OPERATION & MAINTENANCE MANUAL ZY210

Transcription

1 ZY/S-210/11.04-CZ OPERATION & MAINTENANCE MANUAL Hydraulic Crawler Excavator Hefei Zhenyu Engineering Machinery Co., Ltd.

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3 FOREWORD This operation manual is provided for operators to operate and maintain the machine properly. Please read the manual carefully before operation. A good understanding of correct operation and maintenance is very important for the machine to operate normally and effectively, and avoiding possible damage and accidents. The manual should be furnished when the machine is resold or made over, as it is a permanent part of the machine. All the dimensions in the manual are metric because the machine is designed with metric system. Please use stipulated parts and tools with metric system only. The right or left side of the machine is determined according to the traveling direction with operator facing forwards. That is, the side where the cab locates on the machine is left side and the counterpart is right side. Please fill in the forms in the section "Type and Model" of the manual, giving the models and serial numbers of your machine and the main parts for convenience of getting the information later. The information should be provided when ordering parts. Note down the information in a reliable place if the manual is kept on the machine. HEFEI ZHENYU will provide its customers warranty period. Refer to the Warranty certificate provided by the seller for the warranty period items. Service can be obtained from HEFEI ZHENYU within warranty period when there is trouble with the machine. The warranty period will be cancelled if the machine is operated abusively, or changed in performance beyond the stated performance, or overloaded, and field service may be turned down. The machine should be operated by the experienced and skilled operators with relevant certificate from authoritative organizations and maintained by the qualified maintainers. Do read carefully all the important safety rules in the manual and observe it when operating. The manual contains last-minute products information gathered before publishing. HEFEI ZHENYU reserves the right of machine modification without notice. Hefei Zhenyu Engineering Machinery Co., Ltd.

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5 CONTENTS Machine Number 1 Safety4 Cab30 Components Name 30 Cab Front View 31 Monitor Panel 32 Switch Panel 39 Control Panel of Air Conditioner 40 Breaking in Operation 42 Checking before Starting Engine 43 Starting Engine 46 Starting Excavator 46 Using Booster Battery 48 Adjusting Operator s Seat 49 Travel Operation 50 Digging Operation 53 Operating Mode 53 Backhoe Operation 59 Lifting Operation 62 Transportation 63 Maintenance 67 Correct Maintenance and Inspection Procedures 67 Maintenance Guide 70 A. Greasing 73 B. Engine Oil 74 C. Gear Oil 76 D. Hydraulic System 78 E. Fuel System 86 F. Air Cleaner filter 90 G. Engine Cooling & Hydraulic Oil Cooler 93 H. Miscellaneous 95 Checking Bucket Teeth Daily 96 Checking Track Sag 97 Tightening Torque Table of Important Bolts and Nuts 99 I. Electrical System 100 Maintenance under Special Environment Conditions 104 Storage 106 Troubleshooting 108 Overall Dimensions 121 Transportation Dimensions 122 Working Ranges 123 Lifting Capacity 124 Technical Instructions 125 Optional Equipments 128

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7 MACHINE NUMBER Excavator Model and Serial Number Model: Machine Code: Serial Number: Engine Model and Serial Number Model: Serial Number: NOTE: In the figure, A stands for model and B for code and C is nameplate, which locates on engine case commonly but on the engine cooler hood for some models. Travel Motor Model and Serial Number Model Serial Number Manufacturer NOTE: The nameplate locates on motor casing near motor shaft and can be seen when travel mechanism casing is removed. 1

8 MACHINE NUMBER Travel Reducer Model and Serial Number Model: Serial Number: Manufacturer: NOTE: The nameplate locates on outboard of track sprocket. Swing Motor Model and Serial Number Model: Serial Number: Manufacturer: NOTE: The nameplate locates on motor of swing gearbox. Swing Gearbox Model and Serial Number Model: Serial Number: Manufacturer: NOTE: The nameplate locates on swing gearbox. 2

9 MACHINE NUMBER Hydraulic Pump Model and Serial Number Model: Serial Number: Manufacturer: NOTE: The nameplate locates on hydraulic pump casing. Monoblock Valve Model and Serial Number Model: Serial Number: Manufacturer: NOTE: The nameplate locates on monoblock valve body. 3

10 SAFETY SAFETY MARK RECOGNITION These are the SAFETY ALERT SYMBOLS. When you see these symbols on your machine or in this manual, be alert to the potential for personal injury. Please follow recommended precautions and safe operating methods. UNDERSTAND SIGNAL VOCABULARY Vocabulary of indication of danger level-danger, WARNING or CAUTION is used with mark of paying attention to safety together. On safety indexing plate of excavator. The DANGER is referred to condition of direct danger, as unavoidable danger will cause death or severe injury. WARNING is referred to condition of latent danger, as unavoidable condition can cause death or severe injury. CAUTION is referred to condition of latent danger, as unavoidable condition can cause slight or medium wound. DANGER or WARNING safety indexing plate is set up near specific harmful places. The general matters needing attention are written on CAUTION safety indexing plate. This excavator also applies some safety indexing plates, they don t use above prescribed signal vocabulary after safety warning mark. CAUTION is also used to remind people of paying attention to safety instruction in this handbook. The signal vocabulary IMPORTANCE is used to indicate the condition of possible creation of excavator damage in order to avoid confusion between excavator protection and personal safety instruction. NOTE is used to show an additional explanation for individual information. 4

11 SAFETY FOLLOW SAFETY RULES Read and follow all safety indexing plates on excavator, and all contents about safety in this handbook carefully. Installation, maintenance and replacement of safety indexing plate when necessary. If the safety indexing plate or this handbook is damaged or lost, use same method as purchasing of other replacement parts to order the replacement articles (Model and serial number of excavator should be written clearly when ordering) to designated dealer. Learn how to operate excavator and its controller correctly and safely. Only permit the trained, eligible appointed person to operate the excavator. Maintain the excavator under proper working state. Unconfirmed refitting of excavator will harm its function and (or) safety possibly, and will affect the working life of the excavator. Safety instruction in safety chapter is basic safety rules of the excavator. But, these related safety instructions are impossible to deal with every-kind dangerous conditions, which you will come across possibly. If there is problem, it is sure to ask your foreman for instructions firstly before operation and maintenance of excavator. GUARD AGAINST CRITICAL SITUATION It is necessary absolutely to guard against occurrence of fire or accident. The first-aid kit and extinguisher should be disposed near excavator. Read and understand the explanation pasted on the extinguisher carefully, use the extinguisher correctly. Work out emergent countermeasure guide against fire and accident. Keep emergency numbers for doctors, ambulance service, hospitals, and fire department posted near your telephone. 5

12 SAFETY WEAR PROTECTIVE CLOTHING Wearing close-fitting clothes and providing safety articles for use suitable to work. You may need following safety articles: Hard safety helmet Safety shoes Safety glasses, goggles or face guard Thick gloves Hearing protector Reflecting clothes Rain gear Gauze mask or filtering mask Be sure to wear the correct equipment and clothing for the job. Do not take any chances. Avoid wearing loose clothing, jewelry, or other items that can catch on control levers or other parts of the machine. Safe operation of excavator demands operator to work with rapt attention. Do not wear radio or music headphones while operating the machine. PROTECT AGAINST NOISE Long time operation in loud noise will lead to hearing damage or loss. Put on proper hearing protector as ear muff or earplug in order to avoid harmful or unpleasant loud noise. INSPECT MACHINE In order to avoid personnel injury,carry out a circuit checking round excavator carefully before starting up of engine in everyday or every shift. In the walk-around inspection, be sure to cover all points described in the PRE-START INSPECTION chapter in the operator s manual. 6

13 SAFETY GENERAL MATTERS NEEDING ATTENTION IN CAB Remove mud, soil and greasy dirt from bottom part of shoes cleanly before operator will enter into cab. If the bottom part of work shoes is stuck with mud, soil and greasy dirt, the feet of operator can slip down from pedal, this action will lead to personal injury accident, when the operator maneuvers the controller of the pedal etc. Don t place parts and tools round operating seat. Store them in designated place. Avoid placing of transparent bottle in cab. Don t hang any-kind transparent ornament on window-sill because they can accumulate sunlight to induce fire. Don t listen to radio or use earphone and mobile phone when operating excavator. Don t place any explosives and combustibles in cab. Always cover ashtray to extinguish match and cigarette end after the ashtray is used. Don t leave lighter in cab, because when temperature in cab rises, the lighter can explode. 7

14 SAFETY USE HANDRAIL AND STEPS Falling is one of main cause of personal injury. When you get on and off the machine, always face the machine. Maintain a three-point contact with the steps and handrails. Do not use any controls as handrails. Never jump on or off the machine. Never mount or dismount a moving machine. Pay attention to slippage of turntable, foot pedal and handrail when departing from excavator. ADJUST OF OPERATOR S SEAT A poorly adjusted seat for either the operator or for the work at hand may quickly fatigue the operator leading to mis-operation of the machine. The seat should be adjusted whenever the operator for the machine changes. The operator should be able to fully depress the pedals and to correctly operate the control levers with his back firmly against the seat back. If not, readjust the seat forward or backward, and check again. 8

15 SAFETY START ENGINE CORRECTLY Inappropriate engine starting procedures may cause the machine to runaway, possibly resulting in serious injury or death. Start the engine only when seated in the operator s seat. Never start the engine while standing on the tracks or on ground. Do not start engine by shorting across starter terminals. A hazardous situation may be created and/or possible damage to the machine may result. Before starting the engine, confirm that all control levers are in neutral. NEVER HITCH PASSENGERS ON MACHINE Riders on machine are subject to injury such as being struck by foreign objects and being thrown off the machine. Riders also obstruct the operator s view, resulting in the machine being operated in an unsafe manner. Only allow the operator is allowed on the machine. Keep riders off. AVOID POWER LINES Serious injury or death can result if the machine or front attachments are not kept a safe distance from electric lines. When operating near an electric line, NEVER move any part of the machine or load closer than 3 m (10 ft) plus twice the line insulator length. Check and comply with any local regulations that may apply. Wet ground will expand the area that could cause any person on it to be affected by electric shock. Keep all bystanders or co-workers away from the site. 9

16 SAFETY AVOID INJURY FROM BACK-OVER AND SWING ACCIDENTS If any person is present near the machine when backing or swinging the upperstructure, the machine may hit or run over that person, resulting in serious injury or death. To avoid back-over and swing accidents: Always look around before you back up and swing the machine. Be sure that there is no bystander around the machine. Keep the travel alarm in working condition (if equipped). Always be alert for bystanders moving into the working area. Use the horn or other signal to warn bystanders before moving machine. Use a signal person when backing up if your view is obstructed. Always keep the signal person in view. Use hand signals, which conform to your local regulations, when work conditions require a signal person. No machine motions shall be made unless signals are clearly understood by both signalman and operator. Learn the meanings of all flags, signs, and markings used on the job and confirm who has the responsibility for signaling. Keep windows, mirrors, and lights clean and in good condition. Dust, heavy rain, fog, etc., can reduce visibility. As visibility decreases, reduce speed and use proper lighting. Read and understand all operating instructions in the operator s manual. 10

17 SAFETY DIG CAREFULLY Accidental cut-off of underground electrical cable or gaspipe will cause explosion and fire possibly, leading to occurrence of severe injuries and deaths accident. Check positions of electrical cable, gas pipe and water pipe before excavation. Keep the minimum legal distance with electrical cable, gas pipe and water pipe at least. If the optical fiber electrical cable is cut off by accident, don t see the end part of electrical cable. Otherwise, it may result in serious eye injury. If there is hot excavating line in your lived district, please make liaison with it; or contact directly with local public utilities company. Let them mark out all underground electrical cable, pipe line. MOVE AND OPERATE MACHINE SAFELY The bystanders' position must be known well while traveling or swinging the machine. Alarm horn to warn the bystanders before excavator is traveling or swinging. When the machine is traveling, swinging or operating in a narrow zone, signalman is needed. It is necessary to co-ordinate gesture signal before starting up of this excavator. OPERATE MACHINE SAFELY Keep all people that aren't working personnel beyond the working zone. Ensure that there is enough supporting force in the working zone to support the machine firmly. When the machine is working near hollow, the travel motor should be put in the rear side of the machine, and keep the angle between the travel direction of the tracks and the direction of the hollow's wall being vertical. Thus, if the hollows will collapse, the machine could back freely. When digging deeply, prevent the bottom of the boom and the cylinder from colliding with ground. The bucket is only used to dig. Never use it as air pick or destructive globe in order to prevent accidents. 11

18 SAFETY AVOID TIPPING Never try to jump off the tipping machine, otherwise it may result in serious or fatal crush. The tipping speed of machine is more quickly than your jumping speed. Fasten your seat belts. The tracks should be parked along the slope when the machine is working on a slope. Retract the bucket and keep it near ground and the machine as much as possible to avoid tipping. The swing speed must be reduced to prevent the machine from tipping over when it swings with heavy load. When operating excavator on frozen ground, prevent earth from becoming soft because of the rising temperature, which will reduce the stability of the machine. DRIVE MACHINE SAFELY Above all, make clear that the direction of the travel control pedals or levers should correspond with the driving direction before driving the machine. When step on the forth of the travel control pedals or push the travel control levers forwards, the machine travels towards the idler wheels. Otherwise it travels towards the sprocket wheels. Put the bucket to the position indicated in the figure and let it keep from ground between 200 and 300 mm when climbing up or down slope. If the machine is sliding or getting unstable, put down the bucket immediately. BEWARE TO TAKE IN SMOKE Taking in the exhaust smoke of the engine could cause diseases or death. If you must operate the machine in building, open the doors and windows of the building to take in enough air from outside and ensure that the air in working zone circulates fully. Use the prolonged exhaust tube to exhaust the smoke. 12

