swivel joint is scored or oil is leaking.

Repair or replace.

Unequal tensions on crawlers.

Adjust tension.

Set pressures of main relief valves unbalanced.

Adjust.

Performances of hydraulic travel motor has deteriorated.

Repair or replace.

Unbalanced flow from control valve.

Repair or replace.

Unbalanced discharge from hydraulic pump.

Repair or replace.

Unbalanced flow from brake valve.

Repair or replace.

Unbalanced flow between RH swivel joints.

Repair or replace.

Traveling power is insufficient.

Machine does not travel in a straight line.

176

SECTION VII - TROUBLESHOOTING HYDRAULIC Problem

Probable cause

Possible remedy

Temperature rise in the hydraulic oil temp.

Oil cooler core clogged.

Clean.

Engine fan belt slipping.

Adjust or replace.

Low hydraulic oil level.

Refill to specified level.

Wrong type hydraulic oil used.

Replace with correct, new oil.

Hydraulic pump is not working.

Repair or replace.

177

SECTION VII - TROUBLESHOOTING GAUGE CLUSTER DISPLAY Problem

Probable cause

Possible remedy

Engine oil pressure is too low.

Engine oil level low.

Fill to specified level.

Oil leaking.

Repair and fill to proper level.

Wrong oil viscosity.

Replace with proper oil.

Low coolant.

Fill to proper level.

Coolant leaking.

Repair and fill to proper level.

Loose radiator cap.

Tighten.

Radiator core clogged.

Clean cooling system.

V-belt loose or damaged.

Tighten to proper tension.

Rust or scale in coolant.

Flush system/fill to level.

Faulty thermostat.

Replace.

Battery terminals disconnected, loose, or corroded.

Clean and connect.

Low battery electrolyte.

Replenish.

Slipping of V-belt or damaged.

Adjust or replace.

Battery service life has run down.

Replace.

Abnormal rise in the coolant temperature.

Battery charge

178

SECTION VII - TROUBLESHOOTING ENGINE Problem

Probable cause

Possible remedy

Starter does not turn or turns slowly which does not start the engine.

Battery disconnected.

Connect.

Battery discharged.

Charge.

Battery terminals disconnected, loose, or corroded

Clean and connect.

Ground cable disconnected.

Connect.

Engine oil viscosity too thick (Cold Weather)

Change to proper oil.

Insufficient fuel.

Refuel.

Improper starting procedure.

Refer to section “BASIC MACHINE OPERATION”.

Air in fuel line.

Remove.

Clogged fuel filter.

Replace element.

Clogged air cleaner.

Replace elements.

Air heater circuit malfunctioning.

Check circuit.

Low idling RPM.

Contact authorized workshop/Dealer.

Fuel filter clogged.

Replace element.

Air cleaner clogged.

Replace elements.

Improper valve clearance.

Contact authorized workshop/Dealer.

Fuel filter clogged.

Replace element.

Air cleaner clogged.

Replace element.

Improper valve clearance.

Contact authorized workshop/Dealer.

Loose clamps on the air inlet hose.

Tighten clamps.

Cracked air inlet hose.

Replace hose.

Insufficient coolant

Refill coolant.

Clogged radiator.

Clean cooling components.

V-belt to loose or damaged.

Adjust or replace belt.

Faulty thermostat.

Replace.

Starter turns but engine does not start.

Engine tends to stop at low speed.

No power.

Engine overheats.

179

SECTION VII - TROUBLESHOOTING ENGINE Problem

Probable cause

Possible remedy

Engine exhaust is black.

Air cleaner clogged.

Replace elements.

Improper valve clearance.

Contact authorized workshop/Dealer.

Fuel leak.

Contact authorized workshop/Dealer.

Air cleaner clogged.

Replace elements.

Loose clamps on suction hose.

Tighten clamps.

Cracked suction hose.

Replace w/new hose.

Engine oil level is too high.

Reduce to specified level.

Improper oil.

Replace with correct oil.

Oil leak.

Contact authorized workshop/Dealer.

Improper oil replacement intervals.

Change at correct interval.

Improper warming-up operation.

Refer to the section III.

Low oil volume.

Fill to specified level.

Oil leak.

Contact authorized workshop/Dealer.

Improper oil viscosity.

Replace with proper oil.

Battery teminals disconnected loose, or corroded.

