This manual provides rules and guidelines which will help you use this machine safely and effectively. The precautions in this manual must be followed at all times when performing operation and maintenance.
Most accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines. Accidents can be prevented by knowing beforehand conditions that may cause a hazard when performing operation and maintenance.
COVER........................................................................... 1
FOREWORD........................................................................ 2
FOREWORD.................................................................... 3
SAFETY INFORMATION.......................................................... 6
INTRODUCTION................................................................ 8
DIRECTIONS OF MACHINE................................................... 8
PRODUCT INFORMATION......................................................... 9
MACHINE SERIAL NUMBER PLATE AND ITS LOCATION............................ 9
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION............................. 9
EMISSION CONTROL INFORMATION LABEL AND ITS LOCATION..................... 10
SERVICE METER LOCATION.................................................. 10
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR............................. 11
CONTENTS........................................................................ 12
SAFETY.......................................................................... 15
SAFETY INFORMATION.......................................................... 16
WARNING LABELS AND PICTOGRAMS............................................... 18
WARNING LABELS AND PICTOGRAMS-LOCATION.................................. 19
WARNING LABELS AND PICTOGRAMS-ACTUAL.................................... 20
SAFETY INFORMATION.......................................................... 26
SAFETY RULES............................................................ 26
IF ABNORMALITIES ARE FOUND.............................................. 26
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS.............................. 26
FIRE EXTINGUISHER AND FIRST AID KIT..................................... 26
SAFETY EQUIPMENT........................................................ 26
KEEP MACHINE CLEAN...................................................... 27
KEEP OPERATOR'S COMPARTMENT CLEAN....................................... 27
LEAVING OPERATOR'S SEAT WITH LOCK....................................... 27
HANDRAILS AND STEPS..................................................... 28
MOUNTING AND DISMOUNTING................................................ 28
NO PERSONS ON ATTACHMENTS............................................... 28
DO NOT GET CAUGHT IN ARTICULATED PORTION................................ 28
BURN PREVENTION......................................................... 29
FIRE PREVENTION AND EXPLOSION PREVENTION................................ 29
ACTION IF FIRE OCCURS................................................... 30
WINDSHIELD WASHER FLUID................................................. 30
FALLING OBJECTS,FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION......... 30
ATTACHMENT INSTALLATION................................................. 31
ATTACHMENT COMBINATIONS................................................. 31
CAB WINDOW GLASSES...................................................... 31
UNAUTHORIZED MODIFICATIONS.............................................. 31
SAFETY AT JOBSITE....................................................... 31
WORKING ON LOOSE GROUND................................................. 31
DISTANCE TO HIGH VOLTAGE CABLES......................................... 32
ENSURE GOOD VISIBILITY.................................................. 32
VENTILATION FOR ENCLOSED AREA........................................... 32
SIGNALMAN'S SIGNAL AND SIGNS............................................ 33
EMERGENCY EXIT FROM OPERATOR'S CAB...................................... 33
ASBESTOS DUST HAZARD PREVENTION......................................... 33
SAFETY MACHINE OPERATION.................................................... 34
STARTING ENGINE......................................................... 34
CHECKS BEFORE STARTING ENGINE....................................... 34
SAFETY RULES FOR STARTING ENGINE.................................... 34
STARTING ENGINE IN COLD WEATHER..................................... 35
OPERATION............................................................... 36
CHECKS BEFORE OPERATION............................................. 36
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS........................ 36
SAFETY RULES FOR TRAVELING.......................................... 37
TRAVELING ON SLOPES................................................. 38
OPERATIONS ON SLOPES................................................ 39
PROHIBITED OPERATIONS............................................... 39
OPERATIONS ON SNOW.................................................. 40
PARKING MACHINE..................................................... 41
TRANSPORTATION.......................................................... 42
LOADING AND UNLOADING............................................... 42
SHIPPING THE MACHINE................................................ 42
BATTERY................................................................. 43
BATTERY HAZARD PREVENTION........................................... 43
STARTING ENGINE WITH BOOSTER CABLES................................. 44
TOWING.................................................................. 45
SAFETY RULES FOR TOWING............................................. 45
LIFTING OBJECTS WITH BUCKET............................................. 46
SAFETY RULES FOR LIFTING OBJECTS.................................... 46
SAFETY MAINTENANCE INFORMATION.............................................. 47
WARNING TAG............................................................. 47
KEEP WORK PLACE CLEAN AND TIDY.......................................... 47