19 SAFETY PAY ATTENTION TO OPERATION If the front-end attachments or another parts of excavator knock down overhead object of over Line Bridge etc, excavator and overhead object all will damage, can still create personnel to get injured. Be careful to prevent boom or arm from colliding with overhead object. PREVENT FROM ACCIDENTS It would cause severe injuries or death if you try to get on or block the traveling machine. In order to prevent the machine from being out of control, do as followings: Select a level ground to park the machine as much as possible. Lower the bucket down to ground. Let the engine run in free load for 3 minutes to let the machine cool down. Stop the engine and take out the key from the key switch. Turn off the pilot control switch. If you have to park tile machine on a slope, use the dog to block the tracks on both sides, lower the bucket with its teeth in earth. Locate the machine firmly to prevent it from being out of control. Park the machine in a proper distance to keep away from other machine. 13

20 SAFETY PARK MACHINE SAFELY In order to prevent accident, do as follows when the machine is going to stop work. 1. Place excavator onto horizontal earth surface. 2. Lower bucket onto ground. 3. Run idle engine for five minutes with low idle speed. 4. Put speed-changing lever at neutral position, and put braking switch at parking position. Turn key switch to off position to stop running of engine. 5. Take out the key from key switch. 6. Pull pilot control shut-off lever to locking position. 7. Close windows, skylight and door of cab. 8. Lock all access doors, cases and cab. HANDLE FLUIDS SAFELY AVOID FIRES Careful disposal of fuel must be carried out because it is highly combustible. If fuel is burned, it can produce explosion and (or) fire, leading to personal injuries and deaths. Don t pour fuel to excavator when smoking or near open flame or spark. Be sure to stop running of engine before pouring of fuel or oil. Pour fuel into fuel tank out of doors. All fuel, most part of lubricant and some coolant all are combustible. Store combustible fluid far from dangerous fire-catching places. Don t burn or pierce pressure container. Don t keeps rag with oil, fuel and grease, they can be ignited or burn spontaneously. Screw down fuel and machine oil filler lid. 14

21 SAFETY PRACTICE SAFE MAINTENANCE Understand the maintenance specification before working. And keep the working zone clean and dry. Never add lubricants to the machine or maintain it when traveling. Prevent hands, feet or clothes from contacting with the transmitting units. Before maintaining the machine: Park the machine on a level ground. Lower down the bucket to ground. Let the engine running idle at low speed for 5 minutes. Pull the parking lever to the most front end and stop the engine, take out the key from the switch. Hang the plate of "Please not operating! ' on the right travel control lever. Turn off the pilot control switch. Let the engine cool down. If the maintenance process must be done in running the engine, peoples should be in the cab. If the machine must be lifted, keep the angle between the boom and the arm within , and firmly support any units of the machine that should be lifted in maintenance. Never work under the machine being lifted by the boom. Periodically check some parts, and if necessary, they must be repaired or replaced. Refer to the contents of chapter "Maintenance" in this manual for more information. Keep all parts of the machine in fine condition, and being installed properly. The damaged parts should be dealt with in time. Replace the wearing or broken parts and clear any lubricants, oils or fragments gathered together. Before adjust the electrical system or weld the parts of the machine, should disconnect the earth connecting cable (-) of the batteries. 15

22 SAFETY CLEAR THE RUBBISH ON MACHINE Keep the engine and the radiator, batteries, hydraulic pipelines, fuel tank, and the cab clean. The temperature around the engine may be increased immediately, after the engine is stopped. During this time, watch out for firing. Open the door of checking to let the engine cool quickly, and clear the engine room. WARN OTHERS OF SERVICE WORK Erroneously operating the machine could cause grievous bodily harm when the machine is in maintenance. Before maintaining the machine, attach a "DON NOT OPERATE" tag on the left travel control lever. This tag is available from your appointed dealer. CLEAN MACHINE PERIODICALLY Clear all lubricants, oils or fragments gathered together to prevent body from possible injury or to prevent the machine from being damaged. Don't spout water or steam into the cab. STORE ATTACHMENT SAFELY Stored attachments such as buckets, hydraulic hammers etc can fall and cause serious injury or death. Securely store attachments and implements to prevent falling accidents. Keep children and bystanders away from storage areas. 16

23 SAFETY PREVENT FROM TAKING IN THE DANGEROUS ASBESTOS DUST Avoid to taking in the dusts produced in dealing the parts of asbestos fibres, which would cause lung cancer. The components with asbestos fibres are some washers. The asbestos in these components are normally in resins or blocked with certain way. Provided the components with asbestos don't produce dust, the usual treatments have no danger. In order to prevent asbestos from causing dust, don't clean with compressed air, and avoid of brushing or wearing out the material with asbestos. Please wear specified gauze mask in maintaining. Recommend using special dust collector to clean the asbestos, if it has not been got, wet the material with asbestos by using few oil or water. Observe the rules and tile regulations of the working place, and submit yourself to the environment rules and regulations about dealing with the asbestos. Prevent other people from entering working zone. PREVENT FROM SPLASHING MATTER Use goggles or safety glasses to prevent people from being injured by the splashing metal fragment or scrap. Before striking materials, prevent other people from entering into working zone to avoid being injured. 17

24 SAFETY PREVENT PARTS FROM FLYING OUT The lubricants in the tensioning device of track are in high-pressure condition. Never dismount grease cups, valves, parts and so forth. Face and body must leave valve cases to prevent parts from flying out accidentally. There is pressure in the traveling gearbox. Face and body must leave the discharge cocks to prevent from being injured by parts flying out accidentally. The gear oil is heat. After it has cooled, gradually loosen the air discharge cock to release the pressure. KEEP DISTANCE WITH THE TRANSMITTING PARTS Contacting the transmitting parts would cause seriously injured. In order to preventing from accidents occurring, when the transmitting parts are turning, pay attention to preventing your hands, feet, clothes, or hair from being reeled in. SUPPORT MACHINE CORRECTLY Don t carry out repair and maintenance work absolutely before no supporting of excavator well. Always lower front-end attachments onto ground before repair and maintenance of excavator will be carry out. It is necessary to raise excavator or front end fittings to carry out maintenance and repair, be sure to support excavator or front end fittings firmly. Don t support excavator with slag brick, hollow tyre or bracket, they will collapse under action of continuous load. Don t work under supporting of excavator with single jack. 18

25 SAFETY PREVENT BURNS Hot spraying fluids: After operation, engine coolant is hot and under pressure. Hot water or steam is contained in the engine, radiator and heater lines. Skin contact with escaping hot water or steam can cause severe burns. To prevent possible injury from hot spraying water, stop the engine. Begin to work after the engine and radiator are sufficiently cooled. DO NOT remove the radiator cap until the engine is cool. When opening, turn the cap slowly to the stop. Allow all pressure to be release before removing the cap. The hydraulic oil tank is pressurized. Again, be sure to release all pressure by slowly removing the cap. Hot fluids and surfaces: Engine oil, gear oil and hydraulic oil also become hot during operation. The engine, hoses, lines and other parts become hot as well. Wait for the oil and components to cool before starting any maintenance or inspection work. PRECAUTIONS FOR WELDING AND GRINDING Welding may generate gas and/or small fires. Be sure to perform welding in a well ventilated and prepared area. Store flammable objects in a safe place before starting welding. Only qualified personnel should perform welding. Never allow an unqualified person to perform welding. Grinding on the machine may create a fire hazard. Store flammable objects in a safe place before starting grinding. After finishing welding and grinding, recheck that there are no abnormalities such as the area surrounding the welded area still smoldering. 19

26 SAFETY AVOID HEATING NEAR PRESSURIZED FLUID LINES Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials. Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area. Install temporary fire resistant guards to protect hoses or other. AVOID APPLYING HEAT TO LINES CONTAINING FLAMMABLE FLUIDS Do not weld or flame cut pipes or hoses that contain flammable fluids. Remove flammable fluids thoroughly with nonflammable solvent before welding or flame cutting pipes or hoses that contained flammable fluids. AVOID HIGH-PRESSURE FLUIDS The liquids that sprayed in high pressure could pierce through the skins and cause severe injury. Before separate the liquids or other pipes, release the pressure to prevent from this danger. Release the pressure by operating travel control levers several times. Tighten all junctions before pressuring. Check leakage with cardboard, and pay attention to protect your hands and body from contacting the hydraulic liquids. If someone has any accident, immediately see the doctor who knows this kind of wound well to ask for treatment. Any liquids injected into skins must be removed by surgical operation in few hours, otherwise would cause gangrene. 20

27 SAFETY PREVENT FIRES 1. CHECK FOR OIL LEAKAGE: Fuel, hydraulic oil and lubricant leaks can lead to fires, possibly resulting in personal serious injury. Check for missing or loose clamps, kinked hoses, lines or hoses that rub against each other, damage to the oil-cooler, and loose oil-cooler flange bolts, for oil leaks. Check for oil leakage with a cardboard. The injection of the liquid under pressure can penetrate the skin, resulting in serious injury. Do not check for oil leakage with bare hands Tighten, repair or replace any missing, loose or damaged clamps, lines, hoses, oil-cooler and oil-cooler flange bolts. Do not bend or strike high-pressure lines. Never install bent or damaged lines, pipes or hoses. 2. CHECK FOR SHORT CIRCUIT Short circuit can cause fire and result in serious injury. Clean and tighten all electrical connection. Check looseness, kink, hardening or cracking of electrical cable and electrical wire before every shift or after 8-10 hours operation. Check loss or damage of terminal end cover before every shift or after 8-10 hours operation. Do not operate machine if cable or wires are loose, kinked, etc. Before operation, tighten, repair or replace any loose or damaged cables, wires and wiring cover. 3. REMOVAL OF EASILY COMBUSTIBLE MATERIAL Spilled fuel and oil, accumulated coal dust, and other flammables may cause fires and personal serious injury. Prevent fires by inspecting and cleaning the machine daily. 4. CHECK IGNITON KEY SWITCH: If fire breaks out, failure to stop the engine will escalate the fire, hampering fire fighting. Always check key switch function before operating the machine every day: 1) Start the engine and run it at slow idle. 2) Turning key switch to off position, confirm whether engine stops or not. If any abnormalities are found, be sure to repair them before operating the machine. 21

28 SAFETY PREVENT BATTERY FROM EXPLOSIONS Air in battery can explode. Avoid spark, igniting match and flame to near the top of the battery. Should use voltmeter or gravimeter. It is impossible to use the method of placing one metallic material across terminal to check quantity of electricity of battery. Don t charge the freezing battery, otherwise it will cause explosion. Heat battery to 16. Don t continue to use battery or don t charge the battery when electrolytic liquid level is lower than specified value. Otherwise it can cause explosion of battery. Looseness of terminal can produce spark. Tighten all terminals Electrolyte of battery is poisonous. If battery explodes, the electrolyte of battery will splash into eyes, it can lead to lose the sight of both eyes. Be sure to wear goggles well when checking specific gravity of the electrolyte. MAINTAIN AIR CONDITIONER SYSTEM SAFELY Splashing of refrigerant onto skin can create frostbite. Refer to explanation on Freon window to use the Freon correctly, when maintaining the air-conditioning system. Use recovery or cyclic system, so as to prevent Freon from exhausting to air. Don t let Freon liquor contact with skin absolutely. 22

29 SAFETY HANDLE CHEMICAL PRODUCTS SAFELY Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with your machine include such items as lubricants, electrolyte, coolants, paints, and adhesives. A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques. Check the MSDS before you start any job using a hazardous chemical. Then follow the correct procedures and use recommended equipment. DISPOSE OF WASTE PROPERLY Improper garbage disposal will bring harm to environment and ecology. There are latent, harmful waste materials such as oil, fuel, coolant, braking fluid, filter and battery etc in equipment of Hefei Zhenyu engineering machinery company. Use the leakproof container when liquor will be exhausted. Don t use containers for foodstuff or drink, because they can lead to wrong drinking. Don t pour waste liquor to ground, sewer or pour into any source of water. Leakage of air-conditioning refrigerant into air can sabotage atmospheric layer of the earth. The regulations of government perhaps demand a certificate-holding air-conditioning service center to recover and regenerate air-conditioning refrigerant. Inquire local environmental protection center or recovery center, or your appointed dealer about correct method of recovery or waste material disposal. 23

30 SAFETY MARKS All safety marking plates and their positions pasting on excavator are introduced through illustration in this class. It is imperative to read contents in safety marking plate pasting on excavator practically to ensure safe operation of excavator. It is sure to keep the cleanness of safety marking plate from beginning to end. If the safety marking plate is damaged or lost, should demand new substitute at once and re-paste it onto designated positions of excavator. This marking plate shows that departure of excavator from transmission line is too near, this condition can create danger of electric shock, so it is necessary for excavator to keep safety distance away from transmission line. This marking plate shows that window will create falling danger. It is sure to lock the window with locking pin after the window is lifted up. Don t put your hands and head out of the window. Otherwise they can be knocked by boom possibly. 24