Clean and tighten terminals.

Low battery electrolyte.

Fill cells w/distilled water.

V-belt loose or damaged.

Adjust or replace belt.

Defective battery.

Replace battery.

Poor fuel consumption.

Excessive oil consumption.

Engine oil pressure does not rise.

Battery dies often.

180

Section VIII OPTIONAL EQUIPMENT

SECTION VIII - OPTIONAL EQUIPMENT

8.1 OPERATION OF HYDRAULIC BREAKER AND NIBBLER A. SELECTION OF HYDRAULIC BREAKER AND NIBBLER When installing a hydraulic breaker or nibbler to the machine,select the optimal breaker or nibbler taking the matters into consideration such as stability, blowing force, grasping force, required hydraulic oil volume, etc.

B. BEFORE OPERATING BREAKER OR NIBBLER • Consult with your Dealer for the additional piping work and reinforcement for the arm to install the breaker or nibbler to the machine.

• When using the breaker or nibbler, fully understand and peruse the operation manual of its manufacturer and the SAFETY PRECAUTIONS for the work mentioned in this MANUAL, in order to get full performance of them paying attention to damages on the machine and hydraulic breaker or nibbler.

C. PRECAUTIONS FOR IMPURITY AND HYDRAULIC OIL When the hydraulic breaker or nibbler is removed after its installation, apply a blinding plug to the stop valves attached on the tip of arm and openings on the hydraulic pipings for the hydraulic breaker or nibbler to prevent them from invasion of dust, water, etc.

Before the operation, check the looseness on the clamps which are fixing the piping for attachment, and the leakage on connections of tubes and hoses.

D. OPERATION There are two specifications for the machine, one is single hydraulic circuit for breaker only, and the other is combined hydraulic circuits for both breaker and nibbler. An option pedal is provided at left front of the operator’s seat to operate them.

1. OPERATING PEDAL 1. Single Hydraulic Circuit for Breaker only Release the pedal lock for the operating pedal located at left front of driver’s seat, and operate the pedal.

Operation

Pedal Depressing Direction

Left side (A) Right side (B)

Breaker is not operated.

Breaker is operated.

Breaker stops at releasing pedal.

2. Combined Hydraulic Circuit for Breaker and Nibbler Release the pedal lock for the operating pedal located at left front of driver’s seat, and operate the pedal.

Hydraulic breaker operation Operation

Pedal Depressing Direction

Left side (A) Right side (B)

Breaker is not operated.

Breaker is operated.

Breaker stops at releasing pedal.

Nibbler operation Pedal Depressing Direction

Left side (A) Right side (B)

182

OPTION PEDAL

(B)

Operation Grasping operation.

Opening operation.

(A)

F19441

SECTION VIII - OPTIONAL EQUIPMENT 2. PEDAL LOCK DEVICE This is a device to lock the pedal.

( 1 ) LOCKED

DANGER Make sure to set the pedal lock to “LOCKED” position while the breaker or nibbler is not used.

Careless contact with UNLOCKED position of pedal may cause severe accident and injury. ( 2 ) UNLOCKED

(1) Position ................. LOCKED (2) Position ................. UNLOCKED E. CONNECTION TO HYDRAULIC CIRCUIT FOR ATTACHMENT Connect the hydraulic circuit for the breaker and nibbler with the following procedures.

1. Remove the PF 1/2 blinding plugs (A) on pipings for stop valves (2 points of left and right).

Pay attention not to give any damages on the blinding plugs removed, or lose them.

2. Connect the hydraulic pipings for the breaker and nibbler to the positions where the blinding plugs are removed at the above (1).

F19442

PLUG (PF1/2) ARM

PLUG (PF1/2)

STOP VALVE

LOCK POSITION

NOTE: Stop valves are to stop the flow of hydraulic oil.

• LOCK : The hydraulic oil flow is stopped.

• FREE : The hydraulic oil flows.

• When installing or removing the hydraulic breaker or nibbler, make sure to set the stop valve at “LOCKED” position and attach the blinding plugs.

NOTE: • The engine must be operated at 85% of rated speed while the work for breaker or nibbler.

• From time to time, stop the work for a while, and make the engine speed at idling to cool the hydraulic oil.