APPOINT LEADER WHEN WORKING WITH OTHERS................................. 47
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE............................. 47
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING...................... 48
PROPER TOOLS............................................................ 49
PERSONNEL............................................................... 49
ATTACHMENTS............................................................. 49
WORK UNDER THE MACHINE.................................................. 49
NOISE................................................................... 49
WHEN USING HAMMER....................................................... 50
WELDING WORKS........................................................... 50
REMOVING BATTERY TERMINALS.............................................. 50
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION.... 50
DO NOT DISASSEMBLE RECOIL SPRINGS....................................... 50
SAFETY RULES FOR HIGH-PRESSURE OIL...................................... 51
SAFETY HANDLING HIGH-PRESSURE HOSES..................................... 51
WASTE MATERIALS......................................................... 51
AIR CONDITIONER MAINTENANCE............................................. 51
COMPRESSED AIR.......................................................... 52
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS........................... 52
OPERATION....................................................................... 53
MACHINE VIEW ILLUSTRATIONS.................................................. 54
OVERALL MACHINE VIEW.................................................... 54
CONTROLS AND GAUGES..................................................... 55
DETAILED CONTROLS AND GAUGES................................................ 56
MONITORING SYSTEM....................................................... 56
SWITCHES................................................................ 61
CONTROL LEVERS AND PEDALS............................................... 64
WINDSHIELD.............................................................. 69
SLIDING DOOR............................................................ 73
SLIDING WINDOW.......................................................... 73
REAR WINDOW............................................................. 74
EMERGENCY ESCAPE HAMMER................................................. 75
CAP WITH LOCK........................................................... 76
ENGINE HOOD............................................................. 77
MUD COVER............................................................... 78
FUSE ................................................................... 79
BLOCK FUSE.............................................................. 79
AUXILIARY ELECTRIC POWER................................................ 80
CAR HEATER CONTROLS..................................................... 81
ACCUMULATOR............................................................. 83
OPERATION MANUAL STORAGE................................................ 83
TOOL BOX................................................................ 84
GREASE PUMP HOLDER...................................................... 84
ASHTRAY................................................................. 84
MACHINE OPERATIONS AND CONTROLS............................................. 85
BEFORE STARTING ENGINE.................................................. 85
STARTING ENGINE......................................................... 98
AFTER STARTING ENGINE...................................................101
STOPPING THE ENGINE.....................................................103
CHECK AFTER SHUT OFF ENGINE.............................................103
MACHINE OPERATION.......................................................104
STEERING THE MACHINE....................................................108
SWINGING................................................................110
WORK EQUIPMENT CONTROLS AND OPERATIONS..................................111
PROHIBITED OPERATIONS...................................................113
GENERAL OPERATION INFORMATION...........................................115
TRAVELING ON SLOPES.....................................................117
ESCAPE FROM MUD.........................................................119
RECOMMENDED APPLICATIONS................................................120
BUCKET REPLACEMENT......................................................122
PARKING MACHINE.........................................................123
MACHINE INSPECTION AFTER DAILY WORK.....................................124
LOCKING.................................................................124
RUBBER SHOES AND ROAD LINERS............................................125
TRANSPORTATION..............................................................130
TRANSPORTATION PROCEDURE................................................130
LOADING AND UNLOADING WITH TRAILER......................................130
LIFTING MACHINE.........................................................134
COLD WEATHER OPERATION......................................................136
COLD WEATHER OPERATION INFORMATION......................................136
CAB HEATER IN COLD WEATHER..............................................137
AFTER DAILY WORK COMPLETION.............................................138
AFTER COLD WEATHER SEASON...............................................138
LONG TERM STORAGE...........................................................139
BEFORE STORAGE..........................................................139
DURING STORAGE..........................................................139
AFTER STORAGE...........................................................139
TROUBLES AND ACTIONS........................................................140
RUNNING OUT OF FUEL.....................................................140