31 SAFETY MARKS ATTENTION: If placing excavator is moved by accident, it will lead to severe injuries or deaths because of striking. It is definite to lower front fittings onto ground, lock control rod, and take out key of engine before excavator is in state of no person operation. This marking plate shows that there will be danger to be knocked down by working attachments of excavator. It is necessary for surrounding people to depart far from excavator in operation. 25

32 SAFETY MARKS This marking plate shows that if open oil-inletting port lid in operation of excavator or after just ended operation, compressed air and hot oil will spray out to lead to scald of personnel. Read this handbook and operate excavator safely and correctly. This marking plate shows that if open lid of radiator or hydraulic oil tank before the radiator or hydraulic oil tank doesn t cool, the hot water or hot oil will spray out, leading to scald of personnel. Only after the radiator or hydraulic oil tank cools, can operator just open the lid. This marking plate shows danger of person falling. Don t stand up at this place. This marking plate shows danger of person falling down from mudguard and mantle. Don t stand up at the edge of mudguard and mantle. 26

33 SAFETY MARKS This marking plate shows danger to be squeezed down by upper revolving mechanism, it is necessary for surrounding people to depart far from revolving scope of excavator. This marking plate shows that if open lid of radiator or hydraulic oil tank before the radiator or hydraulic oil tank doesn t cool, the hot water or hot oil will spray out, leading to scald to personnel. Only after the radiator or hydraulic oil tank cools, can operator just open the lid. This marking plate shows danger to be involved into excavator by turning components of belt etc. Stop operation of excavator before check and maintenance will be carried out. 27

34 SAFETY MARKS This marking plate shows danger of electric shock. Read this handbook and operate excavator safely and correctly. This marking plate shows danger of explosion. Electrolyte in contact with skin can cause burn, its splashing into eyes can lead to lose one s sight of both eyes. Be careful not to contact electrolyte. 28

35 SAFETY MARKS MEMO 29

36 CAB COMPONENTS NAME 1. Bucket cylinder 2. Arm cylinder 3. Boom 4. Boom cylinder 5. Arm 6. Bucket 7. Cab 8. Center joint 9. Rotary device 10. Control valve 11. Fuel tank 12. Hydraulic oil tank 13. Pilot filter 14. Steering filter 15. Hydraulic pump 16. Engine 17. Radiator, oil cooler assembly 18. Air cleaner 19. Counterweight 20. Battery 21. Adjuster device 22. Swing bearing 23. Track assy 24. Upper roller 25. Lower roller 26. Travel reducer Fig.1 Fig.2 Fig.3 30

37 CAB CAB FRONT VIEW Fig.4 1. Right joystick (for boom and bucket operation) 2. Angle adjusting handle of seat backrest 3. Monitor panel 4. Left travel lever & pedal 5. Window washer device 6. Right travel lever & pedal 7. Break pedal 8. Evacuation hammer 9. Radio 10. Left joystick (for arm and swing operation) 11. Pilot control shut-off lever 12. Height adjusting handle of seat 13. Seat longitudinally adjusting handle 14. Handrail 15. Spare pedal 16. Horn button 17. Operator's seat 31

38 CAB MONITOR PANEL Fig.5 No. Name No. Name 1 Working voltage display 14 Preheating indicator 2 Throttle knob gear display 15 Low power mode indicator 3 Coolant temperature gauge 16 Standard power mode indicator 4 Function zone 1 display 17 High power mode indicator 5 Function zone 2 display 18 Cursor left button 6 Engine speed display 19 Cursor right button 7 Hour meter 20 Cursor up / add button 8 Fuel gauge 21 Cursor down / subtract button 9 Function zone 3 display 22 Fast travel mode button 10 Function zone 4 display 23 Automatic idle mode button 11 Silencing indicator 24 Menu button 12 Automatic idle indicator 25 Silencing / Ok button 13 Traveling at high speed indicator 32

39 CAB MONITOR PANEL WORKING INTERFACE Internal parameter of monitor is initialized when the ignition key switch is turned on. If there isn t anything wrong, the working interface will exist after 3 seconds. WORKING VOLTAGE The working voltage of machine is 24V. ENGINE SPEED Panel interface indicates the real-time engine speed. Fig.6 HOUR METER The hour meter in the upper right corner of LCD displays the total accumulated working hours of engine in digit. The display range of hour meter is 0 to hours. While the engine is running, the hour meter starts to time. Once the engine is shut off, hour meter stops timing. THROTTLE KNOB GEAR DISPLAY This display shows the real-time engine gear. The machine has 10 throttle gears. DATE/TIME DISPLAY The date/time display can be set. (Please refer to the following Consumer s setting instruction.) COOLANT TEMPERATURE GAUGE The pie section of coolant temperature gauge contains 10 segments. When engine coolant temperature is over 103, the buzzer sounds at the same time. Immediately stop machine operation and reduce engine speed to the slow idle speed for a period of time. FUEL GAUGE The gauge pie section contains 10 segments. When the remaining fuel amount in the fuel tank is less than 10%, warning buzzer sounds to remind operator to refill fuel as soon as possible. 33

40 CAB BUTTON INSTRUCTIONS When machine under standard power mode, press cursor left button to set high power mode. The red indicator of H-power mode lights. When machine under standard power mode, press cursor right button to set low power mode. The red indicator of L-power mode lights. Fig.7 CURSOR UP/ADD BUTTON The cursor up/add button can move the cursor upward. CURSOR DOWN/SUBTRACT BUTTON The cursor down/subtract button can move the cursor downward. FAST TRAVEL MODE BUTTON This button enables the switching between fast & slow travel modes. AUTOMATIC IDLE MODE BUTTON Press the automatic idle mode button, the LED indicator lights (green). There is no movement of machine within 8 seconds and the engine enters idle mode automatically. When operating the machine again, the engine speed will automatically increase to the former speed before idling. Press this button again, the auto-idle indicator goes out, and the engine speed will be back to throttle knob control state. MENU BUTTON All setting items of machine will be displayed on the monitor panel after pressing the menu button. SILENCING / OK BUTTON Operator can press this button to stop the warning sound when the buzzer sounds. After pressing this button, the silencing indicator comes on (red). The indicator shall turn off by pressing this button again. When the menu button being pressed, the pull-down menu exists, press the OK button to display the submenu of the menu that cursor located at or to confirm the settings. 34

41 CAB BUTTON OPERATION WHEN ENTERING THE MENU INTERFACE On work interface, operator can press the menu button to enter the pull-down menu on the panel. Fig.8 WORKING PARAMETER On the menu display interface, press the cursor up / add button or cursor down / subtract button to move the cursor to the working parameter contents, and then press the silencing / ok button to enter the pull-down menu of the working parameter. Fig.9 WARNING PARAMETER On the menu display interface, press the cursor up / add button or cursor down / subtract button to move the cursor to the warning parameter contents, and then press the silencing / ok button to enter the pull-down menu of the warning parameter. USER SETTING Choose the user setting option on the menu working interface by pressing the cursor up / add button or cursor down / subtract button. Press the silencing / ok button, the system will prompt to input the user s password. Press the cursor left / right button and the ok button to input the password and enter user settings interface. Then press the cursor up / add button or cursor down / subtract button to move the cursor to the desired content. Enter the corresponding item by pressing silencing / ok button. Fig.10 Fig.11 35

42 CAB WORKING HOUR DISPLAY This display shows the engine working hours. Press the ok button again in the current option, the system will display the period time. In the same way, operator can select the display between the working time and stage time. DATE ADJUSTING According to the presentation from 0 to 9, etc. in the 13 squares on the LCD, press the corresponding buttons and input the desired digits on the LCD input area. Fig.12 TIME ADJUSTING According to the presentation from 0 to 9, etc. in the 13 squares on the LCD, press the corresponding buttons and input the desired digits on the LCD input area. Fig.13 CONTRAST CONTROL After entering the contrast control interface, press the cursor left / right button to move the cursor to the desired position, then press the silencing / ok button to confirm and save. To exit, press the menu button. Fig.14 Fig.15 36

43 CAB BRIGHTNESS ADJUSTING Press the cursor left / right button to move the cursor to the desired position after entering the brightness adjusting interface. Then press the silencing / ok button to confirm and save. To exit, press the menu button. ENGINE THROTTLE SETTING ATTENTION: To use normally, operator should set the throttle when first using or after adjusting and changing the throttle system. After existing the user setting interface, press the cursor up / add button or cursor down / subtract button to move the cursor and choose the auto throttle setting item. Then press the silencing / ok button to enter the throttle setting interface, start the engine, and the auto throttle setting will begin. When prompted throttle setting process is completed, the engine throttle knob divides the no-load speed of engine from low to high into 10 gears. Fig.16 Fig.17 SYSTEM SETTING Choose the system setting item on menu working interface by pressing the cursor up / add button or cursor down / subtract button. System will be prompted to input the password after pressing the silencing / ok button. This item is setup by the machine manufacturer. The consumer cannot be allowed to modify the setting, otherwise the warranty period will be invalid. To exit, press the menu button. Fig.18 37

44 CAB LANGUAGE SETTING Enter the menu interface by pressing the menu button when at the working interface. Press the cursor up / add button or cursor down / subtract button to select the English language item, and the system enter the English language interface after pressing the silencing / ok button. If needing to return to Chinese language interface, at this interface, to select the Chinese language option by press the cursor up / add button or cursor down / subtract button. After pressing the silencing / ok button, the system is back to Chinese language interface. To exit this interface, press the menu button. Fig.19 CHECK SENSOR STATUS Press the cursor up / add button or cursor down / subtract button on menu interface to select the sensor status option. Then the system enters the sensor status interface after pressing the silencing / ok button. Fig.20 MALFUNCTION INQUIRY Select the malfunction inquiry option by pressing the cursor up / add button or cursor down / subtract button at menu interface. Press the silencing / ok button, the system will enter the malfunction inquiry interface. Fig.21 38

45 CAB SWITCH PANEL Fig Radio control panel 2. Quick coupler switch 3. Swing warning lamp switch 4. Wiper switch 5. Washer switch 6. Rear lamp switch 7. Boom lamp switch 8. Front top lamp switch 9. Frame lamp switch 10. Throttle knob 11. Ignition key switch 12. Cigar lighter 39

46 CAB CONTROL PANEL OF AIR CONDITIONER Fig Temperature display 2. Indicators 3. Turn-on button 4. Temperature turning down button 5. Temperature turning up button 6. Cooling button 7. Heating button 8. Blower speed setting button 9. Turn-off button 10. Ventilating switch 40

47 CAB AIR CONDITIONER OPERATION A. HEATING OPERATION 1. Start the engine, press button 1 on the air conditioner control panel to turn on the power of air conditioner. Then press heating button, system enter heating mode, and temperature will be displayed on the screen. Press the temperature turning down button to turn down the temperature and press temperature turning up button to turn up the temperature. Press blower speed setting button to set an appropriate wind speed. 2. Warm air enters cab through some air vents, one of which is facing the front window squarely. Open this air vent can achieve defrosting function. There are two air vents, on the interior trimming parts behind the seat, which blow arm air to the back and upside of cab. Below operator s seat, another two air vents send warm air to the front and bottom part of the cab. Operator can adjust the air vents according to his own need. Fig.24 B. COOLING OPERATION Press cooling button on the air conditioner control panel, system enter cooling mode. Please refer to heating operation mentioned above to do other operation. C. VENTILATING OPERATION 1. Open cab front window, side window or door to realize internal and external air circulation of cab. 2. Press ventilating switch (Fig.24-2), system will do external circulation and fresh air ventilating in cab. CAB OVERHEAD WINDOW The overhead window can be adjusted towards any direction. If the front window is closed, the atmosphere can circulate effectively by adjusting the overhead window. Fig.25 41

48 BREAKING IN OPERATION OBSERVING DIESEL ENGINE RUNNING CAREFULLY IMPORTANCE! Be Careful in the initial 50 hours as much as possible until completely know the sound and the sense of the machine well. 1. When digging, the engine power should be held beneath 80% of the fully load. 2. Avoid tired engine idling excessively. 3. Often check tile indicators and display gauges in operating. EVERY 8 HOURS OR DAILY 1. Perform maintenance every 8 hours or daily. (Refer to the maintenance guide every 8 hours.) 2. Pay attention to liquid leakage. 3. In the initial I00 hours or working in mud and water, lubricate shafts and pins of the working attachments every 8 hours. AFTER THE INITIAL 50 HOURS 1. Perform 50 hours maintenance. (Refer to the maintenance guide...50 hours.) 2. Check tile torque of bolts and nuts. (Refer to the maintenance guide for the tightening moment of the main bolts and nuts.) AFTER THE INITIAL 100 HOURS Perform 50 hours and 100 hours' maintenance. (Refer to the maintenance guide 50 hours and 100 hours' maintenance.) 42