STOP VALVE

FREE POSITION

TO SELECTOR VALVE TO STOP VALVE

LOW IDLING POSITION

183

SECTION VIII - OPTIONAL EQUIPMENT F. SELECTOR VALVE SHIFTING PROCEDURES When installing the hydraulic beaker or nibbler, the selector valve (1) must be installed to the main circuit. It is necessary to shift the selector valve to either of proper position.

NOTE: • Improper shifting of the selector valve may cause deterioration of working efficiency and lowering the working speed as well as damages on the machine occasionally. Make sure to shift the selector valve to the proper position.

• The selector valve needs to be periodically shifted every one or two times a month.

BOOM

1. SHIFTING PROCEDURES NOTE: To shift the selector valve, make sure to stop the engine and lower the attachment to the ground making the machine at stable conditions.

Tools to be used for selector valve (A) Location............Side of hydraulic tank Tool...................Spanner (24 mm) Allen wrench (5 mm) 1. Remove the socket bolt (B) on the selector valve (A) with allen wrench (C).

2. Shift the selector valve to the proper position with the spanner (E).

Install the socket bolt (B) to the corresponding position.

Marks on the selector valve show: B: Breaker N: Nibbler

184

SELECTOR VALVE SHIFTING POSITION USE BREAKER TO C/V B6

USE NIBBLER TO C/V B6

TO ATT TO TANK

TO ATT TO TANK

SECTION VIII - OPTIONAL EQUIPMENT

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

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

A. USE FOR INTENDED PURPOSE Use the attachment only for its intended purpose. If not used in accordance with the manufactures instructions, the excessive pressure exerted on the boom, arm and frame structure of the machine will cause premature failure of the components.

B. PASSENGERS Never allow passengers on the attachment or machine.

C. PROTECTIVE EQUIPMENT When operating attachments that produce flying debris, it is highly recommended to procure and install protective guards on the machine and close the all window to protect the operator from flying debris. Also the operator and all personnel in the vicinity of the machine should wear protective gear such as safety shoes, hard hat, gloves and face shield or goggles.

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

E. AVOID CONTINUOUS OPERATION Operate the nibbler/breaker 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 pump damage.

185

SECTION VIII - OPTIONAL EQUIPMENT F. HOSE SURGE Should the hydraulic hoses begin to surge or vibrate abnormally during operation of a Breaker or Nibbler, 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.

G. 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.

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

I. 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.

186

SECTION VIII - OPTIONAL EQUIPMENT J. WORKING RANGES LATERAL WORK PROHIBITED

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

FRONT OK

REAR OK

LATERAL WORK PROHIBITED

The balance on the machine becomes unstable at the position shown in the right figure involving a possibility of turning over the machine. Never carry out the breaker work with this position.

NOTE: • Refer to this SECTION for the work with the other attachment than the hydraulic breaker, too.

• Use the reinforced arm for the work with the hydraulic breaker, etc. The use of standard arm for such work may cause damages on the arm.

K. TO PRY AND BREAK FORCIBLY Do not use the breaker to pry and break rock and concrete.

This may damage the hydraulic breaker, and also boom, arm and cylinder.

L. ARM IN VERTICAL POSITION The arm should not be operated in the vertical position to prevent the arm cylinder from vertical shocks.

This may damage the rod packing and piston and cause the oil leaking from those sections.

187

SECTION VIII - OPTIONAL EQUIPMENT

8.3 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 breaker hasten deterioration of hydraulic oil comparing with normal operation using bucket. Replace filters and hydraulic oil, referring to the following table :

Inspection /

Location

maintenance

Replacement interval First

2nd replacement

Regular

Hydraulic oil

Hydraulic tank

-

-

Every 500h

Return filter

Hydraulic tank

25h

100h

Every 200h

B. MAINTENANCE RECORD SHEET (EXAMPLE)

DATE

HRS

FILTER REPLACEMENT

HYD. OIL CHANGE

C. PUMP DELIVERY CAPACITY (for reference) 29.6 liters/min. X 85% of rated speed = 25.2 liters/min (6.7 gal/min) Note: see Section IX paragraph “E. CONNECTION TO HYDRAULIC CIRCUIT FOR ATTACHMENT” for the 85% of rated speed.

188

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

Reproduction of text or illustrations, in whole or in part, is strictly prohibited

Print No. 604.21.391.00 - 02 - 2005