PHENOMENA THAT ARE NOT FAILURES.........................................140
TOWING THE MACHINE......................................................140
SEVERE JOB CONDITION....................................................141
DISCHARGED BATTERY......................................................141
OTHER TROUBLE...........................................................145
MAINTENANCE.....................................................................148
MAINTENANCE INFORMATION.....................................................149
LUBRICANTS, COOLANT AND FILTERS.............................................151
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC..................151
ELECTRIC SYSTEM MAINTENANCE.............................................153
WEAR PARTS..................................................................154
WEAR PARTS LIST.........................................................154
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS.................................155
PROPER SELECTION........................................................155
TIGHTENING TORQUE SPECIFICATIONS............................................159
TIGHTENING TORQUE LIST..................................................159
SAFETY CRITICAL PARTS.......................................................160
SAFETY CRITICAL PARTS LIST..............................................160
MAINTENANCE SCHEDULE........................................................161
MAINTENANCE SCHEDULE CHART..............................................161
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER..............................162
MAINTENANCE PROCEDURE.......................................................163
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)..........163
WHEN REQUIRED...........................................................164
AIR CLEANER ELEMENT-CHECK/CLEAN/REPLACE.............................164
COOLING SYSTEM COOLANT-CLEAN/CHANGE.................................166
WATER SEPARATOR ELEMENT-CLEAN.......................................169
FUEL TANK-DRAIN.....................................................169
TRACK SHOE BOLTS-CHECK/TIGHTEN......................................170
TRACK TENSION-CHECK/ADJUST..........................................171
RUBBER SHOES OR ROAD LINERS-CHECK...................................173
RUBBER SHOE TENSION-CHECK/ADJUST....................................175
RUBBER SHOES-REPLACE................................................177
ROAD LINERS-REPLACE.................................................179
ROAD LINERS OR STEEL SHOES TO RUBBER SHOES-CHANGE...................180
BUCKET TEETH-CHECK/REPLACE..........................................181
WINDSHIELD WASHER FLUID LEVEL-CHECK/ADD.............................184
CAB SLIDE DOOR RAIL AND ROLLER-CHECK/CLEAN/LUBRICATE................185
HYDRAULIC SYSTEM-BLEED AIR..........................................186
CHECK BEFORE STARTING...................................................187
EVERY 100 HOURS MAINTENANCE.............................................188
LUBRICATING.........................................................188
EVERY 250 HOURS MAINTENANCE.............................................189
ENGINE CRANKCASE OIL-CHANGE.........................................189
HYDRAULIC OIL FILTER ELEMENT-REPLACE................................190
COOLING FAN BELT TENSION-INSPECT/ADJUST.............................191
BATTERY ELECTROLYTE LEVEL-CHECK.....................................193
EVERY 500 HOURS MAINTENANCE.............................................195
ENGINE CRANKCASE OIL FILTER CARTRIDGE-REPLACE.......................195
FUEL FILTER ELEMENT-REPLACE.........................................196
FINAL DRIVE CASE OIL LEVEL-CHECK/ADD................................197
LUBRICATING.........................................................198
RADIATOR FINS,OIL COOLER FINS-CLEAN/CHECK...........................199
EVERY 1000 HOURS MAINTENANCE............................................200
FINAL DRIVE CASE OIL-CHANGE.........................................200
ENGINE VALVE CLEARANCE-CHECK/ADJUST.................................200
EVERY 2000 HOURS MAINTENANCE............................................201
HYDRAULIC OIL AND STRAINER-CHANGE/CLEAN.............................201
ALTERNATOR AND STARTING MOTOR-INSPECT...............................202
SPECIFICATIONS..................................................................203
SPECIFICATIONS..............................................................204
ATTACHMENTS, OPTIONS............................................................206
ATTACHMENTS AND OPTIONS-GENERAL INFORMATION.................................207
SAFETY FIRST............................................................207
ATTACHMENT INSTALLATION.................................................208
BUCKET WITH HOOK............................................................209
HOOK CONDITION..........................................................209
PROHIBITED OPERATIONS...................................................209
MACHINE READY FOR ATTACHMENT................................................210
LOCATIONS...............................................................210
HYDRAULIC CIRCUIT.......................................................212
ATTACHMENT OPERATIONS...................................................213
LONG TERM STORAGE.......................................................215
CHANGING MACHINE CONTROL PATTERN(IF PATTERN CHANGE VALVE EQUIPPED)..........216
CONTROL PATTERN CHANGE PROCEDURE........................................216
MACHINE CONTROL PATTERNS................................................217
ATTACHMENT GUIDE............................................................218
ATTACHMENT COMBINATIONS.................................................218
RECOMMENDED ATTACHMENT OPERATIONS...........................................219
HYDRAULIC BREAKER.......................................................219
INDEX...........................................................................224