49 CHECKING BEFORE STARTING ENGINE ELECTRICAL SYSTEM Check circuitry for wearing and splinter. Check terminals for poor contact. BOOM, ARM, BUCKET, THIN METAL PLATE, TRACK SHOE Check parts for deformation, for damage and loss. BOLTS AND NUTS Check parts for poor contact or loss. FUEL SYSTEM Remove the water and sediments in fuel tank. HYDRAULIC SYSTEM Check hydraulic components for leakage and check hoses for twist. Check hoses and lines or other parts for rubbing. LUBRICATION Check the specified parts referring to periodic maintenance table. PROTECTOR Check protection plates and mud guard. SAFETY Move the obstacles and all people near the excavator must leave. 43

50 CHECKING BEFORE STARTING ENGINE CHECK ENGINE OIL LEVEL Park the excavator on a level ground and check the engine oil level (Shut off the engine for a while to let oil flow to crankcase). The engine oil level must locate between the "MIN" and "MAX" position on the dipstick (Fig.26). The methods of using and maintaining engine refer to documents packaged with the machine for Isuzu Operation and Maintenance Manual. Fig.26 ELECTRIC EQUIPMENT Check all switches (Fig.27), indicators, safety alarm equipment, batteries electrolyte acidity, and fuses. Fig.27 FUEL STORAGE When LCD (Fig.28-1) flickers in fuel gauge, it shows very few quantity of fuel left for using in fuel tank. (Option for operator.) Drain the fuel filter and the fuel tank every day. If the using conditions and the fuel quality permit, the maintenance period may be extended to one week. Fig.28 44

51 CHECKING BEFORE STARTING ENGINE AIR FILTER If the negative pressure exceeds its max value, the indication lamp on the instrument panel will light. Then maintain the air filter or replace the paper cartridge. OIL LEVEL IN THE HYDRAULIC OIL TANK Fig.29 IMPORTANCE! When refuel the hydraulic tank, pay attention to following items: When the excavator is parked on a level ground and the piston rod of the cylinder draws back fully, the oil level shouldn't exceed the upper oil observation window. (Fig.30) In the same conditions, when the piston rod of the cylinder stretches out fully, the oil level shouldn't be lower than the lower observation window. OIL QUALITY While refueling the machine, the oil quality must be selected according to the lubrication material tables. Refueling or filling the hydraulic oil must be through the filter. Everyday maintenance refers to the specifications. Fig.30 PILOT CONTROL SHUT-OFF LEVER 1. Make sure pilot control shut-off lever is set to the LOCKED position. 2. Confirm that all control levers are placed in neutral. Fig.31 45

52 STARTING ENGINE STARTING EXCAVATOR Ignition key switch position (Fig.28): PREHEAT, OFF, ON & START It is necessary to check following all functions before starting of diesel engine. A. PUT THE IGNITION KEY INTO THE KEY SWITCH, TURN THE KEY TO PREHEAT POSITION ACCORDING TO THE CLOCKWISE. THE FOLLOWING INFORMATION MUST EXIST ON INSTRUMENT PANEL (FIG.33): 1. Engine oil pressure is too low. 2. Alternator does not work. Fig.32 B. STARTING PROCEDURE WHEN THE ENVIRONMENT TEMPERATURE IS BELOW 0. Adjust throttle control knob to idle position, and turn ignition key to starting position directly. Continuous starting time doesn t surpass 15 seconds. Interval time of two starts must be longer than 2 minutes. Fig Engine oil pressure indicator 2. Charging indicator If one of above indicators don t extinguish, shut off diesel engine at once. If diesel engine is overheated, and the buzzer sound, it is sure to stop diesel engine immediately at this time. 46

53 STARTING ENGINE C. IT IS POSSIBLE TO POUR FLAMMABLE COMBUSTION IMPROVER INTO SUCTION PIPE BEFORE STARTING WHEN ENVIRONMENTAL TEMPERATURE IS LOWER THAN -18 D. STOPPING PROCEDURE Don't stop the diesel engine directly while it runs with full load. Let the diesel engine run at idle speed for a while to unload the heat load, and then stop it. E. PREHEATING OPERATION Normally, when the machine is working, the oil temperature should be 50~80. Preheat is necessary if it is below 20. Don't let the machine start running or operating until the oil temperature rises to about 30. Steps are as below: 1. When the oil temperature is about 10 lower than the specified limit, adjust the velocity to its rated value after starting the diesel engine. Operate the cylinder and the hydraulic motor, and contact the cylinder to the dog momentarily. The operating time is about 10 minutes. 2. If the oil temperature is too low, preheat the oil tank before starting the diesel engine (such as: using 4 kilowatts heater). 47

54 STARTING ENGINE USING BOOSTER BATTERIES ATTENTION! The electrolyte of battery emits explosive gas while they are charging or being used. Prevent to let fires or sparks near the battery, and the battery should charge in the full air circulation areas. Park the excavator on a dry hard ground or on a cement ground, not on a steel plate. If park the excavator on the steel plate, the unexpected sparks will be produced on the machine. Never contact the positive pole with the negative pole because of short circuit. IMPORTANCE! The machine electrical system is a 24V negative (-) ground. Use only 24V booster battery. 1. CONNECTING BOOSTER BATTERIES a. Stop the engine that is equipped with booster batteries. b. Connect one end of the red cable 1 to the positive (+) terminal of batteries of the machine being starting, and the other end to the positive (+) terminal of the booster batteries. c. Connect one end of the black cable 2 to the negative (+) terminal of the booster batteries, and the other end to the upper frame of the excavator which is going to start as ground. Ensure the connection far away from the wire connector of battery. d. Start the engine. 2. DISCONNECTING BOOSTER BATTERIES a. At first, disconnect the black cable 2 negative (-) from machine upper frame. b. Disconnect the other end of the black cable 2 negative (-) from the booster batteries. c. Disconnect the red cable 1 positive (+) from the booster batteries. d. Disconnect the red cable 1 positive (+) terminal from the machine batteries. Fig.34 Fig.35 48

55 ADJUSTING OPERATOR S SEAT SEAT ADJUSTMENT ANGLE ADJUSTING OF BACKREST 1. Adjust back angle of chair with handle (Fig.36-1). Seating on chair, operator takes away the handle in No.1 of right figure upward with right hand, the back of chair becomes a bit more flexible, then moving backward with back brings along back of chair sway, when operator feels comfortable, release handle shown in No.1 of figure just right. HORIZONTALLY ADJUSTING OF SEAT 2. Pull up adjusting lever (Fig.36-2) to carry out horizontal adjustment possibly. Seating on chair falsely, operator presses down handle shown in No.2 of right figure, at this time the chair releases from sliding slot, then pull the chair with left hand to and fro, when operators feel that front and rear distance is suitable, release handle of No.2 in right figure just right. HEIGHT ADJUSTING OF SEAT 3. Adjust height of seating chair with handle (Fig.36-3). Seating on chair falsely, operator takes away the handle in no.3 of right figure upward with left hand, then lift the chair up with right hand, when operators feel the height is suitable, release handle of No.3 in right figure just right. HEIGHT ADJUSTING OF ARMREST 4. Adjust armrest (Fig.37-1) angle of chair with handle. Seating on chair, operator turns the handle (Fig.37-2) left or right with right hand, the angle of chair becomes a bit big or small, then operating the ten cross control lever when operator feels comfortable, just right. IMPORTANCE: When changing operator every time please adjust the seat before any operation to ensure the comfort & safety. Fig.36 Fig.37 49

56 TRAVEL OPERATION DRIVE MACHINE WITH PEDAL Be sure to confirm the traveling position, the front idlers are located in front of the operator s seat and the travel motors at the rear. 1. STRAIGHT FORWARD TRAVEL Step on both pedals forward together to travel forward. Fig STRAIGHT REVERSE TRAVEL Step on both pedals backward together to travel in reverse. NOTE: When the upper structure of machine slewing 180, the travel direction of machine will be reversed. Operator must be careful to avoid accidents occurring. 3. PIVOT TURN Left turn (Fig.39): Step on right pedal forward (Fig.38) and meanwhile step on left pedal downward. Fig.39 Right turn (Fig.39): Step on right pedal downward and meanwhile step on left pedal forward. 4. SPIN TURN (FIG.40) Left turn: Step on right pedal forward. Fig.40 Right turn: Step on left pedal forward. Avoid back turning as much as possible in order to protect the travel mechanism from damaging. Fig.41 50

57 TRAVEL OPERATION DRIVING MACHINE WITH LEVER If needing smooth control of travel, operator can insert the two levers that are packaged with the machine and control travel by the levers. This way is safe and reliable, especially fits for loading or unloading excavator onto/from a trailer. Confirm the traveling position, the front idlers are located in front of the operator s seat and the travel motors at the rear. 1. STRAIGHT FORWARD TRAVEL Push both levers forward together to travel forward. 2. STRAIGHT REVERSE TRAVEL Pull both levers backward together to travel in reverse. NOTE: When the upper structure of machine slewing 180, the travel direction of machine will be reversed. Operator must be careful to avoid accidents occurring. Fig PIVOT TURN Left Turn (Fig.42) Push right lever forward and pull left lever backward. Right Turn (Fig.43) Push left lever forward and pull right lever backward. Fig SPIN TURN (FIG.44) Left Turn Push right lever forward. Right Turn Push left lever forward. Avoid back turning as much as possible in order to protect the travel mechanism from damaging. Fig.44 51

58 TRAVEL OPERATION TRAVELING TIPS 1. Let the arm cylinder and the bucket cylinder entirely reach out to maintain a minimum radius of working attachment. Let the bucket keep half a meter from ground. 2. If possible, let the machine travel on a hard and level ground. Perform straight propelling and large radius turning if condition permits. Always avoid sharp and pivot turning as much as possible. If it cannot be avoid, be sure to drive slowly and smoothly. 3. If the machine should travel on a bumpy ground or wasteland, low the speed to 1.5 km/h so as to reduce vibration. 4. Retrain from backing or retrogressing as much as possible in order to prevent undue damage to the parts having connection with the track. 5. Should excavator be stuck in a muddy or swampy ground, level the bucket on ground to jack up one of the tracks and then rotate it back and forth to shake off mud and sand from the tracks (Fig.45). In order to minimize too much strain, the angle between the boom and the arm should be within 90 ~ The boom and arm can also help excavator get out of difficult situation if it is trapped in mire or ditch (Fig.46). Reach the arm out and lower the bucket to let it keep from ground by half meter when climbing up or down slope (Fig.47). Drive at low speed by controlling the fuel lever and slightly adjusting the pilot valve when climbing down slope to avoid slide or accident. Should excavator tend to slip, lower bucket to ground and stop it immediately. When climbing up or down steep slope, always be on the alert. If diesel engine should extinguish while climbing, always stop the machine with the help of the bucket. Put all the control levers at neutral position before the diesel engine is started again. Fig.45 Fig.46 Fig.47 52

59 DIGGING OPERATION OPERATING MODE In digging with the backhoe longitudinally, put the sprocket backward and the idler forward (Fig.48). In digging with loading shovel longitudinally, put the sprocket forward. In digging stones, put the sprocket backward and the idler forward because of safety. Fig.48 LEFT & RIGHT JOYSTICKS OPERATION (FIG.49) BOOM OPERATION Pull right joystick backward (towards "A") to raise the boom. Push right joystick forward (towards "B") to lower the boom. BACKHOE OR GRAB BUCKET OPERATION (FIG.51) Push right joystick leftward (towards "C") to let the backhoe load earth or let the grab bucket close. Push right joystick rightward (towards "D") to let the backhoe unload earth or let the grab bucket open. Fig.49 ARM OPERATION Push left joystick forward (towards "G") to reach the arm out. Pull left joystick backward (towards "H") to retract the arm. Fig.50 SWINGING FRAME OPERATION (FIG.51) Push left joystick leftward (towards "E") to swing the frame to left. Push left joystick rightward (towards "F") to swing the frame to right. Fig.51 53

60 DIGGING OPERATION COMPOUND MOVEMENT OPERATION 1. The compound movement of the boom and the bucket can be performed simultaneously with the swing of the revolving frame. 2. While the bucket is engaged in digging, the arm can reach out or retract. While the arm is busy digging with the bucket, the boom can lower itself down or raise itself. 3. Apart from the rational co-operation of the right and left levers, move one lever in direction of diagonal line (i.e. 45 ) can bring about a movement of the two neighboring movements. BRAKE OF SWING FRAME Release left joystick of swing control to the neutral position so as to provide enough braking force to brake the frame. 54

61 DIGGING OPERATION PRECAUTIONS FOR DIGGING 1. Operator should wear a safety helmet and work clothing, and make certain safety at the work site before starting operations. 2. Push the pilot control shut-off lever to unlocked position. 3. No bystander is allowed to remain on excavator or stand within a radius of meters. Before starting to load or after having loaded a lorry, operator should give signal by pressing the horn. 4. When digging with the bucket, be sure not thrust it in a forcible manner, especially when earth is hard, to avoid overload, or oil overflowing or bleeding, as it causes a rise in temperature of the hydraulic oil. 5. When operating, try to prevent the hydraulic oil from becoming hot owing to bleeding because of constant overload, which may cause damage to the machine parts 6. Never swing before the bucket is clear of ground in hauling up earth. 7. The bucket can be employed to move, to spread or level the earth that has been loosened by digging. Never do this by flank movement of bucket. 8. Working on a soft ground (especially in raining days, do keep a distance from working face in order to prevent caving in. 9. Turn off all the switches on control console when excavator is stopped. Cut off electricity and shut cab door before leaving. 10. The standing area must be level. Prevent the excavator from digging at slope. 11. The machine should swing smoothly at middle speed. When starting or braking, micro adjustment performance of the pilot valve should be used so as to starting or braking smoothly. 12. When boom subsides, micro adjustment performance of pilot valve should be used so as to subside smoothly and slowly. Do not brake suddenly. 13. In digging, overload digging should be avoided so as to reduce energy consumption and eliminate hydraulic oil overheating. 14. In digging, avoid impacting brake blocks at the stroke end of piston so as to prolong the lifetime of the structure units. 15. Should productivity be satisfied, try to avoid engine running at full throttle. It's best to run at rpm so as to prolong the lifetime of the engine and result in low noise. 16. Every pins of the attachment should be greased according to the stipulation on each shift till the grease is squeezed out from the shaft. The shafts and bushes are jammed if failing to grease. 55

62 DIGGING OPERATION PARKING THE EXCAVATOR 1. Park machine on a hard and level ground. 2. Lower down the bucket to the ground. 3. Adjust throttle control knob to Min. position. 4. Turn ignition key to "OFF" position and then take it out after engine stopping. 5. Pull the pilot control shut-off lever to LOCKED position. 6. Close the front window, the overhead window and the cab door. 7. Lock all of doors and boxes. IMPORTANCE! When it is in cold weather, park the excavator on a hard ground so as to prevent the tracks freezing with the soil. If the tracks freeze with the earth, Please move the excavator carefully by using the boom to raise the tracks in order to prevent the sprocket from damaging. LOCKING THE UPPER FRAME The upper frame of excavator must be locked mechanically with the undercarriage when machine traveling, being transported, parking and being maintained ATTENTION! The swing mechanism can t be operated after locking the upper frame. BRAKE OF TRAVEL If the pedals or the levers were released, they will go to the neutral position automatically, and the excavator stops immediately. When climbing down slope, the hydraulic brake valve limits the speed below specific value. 56

63 DIGGING OPERATION OPERATING ON SOFT GROUND Refrain from traveling on the soft ground which hasn't enough strength to support the excavator as much as possible. If the excavator is working on the soft ground or stuck in a muddy ground, please clean the track frame. Rotate the upper structure 90 angle and lower the bucket down to raise one track from the ground. Keep the angle between the arm and the boom within , and lower the bucket bow down to ground. Fig.52 Rotate the raised track back and forth to shake off mud and dirt. RAISE ONE TRACK USING BOOM AND ARM ATTENTION! Keep the angle between the boom and the arm within , and lower the bucket bow down to ground. Rotate the upper structure 90 angle and lower the bucket down to raise one track from ground. Don't let the bucket teeth dig into soil when using the backhoe. Support the excavator with wooden blocks, or solid logs under the machine's rack. Fig.53 57

64 DIGGING OPERATION AVOID TIPPING Avoid transversal traveling on slope. Keep traveling direction same as that of the slope when traveling on slope. The bucket should point to the traveling direction with a clearance of 200 to 300 mm off ground when climbing up or down. Should the excavator tend to slip or become unstable, lower tile bucket down to ground immediately. Operate carefully at lower swing speed when swinging with hitch load. Fig.54 ATTENTION! Never swing when operating on slope. Fig.55 DRIVING IN WATER OR MUDDY WATER Pay attention to the following when operating in marshland. The working site has enough strength to support machine, avoiding machine suck in water and muddy water. Water must flow slowly. The submersed undercarriage height by water and muddy water could not exceed the upper roller. Pay attention do not submerse the swing bearing, annulus and swing joint. Frequently check the position of excavator, when work in this working condition. Fig.56 58

65 DIGGING OPERATION BACKHOE OPERATION 1) Lower the bucket with its teeth down to the ground and the angle between bucket bottom and the ground is 45. 2) Pull the bucket towards the excavator with the arm as main digging force. 3) Get rid of the mud and earth if they adhere to the bucket by moving the arm and/or the bucket back and forth quickly. 4) Operate the excavator with its track parallel to the ditch when digging a straight ditch. Move the excavator to a required distance after the wanted depth reached. Fig.57 IMPOTANCE! a. Avoid sharp stops when lower down the boom in case the impact force may damage the excavator. b. Avoid letting the cylinder reaching to the stroke ends when operating with the arm in case the cylinder damaged. c. Avoid the bucket bumping against the track when digging at an angle. d. Avoid the hoses of boom or bucket cylinder bumping against the ground when digging deep ditch. GRADING OPERATION IMPOTANCE! Never push or pull the mud and/or earth with the bucket when traveling. Retract the bucket and position the arm a little ahead of its vertical position as shown in Fig.58. Retract the arm while raising the boom. Lower down the boom slowly to keep the bucket moving smoothly on the surface once the arm leaves the vertical position, It will make grading operation more accurate to operate the boom, arm and bucket at the same time. Fig.58 59

66 DIGGING OPERATION AVOID CAVING IN Keep the working face vertical or at an angle to the traveling direction of the excavator, meanwhile keep the travel motor on the back of the machine. Do keep a distance from the working face or ditch brink. Never digging right working face below the excavator. Fig.59 ADVICE FOR OPERATION Avoid the bucket humping against the track when digging. Keep the excavator on a level ground as best as you can. Never use the bucket as a hammer or a staking machine. Never try to move stone or crash a wall with a swing motion. IMPORTANCE! Never strike the ground or press the earth with the bucket when the bucket cylinder reaches out entirely (the bucket retracts entirely) to avoid damaging the cy1inder. Adjust the digging length and depth to make the bucket fully loaded in each digging. Productivity is higher with the bucket fully loaded than that with the bucket partly loaded at a greater cycle speed. To make the bucket fully loaded is the first thing and the speed the second for increasing productivity. IMPORTANCE! Never fling the bucket to dig out rocks under ground with the bucket teeth penetrating the ground when the arm reaches out entirely, otherwise the excavator will he damaged badly. Once the ditch is excavated, the rocks can be pulled out with the bucket pulling upwards. The earth above the rock can be removed one or two layers each time. Never let the bucket flank bear load, e.g. grade the earth or strike objects by swinging the bucket. Fig.60 60

67 DIGGING OPERATION AVOID ABUSIVE OPERATION Never increase the digging force by driving the machine while pushing the bucket into the ground, otherwise the machine will be damaged severely. Never increase the digging force by raising the front or rear end of the machine to apply the machine weight to the bucket teeth, otherwise severe machine damage may result. Fig.61 CHOOSE CORRECT TRACK SHOE IMPORTANCE! The wide track shoe may become bend and/or loose if it used on the rough ground. And the other subassembly of undercarriage may be damaged too. Prohibited to use wide track shoe on rocks, sand pile or sandstone. It is designed to work on soft ground. Must perform periodical inspection on the tightness of the bolts on track shoe. 61

68 LIFTING OPERATION LIFTING OPERATION ATTENTION! Make sure to obey the local laws and regulations when performing lifting operation. Wire rope, tape and rigging may be broken which cause severe injury. Do not use damaged sprocket strip or broken wire ropes, slings and rigging. Do not move a load suddenly. Never move objects over the head of personnel. Make all personnel far away from the lifted objects. Do not let any personnel approach the lifting objects until they are laid down safely and steadily on the supporting block or ground. Position the upper structure and make travel motor in the rear part. Do not hang wire ropes or slings on bucket tooth. Otherwise, bucket tooth may fall off causing the falling of the lifted objects. 1. Make sure hang wire ropes or slings tightly on the loads that need to lift up. 2. Wear gloves well when truss chain hooks and chains. 3. Tightly tie chain hooks and chains on the bucket ring, rolled bucket and draw back arm. 4. Before starting, harmonize the hand signal with the flagman. 5. Familiar the position of all personnel in work site. 6. Mark the mark line of the position of hands on loads, so as to make sure there a distance between loads and the personnel who hold the loads. 7. Try to lift loads before formal lifting. 1) Stop machine near the loads. 2) Pot load on the machine. 3) Lift up loads 50mm(2in) high. 4) At the same time move loads off from machine when keep load in a distance that near the ground. 5) If there is the evidence of lose of stability, low down loads to the ground. 8. Only lift the loads to the needed position. Fig.62 62

69 TRANSPORTATION TRANSPORTING BY ROAD When transporting the machine on public roads, be sure to first be aware of and then, follow all local regulations. 1. Verify the length, width, height and weight of the trailer to be used for transportation. 2. Check the road status, such as limitation of dimensions, weight and the traffic regulations. The excavator needs to be dismantled sometimes in order to satisfy with the dimension and weight limitations. Fig.63 TRANSPORTING WITH A TRAILER The whole excavator can be transported with a trailer. Choose a proper trailer according to the transportation dimensions listed in the section "Transportation Dimensions". RECOMMENDED TRAILER: Loading capacity: above 25 ton Consult your authorized dealer for the details about the trailer. TRAILER LOADING/UNLOADING The trailer should be on a firm level ground when loading or unloading the excavator. ATTENTION! Do use a ramp or slope desk when loading or unloading the excavator. RAMP OR SLOPE DESK 1. Clean the ramp or slope desk and the trailer floor thoroughly before loading or unloading. Oily, muddy or icy surface may cause slipping. 2. Put stoppers below the trailer wheels when using ramp or slope desk for loading or unloading. 3. The ramp or slope desk must be wide, long and strong enough. The gradient of the ramp or slope desk must be less than The stop desk or ramp for loading or unloading must be wide and strong enough to support the excavator. Its gradient must be less than

70 TRANSPORTATION LOADING AND UNLOADING THE EXCAVATOR ATTENTION! The excavator should travel at the lowest speed when climbing up or down the slope desk. It is very dangerous to change travel direction on the slope. Never do so. The excavator should travel back to the ground or the trailer floor if the direction needs to be changed and climb up or clown the slope after the direction has been modified. Drive carefully over the protruding area between the slope top and the trailer floor. Avoid the excavator tipping over and person injuries caused by swing of the upper structure. Retract and lower the arm while the upper structure swings slowly as to get best stability. LOADING 1. The direction of excavator is: With working attachments: Place the attachments in the front and drive excavator forwards. Without working attachments: Drive backwards as shown in the figure The central line of the excavator should coincide with that of the trailer. 3. With working attachments: Prop the bucket with its flat face against the trailer floor. The angle between the arm and the boom should be between 90 and 110. Prop the bucket against the trailer floor just before the excavator tends to tip toward the trailer floor. Drive slowly forwards until the entire track comes into contact with the trailer floor firmly. Raise the bucket a little, retract the arm and keep it in lower position, Swing the upper structure slowly to 180. Lower the bucket down to the blocks. 4. Stop the engine and get the ignition key off the switch. 5. Operate the lever several times to release all the pressure in the hydraulic cylinder. 6. Pull the pilot control shut-off lever to locked position. 7. Close the cab window, top air vent window and door, and cover the exhaust outlet to avoid wind and rain coming in. Fig.64 Fig.65 Fig.66 NOTE: Do warm up the excavator before loading or unloading in cold weather. 64

71 TRANSPORTATION TRANSPORTING ATTENTION! Fasten the chains or ropes on the frame of the excavator. Never let it go through or press the hydraulic piping lines or hoses. Put wedges before and behind the track. Fix the excavator and working attachments on the trailer floor by fastening the four corners of the excavator with the chains or ropes. Fig.67 UNLOADING ATTENTION! Drive carefully over the protruding area between the slope desk and trailer tail. IMPORTANCE! Prevent the working attachments from the possible damage, keep the angle between the arm and boom 90 and avoid retracting the arm as it may damage the excavator when unloading. 1. Prop the bucket with its flat face against the ground as the excavator travels from the trailer tail to the slope. The angle between the arm and boom should be between 90 and 110. IMPORTANCE! Prevent the cylinder from the possible damage. Never let the bucket bump against the ground acutely. Fig The bucket must be propped against the ground before the excavator tends to tip forwards. 3. When the excavator travels forwards, raise the boom while reach the arm until the excavator climbs down the slope desk entirely. Fig.69 65

72 TRANSPORTATION MEMO 66

73 MAINTENANCE CORRECT MAINTENANCE AND INSPECTION PROCEDURES Learn how to service your machine correctly. Follow the correct maintenance and inspection procedures shown in this manual. Inspect machine daily before starting. Check the controls and instruments. Check fuel and oil level. Check for leaks, kinked, frayed or damaged hoses and lines. Go around machine checking for general appearance, noise and heat. Check for loose or missing parts. If there is any problem with your excavator, repair it before operating or contact your authorized dealer. Fig.70 IMPORTANCE! Use only recommended fuel and lubricants. Use only genuine HEFEI ZHENYU parts. Failure to use recommended fuel, lubricants, and genuine ZHENYU parts will result in loss of HEFEI ZHENYU product warranty. Never adjust engine governor or hydraulic system relief valve. Protect electrical parts from water and steam. Never disassemble electrical components of engine fuel pump controls and sensors, etc. 67

74 MAINTENANCE MAINTAIN THE EXCAVATOR PERIODICALLY Practice all the maintenance recommended in the manual (listed in the following pages). CHECK OPERATION TIMER (HOUR METER) REGULARLY Determine when to maintain the excavator according to the operation timer. The intervals listed in the maintenance tables are in normal environment conditions. If the excavator is utilized in bad environment conditions, the intervals should be shortened. USE FUEL & LUBRICANT CORRECTLY IMPORTANCE! Use recommended Fuel and lubricants always. If not, the excavator may be damaged and warranty period will be cancelled. PREPARE BEFORE MAINTENANCE 1. Park the excavator on the level ground (as illustrated to the right). 2. Lower the bucket down to the ground. 3. Stop the engine. (If maintenance must be practiced with the engine running, don't leave the excavator.) 4. Set the pilot control shut-off lever to the locked position. 5. Put a safety sign with "NO OPERATION" on the lever before maintaining the machine. Fig.71 68

75 MAINTENANCE MAINTAIN THE ENGINE Maintain the engine periodically according to the instructions listed in the manual provided by its manufacturer. REPLACE THE HYDRAULIC HOSES PERIODICALLY The excavator must be checked periodically to ensure safe operation. The troubles with following parts will cause severe fire. The intervals listed in following table are recommended as it is generally difficult to estimate the degree of wear, aging or tension loss of the parts listed below by eye-measurement. Nevertheless, if problems have been found by any of the parts while checking, it must be replaced before operating without considering its replacing interval. When replacing the hoses, check their clips for distortion, looseness or damage and replace them if necessary. According to the Following items, check all hoses periodically, and replace or retighten any parts that have problems. Consult your authorized dealer about replacing correctly. Engine Main Machine Working Attachments RECOMMENDED HOSE REPLACING INTERVALS Designation Fuel hose (fuel tank to filter) Fuel hose (filter to injection pump) Heater hose (heater to engine) Pump intake hose (oil tank to main pump) Pump intake hose (oil tank to gear pump) Pump discharge hose (pump discharge to monoblock valve) Pump discharge hose (gear pump to lower pressure circuit) Monoblock valve outlet hose (monoblock valve to working attachments, center joint, swing motor) Low pressure hoses (pilot hose, circuit hose) Boom cylinder hose Arm cylinder hose Bucket cylinder hose Interval 1.5 years 1.5 years 1.5 years 2 years 2 years 2 years 1.5 years 2 years 1.5 years 2 years 2 years 2 years NOTE: Do replace sealing elements such as O-ring when replacing hoses. 69

76 MAINTENANCE MAINTENANCE GUIDE A. GREASING (REFER TO PAGE 73) Each pin on working attachments Dozer blade Designation Connecting pin of boom and frame Pins at both ends of boom cylinder All pins on bucket and arm Connecting pin of cylinder and dozer blade Pieces Swing bearing Interval (in hour) Swing internal tooth rim 1 B. ENGINE OIL (REFER TO PAGE 74) Designation Quantity Engine oil Check oil level 1 Engine oil Replace 19L Engine oil filter Replace 1 Interval (in hour) C. GEAR OIL (REFER TO PAGE 76) Designation Quantity Interval (in hour) Swing reducer Check oil level 1 Replace 4L Travel reducer Check oil level 2 Replace 12L 70

77 MAINTENANCE D. HYDRAULIC SYSTEM (REFER TO PAGE 78) Designation Quantity Interval (in hour) Check hydraulic tank oil level Replace hydraulic oil Replace hydraulic oil tank filter 200L 4.Replace hydraulic oil tank suction filter. 5.Replace pilot filter. 1 6.Check hoses Leakage and Fracture, piping distortion etc. lines. NOTE: The intervals differ on different hydraulic oil. Please refer to the recommended hydraulic oil table. E. FUEL SYSTEM (REFER TO PAGE 86) Designation Pieces Intervals (in hour) Remove sediments from fuel tank. 1 2.Check and remove sediment from precipitator. 1 3.Replace the fuel filter. 1 4.Clean the feed pump filter. 1 5.Check hoses. fuel Leakage, fracture etc. Fracture, distortion etc. F. AIR CLEANER FILTER (REFER TO PAGE 90) 1.Air filter cartridge. Designation Pieces Clean 1 Intervals (in hour) (or when indicating lamp light) Replace 1 After cleaning five times or one year later 2.Air cleaner Clean 1 cartridge Replace 1 When cartridge replaced 71

78 MAINTENANCE G. ENGINE COOLING AND HYDRAULIC OIL COOLER (REFER TO PAGE 93) Designation Pieces Intervals (in hour) Check and clean the engine radiator 1 2.Check and adjust the fan belt tension 1 3.Clean hydraulic oil cooler 1 NOTE: Shorten the interval when the machine is operated in dusty environment. H. MISCELLANEOUS (REFER TO PAGE 95) Designation Pieces Intervals (in hour) Check the bucket teeth for wear and looseness 5 2.Check track sag 1 3.Adjust track sag 1 When necessary I. ELECTRICAL SYSTEM (REFER TO PAGE 100) J. AIR CONDITIONER Evaporator Condenser Compressor Cooling system Items Cooling state Methods Interval(Hour) Inspecting fluid flowing state from inspection fluid glasses Leaked or damaged or not for hoses Piping Leaked or not for joint Loosed or damaged or not for fixed clamp Cooling fluid Replace antifreeze fluid Belt Check strain of belt and abrasion Compressor bracket Condenser bracket Condenser core element Condenser surface Evaporator bracket Circulation wind inlet Completed or not Clean or not Dirty or not Loosed or damaged or not Damaged or not Good ventilation or not Fan motor Good contacted or not 72

79 MAINTENANCE A. GREASING Designation Pieces Intervals (in hour) Joining Pin for boom and 1 frame 1.Each Pin on Pins at both Working ends of boom 4 Attachment cylinder All pins on bucket and arm 8 3.Swing Bearing 2 4.Swing Internal Tooth Rim 1 : Grease everyday within the first 100 operation hours. : Need maintenance when operating in water or mud. Grease all grease fittings illustrated below. Fig.72 73

80 MAINTENANCE DESIGNATION OF RECOMMENDED GREASE Bucket, arm, boom, swing gear, swing bearing etc. -20 to 40 (-4 to 104F) British Petroleum BP Energrease Ls-EP2 Caltex Petroleum Multifax EP2 Esso Beacon EP2 Daphen Coronex Grease Daphne Coronex Grease EP2 Hefei Zhenyu Hefei Zhenyu special grease Japan Petroleum Epinoc Grease EP2 Shell Petoleum Shell Alvania EP Grease2 NOTE Lithium base grease with very high loading capacity NOTE: Each excavator has been lubricated with grease marked with when shipped from factory. B. ENGINE OIL (FOLLOW THE INSTRUCTIONS IN THE DIESEL ENGINE MANUAL) Designation Quantity Interval (in hour) Engine oil Check oil level 1 2.Engine oil Replace 19L 3.Engine oil Main Filter Replace 1 : Do replace engine oil after the first 100 operating hours. Follow the diesel engine instruction when maintaining. Adopt API (American Petroleum Institute)and CCMC specifications in general as engine oil differs greatly in performance and grade. Use CD diesel engine oil according to API diesel engine oil specification. Use D4 diesel engine oil according to CCMC diesel engine oil specification. Plant DESIGNATION OF RECOMMENDED ENGINE OIL Designation -20 to 0-10 to to 40 Esso EssolubeD-3 10W Daphne Coronex Grease Apollo oil Super Wide 15W-40 Mobil 1310 Mobil Delvac Hefei Zhenyu Hefei Zhenyu special engine oil (CF-4) NOTE: Each excavator has been filled with engine oil marked with when shipped from factory. 74

81 MAINTENANCE 1. CHECK ENGINE OIL LEVEL Check oil level before starting the engine everyday. 1) Take out the dipstick, remove oil on it with a piece of clean cloth and insert it back. 2) Take out the dipstick again and read the oil level. It must be between MIN and MAX. 3) Add engine oil through the filter if necessary. NOTE: An inaccurate oil level may get if checking right after the engine stops. Wait for 10 minutes at least to let oil become stable in this case. Fig REPLACE ENGINE OIL Engine oil must be replaced after the first 100 operating hours. Follow the instructions in the diesel engine manual when maintaining. 3. REPLACE ENGINE OIL FILTER EVERY 500 HOURS ATTENTION! Be greatly careful to avoid being scalded for the engine oil is very hot. Dispose of the waste oil properly to avoid contaminating surroundings. Follow the instructions in the diesel engine manual when replacing filters. Fig.74 75

82 MAINTENANCE C. GEAR OIL Interval (in hour) Designation Quantity Check oil 1.Swing level gearbox Replace 4L 2.Travel Check oil reduction level gear Replace 12L DESIGNATION OF RECOMMENDED GEAR OIL Plant Esso Nippon Oil Mobil Hefei Zhenyu Designation Gear Oil -20 to 40 Esso Gear Oil GP80-90, GP85W-90 Gear Lube Sp90 Mobilube Gx90 Hefei Zhenyu special gear oil NOTE: Each excavator has been filled with gear oil marked with when shipped from factory. 76

83 MAINTENANCE 1. CHECK SWING REDUCER OIL LEVEL EVERYDAY Replace gear oil every 1000 hours. Fig.75: 1 fill port 2 drain port ATTENTION! The excavator should be parked on the level ground before checking oil level or replace oil. The gear oil may be hot. Wait for the oil cooling down before replacing. Do add the recommended oil listed in the table. Fig CHECK TRAVEL REDUCER OIL LEVEL EVERY 250 HOURS Change gear oil every 2000 hours. Fig.76: 1 fill port 2 level port 3 drain port ATTENTION! The excavator should be parked on the level ground before checking oil level or replacing oil. The gear oil may be hot. Wait for the oil cooling down before replacing. Do add the recommended oil listed in the table. Fig.76 77

84 MAINTENANCE D. HYDRAULIC SYSTEM Designation Quantity Interval (in hour) Check hydraulic oil level 1 Remove sediment from hydraulic oil tank 1 Replace hydraulic oil 200L Replace oil filter of hydraulic tank 1 Replace pilot filter 1 Leakage Check hoses and piping lines Fracture and distortion NOTE: The intervals differ on different hydraulic oil. Please refer to the table of recommended hydraulic oil. DESIGNATION OF RECOMMENDED HYDRAULIC OIL Oil kinds Hydraulic oil Using place Hydraulic system Replacing period 2000 hours 1500 hours Engine oil plate -20 to to to to 40 Manufacturer Japan oil Esso Standard Essolube D-3 Oil 10W Mobil Oil Apollo oil Super Wide 15W-40 Shell Oil 1310 Hefei Zhenyu Marks Hefei Zhenyu special hydraulic oil Anti abrasion hydraulic oil Use appropriate hydraulic oil according to the environment temperature. Each excavator has been filled with hydraulic oil marked with when shipped from factory. 78

85 MAINTENANCE INSPECTION AND MAINTENANCE OF HYDRAULIC EQUIPMENT ATTENTION! The components in hydraulic system may become very hot during operating. Wait for the excavator cooling down before checking and maintaining. 1. Park the excavator on the level and solid ground before maintaining the hydraulic system. 2. Stop the engine after the bucket is lowered down to the ground. 3. Maintain the hydraulic system until the components, hydraulic oil and lubricants cool down entirely, as there still exist residual heat and pressure for a time after operating. The hot parts or oil may shoot out or gush, which may result in severe injuries, when maintaining the heated and pressurized hydraulic system. Keep body and face far from the plugs or bolts to be removed for they may be still pressurized even in cool state. 4. Do let out the inner pressure of the oil tank before maintaining the hydraulic system. 5. There may still exist pressure in the hydraulic oil circuit after the pressurized air in oil tank is bled. Ensure that each lever is operated several times to release residual pressure in the hydraulic system entirely. 6. Avoid checking, maintaining, traveling and rotating motor circuit on slopes, for they can be pressurized by weight even if the air in the oil tank is bled. 7. Do keep the surface of sealing elements clean and undamaged when joining the hydraulic hoses and piping lines. Keep following tips in mind: a. Wash the hoses, piping lines and the interior of oil tank with detergent, and wipe up them before joining. b. Use undamaged and defect-free O-rings and avoid impairing them when assembling. c. The hose life would be shortened greatly if it is joined in contorted manner. 8. Do use hydraulic oil of' the same type. Never mix different hydraulic oil. Use HM46 hydraulic oil in principle for the excavator has been filled with oil of this make when leaving factory. Do change all hydraulic oil within the hydraulic system when recommended oil listed in the table "Designation of Recommended Hydraulic Oil" is to be used. 9. Never use the hydraulic oil that is not listed in the table "Designation of Recommended Hydraulic Oil". 10. Never start the engine when the hydraulic oil tank is empty. 79

86 MAINTENANCE 1. CHECK HYDRAULIC OIL LEVEL EVERYDAY IMPORTANCE! Never start the engine with the hydraulic oil tank empty. Open the left door on the upper structure of the excavator, check upper oil level orifice. The oil level should be between two oil level orifices. Add oil if necessary. Use recommended hydraulic oil listed in the table "Designation of Recommended Hydraulic Oil". Fig REMOVE SEDIMENT FROM HYDRAULIC OIL TANK EVERY 250 HOURS IMPORTANCE! Never start the engine with tire hydraulic oil tank empty. Park the excavator on the level ground and swing the frame 90 to make the oil tank easy of access. Stop the engine. (Best of all, if it is performed before operating) Keep body and face far from the drain plug. Loosen the drain plug at the bottom of the oil tank with a spanner and let out oil, water and sediment. 3. REPLACE HYDRAULIC OIL EVERY 2000 HOURS ATTENTION! Wait for the hydraulic oil cooling down before replacing, as it may be hot. IMPORTANCE! Replacing interval differs in different hydraulic oil. (Refer to the recommendation tables.) Park the excavator on the level ground and swing the frame 90 in order to make the oil tank easy to access. Retract the arm and bucket cylinders entirely. Lower the bucket down to the ground. Clean the top surface of the hydraulic oil tank to avoid dirt dropping into the hydraulic system. Stop the engine. Keep body and face far from the drain plug. Loosen the drain plug at the bottom of the oil tank with a spanner to let out oil and retighten the plug after the oil drains throughly. Loosen the vent plug at the top of oil tank. Fill the oil tank with clean hydraulic oil through the filter. Check oil level and make it between two oil level orifices. Retighten the vent plug. 80

87 MAINTENANCE 4. MAINTENANCE OF OIL COOLER It is very important to keep the oil cooler clean for keeping best cooling effect. Clean the oil cooler every 250 hours. Shorten the interval of maintenance if the excavator operates in dusty environment. ATTENTION! Wait for the hydraulic oil cooling down before maintaining, as the oil may be hot. 5. REPLACE HYDRAULIC OIL TANK FILTER ATTENTION! The cartridge must be cleaned every day within the first 500 operating hours. Then clean it once a week. The paper cartridge of filter should be replaced after the first 250 operating hours, and thenceforth replaced whenever the signal lamp of pollution sends out light, or every 500 hours, or malfunction due to emergence of polluted hydraulic system. CLEAN FILTER ATTENTION! Wait for the hydraulic oil cooling down, as it may be hot. Keep body and face far from the filter cover. Loosen the six nuts on the cover and remove the cover together with the cartridge. Do away with the dirt on the cartridge carefully. Pay attention to the correct position of O-ring and pressure spring when reassembling the filter. REPLACE FILTER ELEMENT ATTENTION! Wait for the hydraulic oil cooling down before cleaning, as it may be hot. Keep body and face far from the filter cover. Loosen the six nuts on the cover and remove the cover together with the magnetized cartridge. Take out the filtering element after the pressure spring is removed. Put in a new filtering element. Pay attention to the correct position of O-ring and pressure spring when reassembling. The dirt funnel of filtering cartridge should be mounted on the filter-bottom block. Tighten the six nuts on the cover 6. REPLACE PILOT FILTER EVERY 500 HOURS Replace the paper-filtering cartridge whenever the pilot filter (Fig.78-1) is replaced. Unscrew the filter casing. Take out the filtering element. Clean the casing and magnetized cover. Put in a new filtering cartridge. Screw up the filter casing. Fig.78 81

88 MAINTENANCE 7. CHECK HOSES AND LINES EVERYDAY EVERY 250 HOURS ATTENTION! Hydraulic oil may penetrate skins under pressure and cause severe injuries. Use a piece of cardboard for checking to avoid being injured and do keep hands and body away from the pressurized hydraulic oil. Go to see a doctor immediately in case some one has been injured. Any oil penetrated into skin must be removed by surgeon within several hours or it may result in subcutaneous ulcer. ATTENTION! The leaked hydraulic oil and lubricants may cause fire and casualties. The following rules should be observed to avoid the hazard. 1. Park the excavator on the solid and level ground. Lower the bucket down to the ground. Stop the engine. Get the key off the switch. 2. Check the clips for being lost or looseness, hoses for contortion, hoses or lines for rubbing against each other, the oil cooler for damage, oil cooler flange bolts for looseness and find out if there is leakage. Inspect the check positions of the hoses or lines listed below for leakage and any damage that may cause leakage. (Refer to the table 1 on page 84 and tables 2 and 3 on page 85). If anything abnormal, replace or tighten. 3. Tighten, repair or replace any clips, hoses and lines, oil cooler and flange bolts that are loose, lost or damaged. Do not bend or bump against the high- pressure piping lines. Never use contorted or damaged hoses or lines. 82

89 MAINTENANCE PUMP SUCTION HOSES If the suction hose of pump must be cleaned or replaced, please refer to the following: 1. Discharge the pressure in hydraulic system to prevent the oil with high pressure spilling. 2. Totally drain the hydraulic oil from the tank and be careful not to be scalded by hydraulic. 3. Loosen the connecting bolt of pump inlet flange, and drain oil from pump and hose. 4. Loosen clamps of hose ends, then disassemble the hose. 5. Mount the clean or new suction hoses of pump to the hydraulic tank and pump adapters. 6. Tighten the connecting bolt of pump inlet flange. Remember put the O-ring well. 7. Install the clamps at both ends of pump suction hose, and tighten them respectively. BLEED AIR FROM HYDRAULIC PUMP Air must be bled off the pump when maintaining it or replacing hydraulic oil in the hydraulic system. Loosen the seal plug to let air out and tighten it when hydraulic oil begins to spill. Fig.79 83

90 MAINTENANCE TABLE 1 HOSES Interval Check Position Malfunction Method Hose exterior Leakage (1) Replace Hose end Leakage (2) Replace Daily Hose end fitting Leakage (3) Tighten or replace the hose, or O-ring Hose exterior Fracture (4) Replace Hose end Fracture (5) Replace Hose exterior Strengthening Replace material exposing (7) Every 250 hour Hose exterior Hose Local protruding (7) Distorted (8) Replace Replace Hose Contorted (9) Replace (with proper bending radius) Hose end fitting Distorted or corroded Replace (10) NOTE: Refer to right figure 80 for the check position or malfunction concerned. Do use authentic parts from HEFEI ZHENYU. Fig.80 84

91 MAINTENANCE TABLE 2 LINES Interval Check Position Malfunction Method Interface of flange joint Leakage (11) Replace Daily Welding line of flange joint Leakage (12) Replace Tighten or Replace hose, or 0-ring Joint hose Fracture (13) Replace Welding line of flange Fracture (12) Replace Every 250 hours joint Clip Damaged Replace Fig.81 Distorted Replace Loose Replace NOTE: Refer to right figure 81 for the check position or malfunction concerned. Do use authentic parts from HEFEI ZHENYU. TABLE 3 OIL COOLER Interval Check Position Malfunction Method Interface of flange Leakage Replace O-ring or joint tighten bolts Every 250 hours Oil cooler Leakage Replace Joint and rubber Leakage Tighten or replace hose Fig.82 NOTE: Refer to figure 82 or the check position or malfunction concerned. 85

92 MAINTENANCE E. FUEL SYSTEM Designation Pieces Interval (hour) Remove sediment from the fuel tank Inspect and remove sediment from the 1 precipitator. 3. Replace fuel filter Clean feed pump filter. 1 Leakage, Fracture etc. 5. Check the fuel hose. Fracture, Distorted etc. RECOMMENDED FUEL: Use high-quality diesel oil only (GB252 commonly 0#; in winter-10#). Kerosene MUST NOT is used. ATTENTION! Stop the engine before refueling. No smoking when refueling or near the fuel system. Check fuel level indicator on monitor panel, refuel if necessary. Avoid any dirt, dust, water and foreign matter dropping into the fuel tank and fuel system. In order to avoid coagulating, do not spatter fuel onto the excavator or ground when refueling after operating everyday. Cover the fuel tank properly after refueling. 1. REMOVE SEDIMENT FROM FUEL TANK EVERYDAY Parking excavator on lever ground. Swing upper structure 90º for approaching the machine. Using spanner to unscrew the plug in the bottom of fuel tank to discharge water and sediment, and then screw it on. 86

93 MAINTENANCE 2. CHECK AND DRAIN DEPOSITS IN THE CONTAINER EVERY 50 HOURS Loosen faucet of deposition container to drain water. Screw on the faucet after draining water. (IMPORTANCE) If there is excessive water in the fuel, should shorten the check period. Make sure to drain air in the fuel system REPLACE FUEL FILTER EVERY 500 HOURS Close fuel entrance valve door. Use all-purpose tool to get core element off. Use container to receive effluent diesel oil. Clean the surface of bracket. Apply diesel oil or engine oil on the rubber surface of new filter core. Screw in filter core element. At last add into half circle. Open fuel entrance valve door. Discharge air in fuel system. Check infiltration oil. 4. CLEAN DELIVERY PUMP FILTER EVERY 1000 HOURS Close fuel entrance valve door. Loosen the bolt. Remove fastened steel wire. Getting off filter net and cover cup, and then clean them in the diesel oil. Replace washer. Install them over again. Discharge air in fuel system. Check leakage. 87

94 MAINTENANCE 5. BLEED AIR FROM FUEL SYSTEM IMPORTANCE! Air in the fuel system may cause the engine difficult to start and easy to produce the malfunction. Do air bleeding operation from the fuel system after removing water and sediments from precipitator, or replacing the fuel ell filter, or cleaning the feed pump filter or emptying the fuel tank. Loose the bolts on the overflow valve (1). Turn the manual pump head anticlockwise to loose the manual pump (2). Press the manual pump up and down until foamless diesel oil comes out of the overflow valve. Tighten the overflow valve; simultaneously press the manual pump continually. Tighten the manual pump head. Fig CHECK FUEL HOSES EVERYDAY EVERY 250 HOURS ATTENTION! The leaked fuel may cause fire and result in casualties. Following tips are helpful, for avoiding the hazard. 1. Park the excavator on the level and solid ground. 2. Check the hoses for distortion, rubbing against other parts and leakage. Check each checking position of the hoses listed in the following page for leakage or any damage that may cause leakage. Replace or tighten them according to the table 4 when there are troubles. 3. Replace or repair the damaged or loose hoses. Never use distorted or damaged hoses. 88

95 MAINTENANCE TABLE 4 HOSES AND LINES Interval Check Position Malfunction Method Hose End Leakage (1) Tighten or replace Daily Hose with weave Lining Wear (2) Replace Fracture (2) Replace Hose with weave Fracture (3) Replace Lining Hose end Fracture (4) Replace Hose Bent (5) Replace Every 250 hours Hose Contorted (6) Replace (With proper bending radius) Hose end and joint Distorted or Replace Corroded (7) Fig.84 89

96 MAINTENANCE F. AIR CLEANER (REFER TO DIESEL ENGINE INSTRUCTION) Interval (hour) Designation Pieces Outer element of air filter 2. Inner cartridge of air filter Clean 1 Or when the indicator lamp light Replace 1 After cleaned 3 times or over 1 year Replace 1 When the outer element is replaced 1. CLEAN AIR CLEANER OUTER ELEMENT EVERY 250 HOURS OR WHEN INDICATOR LAMP LIGHTS 2. REPLACE AIR CLEANER FILTER INNER & OUTER ELEMENTS AFTER CLEANING SIX TIMES OR AFTER ONE YEAR 1. Park the machine on a solid level surface. 2. Lower the bucket to the ground. 3. Turn off the auto-idle switch. IMPORTANCE: If don t shut off the engine according to correct procedures, the turbocharger may be damaged. 4. Run the engine for 5 minutes at low idle speed. 5. Stop the engine and take out the ignition key from the switch. 6. Pull the pilot control shut-off lever to the locked position. 7. Loosen four clamps (Fig.85-1) and remove the air cleaner cover (Fig.85-2). IMPORTANCE: Do not squeeze the filter and cover forcedly when latching the clamps. Otherwise, it may result in the deformation of clamps, filter and/or cover. Fig.85 90

97 MAINTENANCE 8. Remove the air cleaner out element (Fig.86-3) from the housing. 9. Tap at the out element lightly with hands. Never attempt to clean the element by striking it or knocking it against another hard object. ATTENTION! When using compressed air pressure [less than 0.2 MPa (2 kgf/cm 2 )], to protect against flying debris, keep bystanders away and wear personal protective equipment including goggles or safety glasses. 10. To clean the outer element, blow compressed air along the pleats from the inside. 11. Clean the inside of air cleaner housing before installing the outer element. 12. Set outer element in the housing. 13. Install the cover on four clamps positions and latch the clamps. 14. Start up the engine and operate it at idling for several minutes. 15. Check air filter indicator on the monitor panel. If the indicator comes on, stop engine immediately and replace the outer element. 16. The outer & inner elements should be replaced together when replacing air cleaner. Remove the outer element. Clean the inside of inner element (Fig.86-4) before removing. Then take out the inner element. When reinstalling, first fix the inner element, then install the outer element. Fig.86 91

98 MAINTENANCE ATTENTION! All the cleaner elements should be replaced after cleaned 3 times or worked for one year. SAFETY ELEMENT The safety element cannot be cleaned. It should be replaced after the main element was cleaned 3 times or every year at least. 3. CHECK SEALING OF CONNECTING PIPES BETWEEN AIR FILTER AND ENGINE EVERYDAY REPLACE WHEN PIPING CRACK OR LOSS GAS CAUTION! If the piping between air cleaner and engine loss gas, and replace them not in time, which will damage engine seriously. 92

99 MAINTENANCE G. ENGINE COOLING SYSTEM & HYDRAULIC OIL COOLER Interval (hour) Designation Pieces Check and clean 1 the engine radiator. 2.Check and adjust 1 the belt tension. 3.Clean the hydraulic 1 oil cooler. NOTE: Shorten the interval when operating in dusty environment. 1. CHECK & CLEAN ENGINE RADIATOR EVERY 250 HOURS. IMPORTANCE! It is very important to keep the radiator clean to ensure the engine operates normally. Park the excavator on the level ground. Remove the engine cover. Check all water inlet & outlet hoses interface for leakage every day. Using compressed air to clear away any dirt, especially on the radiator & oil cooler from the engine vent flank. Then install the wind cover. 2. CHECK & ADJUST COMPRESSOR BELT TENSION EVERY 50 HOURS Check compressor belt (Fig.87) for damage or worn. Check compressor belt tension by depressing the belt mid-point with the force of thumb. Deflection must be 10 to 15 mm. ATTENTION! Never check, test or replace by this way when the engine is operating. Push the tension pulley forwards and remove the belt. Then replace a new belt. Fig.87 93

100 MAINTENANCE 3. CHECK & ADJUST ALTERNATOR BELT TENSION EVERY 100 HOURS TENSION ALTERNATOR BELT Loosen the fixing bolt of alternator (Fig.88). Pull the alternator outwards to tighten the belt. Tighten the fixing bolt. Tension the belt again after running the engine for 15 minutes. ATTENTION! Make sure to stop the engine while tension. Fig.88 REPLACEMENT OF ALTERNATOR BELT Loosen the nut. Push the alternator near to engine. Replace the V-belt with a new one. Push out the alternator to tension the belt. Tighten the nut. Re-tension the belt after the engine operates for 15 minutes. ATTENTION! Make sure to stop the engine while replacement. 4. CLEAN HYDRAULIC OIL COOLER & RADIATOR EVERY 250 HOURS IMPORTANCE! It is very important to keep the hydraulic oil cooler & radiator clean for keeping hydraulic system functioning normally. Park the excavator on the level ground. Stop the engine. Blow any dirt off with compressed air downwards from the upside of radiator & oil cooler. If there is putty on blades of radiator or oil cooler, wash it with detergent. Pay attention to protect the wire terminal. 94

101 MAINTENANCE H. MISCELLANEOUS Designation Pieces Interval (hour) Check bucket tooth for wear and looseness Check track sag Adjust track sag. 2 If necessary Fig.89 95

102 MAINTENANCE 1. CHECK BUCKET TEETH DAILY 1. Check bucket tooth for abrasion and looseness. 2. Replace teeth if tooth abrasion exceeds the designation service limit ATTENTION: Wear protection eyes glasses or safety glasses to avoid injury resulted from fly-out metal slices when replacing. Fig.90 REPLACEMENT PROCEDURES: a. Using a hammer and punch to hammer out the lock pin (1). Be careful not to damage rubber lock pin (2) when disassembling. b. Remove the tooth point. Check damage of lock pin (1) and rubber lock pin (1). Replace them if necessary. The too short lock pin and the rubber lock pin in poor condition should be replaced by new ones. Fig.91 c. Clean the surface of tooth adapter. d. Fit the new tooth point onto it NOTE: Different buckets may use different tooth components. Fig.92 96

103 MAINTENANCE 2. CHECK TRACK SAG Check track tension in time after it wears normally For a period of time and adjust it if necessary. The track tension is inadequate in Fig.93 and normal in Fig Remove the cover (Fig.95-4) on track frame. 2. Install the grease gun with rubber hose. (Fig.95-2) 3. Join the grease gun nozzle and tensioning cylinder nozzle through the gap (Fig.95-3). 4. Pump grease into the cylinder until the track tension is adequate. The track sag between the sprocket and the idler or the drive wheel should be 2 cm. To loosen the adjusting cylinder nozzle till grease coming out can decrease the track tension. ATTENTION! Do keep head off the adjusting cylinder nozzle when loosing the track. Fig.93 Fig.94 Fig.95 CHECK TRACK PERIODICALLY Check the tightening bolts for looseness weekly and tighten them if necessary. (Fig.96-5). The tightening torque of the bolt M is 510~540 N.m. Fig.96 97

104 MAINTENANCE CLEAN TRACK MECHANISM a. Clean the track mechanism components before stopping engine if they are too dirty. Hard and frost bound dirt may damage the track mechanism and shorten its life. Set one track on blocks firmly after it is jacked up by the attachment before cleaning. b. Grease the sliding face of slide block of idler after dirt and dust on it are cleared away. REPLACE TRACKS REMOVE TRACKS a. Park the excavator on the level and solid ground, Locate the dismountable track pin (it is different from other pins) before idler with a clearance of about one quarter of the idler diameter off ground. (Fig.97) b. Loosen the track as described in page 96. c. Get the pin out with an ejector pin. d. Drive the excavator backwards until the tracks come off entirely. INSTALL TRACKS a. Place new tracks right before the old ones and drive the excavator towards the new tracks. Adjust the position of new tracks by operating the attachment. ATTENTION! Pay attention to the direction and position of the tracks. (Fig.98) b. Join the new and old track shoes by track pins in case the new tracks come off when idler move on it. c. Drive carefully on the new tracks. Tie the new tracks on the sprocket with a piece of wire after the old tracks removed and then continue driving on the new tracks carefully. d. Untie the new tracks from sprocket and drive the excavator forwards. In this way, the tracks will be pulled over the upper roller and idler. Big wooden blocks can be placed between the idler, sprocket and lower roller if possible. Stop the excavator when there are about 2 track shoes before the idler. Lift the last truck shoe, mount the removed cushion and hammer in the track pin. e. Tighten the track as described in page 96. Fig.97 Fig.98 98

105 MAINTENANCE TIGHTENING TORQUE TABLE OF IMPORTANT BOLTS AND NUTS Some important bolts and nuts on excavator are standard parts made with super material. Do not use bolts and nuts that are not recommended to avoid accidents. Tighten the bolts to the tightening torque listed below when it needs to be tightened during maintenance. DIAMETER PITCH d P STRESS AREA PROOF LOAD N PRELOAD N TIGHTENING TORQUE N.m As(mm 2 ) GENERAL COARSE THREAD M ±2 72±2 82±2 M ±5 120±5 140±5 M ±5 195±5 225±10 M ±10 300±10 350±10 M ±10 420±10 490±10 M ±10 590±15 700±15 M ±15 810±15 955±15 M ± ± ±20 M ± ± ±50 M ± ± ±50 M ± ± ±70 M ± ± ±70 M ± ± ±70 NOTE: When installing new bolts and/or nuts, apply lubricant to the screw threads. 99

106 MAINTENANCE I. ELECTRICAL SYSTEM 1. BATTERIES ATTENTION! The gas inside batteries may cause explosion. Avoid any spark and Fire near batteries. Use a flashlight when checking electrolyte level. Vitriol in electrolyte is poisonous and strong acidity. It may burn skins and clothing, and cause blindness if spattered into eye. Take following measures to avoid the hazard. a. Fill the battery in the breezy place. b. Wear safety goggles and plastic gloves. c. Avoid inhaling the smog when filling with electrolyte. d. Avoid electrolyte spattering. e. Use a proper auxiliary battery. Fig.99 IF SPATTERED BY VITRIOL: a. Rinse skins with water. b. Use sodium bicarbonate or lime to neutralize the acid. c. Rinse eyes with water for ten to fifteen minutes. Get medical treatment immediately. Fig.100 IF VITRIOL BE INGESTED: a. Drink a lot of water and milk. b. Drink mixture of magnesia and eggs or vegetable butter. c. Get medical treatment immediately. IMPORTANCE! Fill the battery with water or charge it before operating in freezing weather. 100

107 MAINTENANCE CHECK ELECTROLYTE LEVEL AND POSTS 1. Check the electrolyte level at least once a month. 2. Park the machine on level ground and stop the engine. 3. Check the electrolyte level. Check if the electrolyte level is between U.L (Upper level) and L.L (Lower level). In case the electrolyte level is lower than the middle level between the U.L and L.L, immediately refill distilled water or commercial battery fluid. Be sure to refill with distilled water before recharging (operating the machine). After refilling, securely tighten the filler plug. 4. Always keep the vicinity around the battery terminals clean to prevent battery discharge. Check battery terminals for looseness and rust. Coat terminals with grease or petroleum jelly to the terminals to prevent corrosion. Fig.101 ATTENTION! Remove the grounded clip at first and fix it at last always. CHECK ELECTROLYTE DENSITY IMPORTANCE! Wait for the electrolyte cooling down to the environment temperature instead of just after stopping the machine when checking electrolyte density. Check electrolyte density in each cell of battery. The lowest electrolyte density depends on electrolyte temperature. It should be kept within the range below. Charge the battery once the electrolyte density is below the lower limitation. 101

108 MAINTENANCE 2. REPLACE BATTERY There are two negative ground 12V batteries on excavator. If one battery in 24V system loses function, but other is still good, operator should use same-type battery to replace function-losing battery. For example, use new maintenance-free battery to replace the function-losing maintenance-free battery. Charging speed of different-form battery can be different. This difference can make one battery among batteries lose function because of overload. Fig REPLACE FUSE If any electrical equipment fails to operate, first check the fuses in the fuse box. Fuse box is situated in right back of operator s seat. If operation is abnormal, a fuse may be blown. Replace blown or faulty fuses with the spare fuses as follows. a. Open the fuse box cover. b. Remove the blown fuse vertically. c. Vertically plug in a new fuse of the same capacity. d. Cover the fuse box cover. IMPORTANCE: It is sure to install fuse with correct amperage, prevent damage of electrical system from overloading. Fig

109 MAINTENANCE MEMO 103

110 MAINTENANCE UNDER SPECIAL ENVIRONMENT CONDITIONS MAINTENANCE UNDER SPECIAL ENVIRONMENT CONDITIONS OPERATING CONDITION Muddy ground, rainy or snowy weather At seaside Dusty air Rocky earth surface Freezing weather Falling rock MATTERS NEEDING ATTENTION ON MAINTENANCE Before operation: Check tensity of plug and all drain cock After operation: Sweep excavator and check whether there are fractured, damaged, loose or lost nut and bolt or not. Lubricate all necessary parts without delay. Before operation: Check whether plug and all drain cock are screwed down or not. After operation: Wash excavator with cleaning water thoroughly to wash away salt. Often maintain electrical appliance to avoid corrosion. Air filter: Sweep filtering core periodically in short maintenance interval. Radiator: Sweep net housing of oil cooler to avoid blocking of radiator core. Fuel system: Wash filtering core and filtering screen of filter periodically in short maintenance interval. Electrical system: Sweep this system periodically, especially sweep terminal of AC generator and starter. Undercarriage: Prudent operation. Often check whether there are fractured, damaged and lost bolt and nut or not. Front-end fitting: When digging rocky earth surface, standard fitting can be damaged. Should use front end stiffened bucket or use heavy duty bucket before usage of them. Fuel: Use high quality fuel suitable to low temperature. Lubricant: use high quality, low viscosity hydraulic oil or engine oil. Engine cooling fluid: Be sure to use antifreezing agent. Battery: Charge battery sufficiently periodically in short maintenance interval. If charge battery insufficiently, electrolyte can freeze. Undercarriage: Keep cleanness of undercarriage. Stay excavator onto solid earth surface to avoid freezing tyre on earth surface. Cab: Install protecting hover of cab if necessary to prevent excavator from damaging because of falling rock. 104

111 MAINTENANCE UNDER SPECIAL ENVIRONMENT CONDITIONS MEMO 105

112 STORAGE STORAGE OF EXCAVATOR 1. Check the excavator and repair worn and damaged parts. Install new parts if necessary. 2. Clean the primary air cleaner element. 3. Retract all hydraulic cylinders if possible. If not just lubricate exposed cylinder rods with grease. 4. Lubricate all lubricating points. 5. Park the tracks on long stable blocks. 6. Clean the excavator. 7. After charging fully, remove the batteries and store them in dry and safe place. If not removed, disconnect the negative battery cable from the (-) terminal. 8. Add antirust agent into the coolant. It is necessary to use antifreezing agent in winter or drain the coolant completely. Be sure to put marking plate of NO WATER IN RADIATOR at eye-catching place if cooling system is emptied of water. 9. Loosen the alternator belt and fan belt. 10. Paint necessary place to avoid rustiness. 11. Store the excavator in a dry, safe place. If store outside, cover it with waterproof cover. 12. If it is necessary to store the excavator for long period, operate the travel, swing and digging hydraulic functions 2 to 3 cycles each to lubricate every parts at least once a month. Be sure to check the coolant level and lubrication conditions before operating. 106

113 STORAGE MOVING EXCAVATOR OUT FROM WAREHOUSE ATTENTION: Start engine only in well-ventilated place. 1. Remove grease from the cylinder rods if coated. 2. Adjust alternator and fan belt tension. 3. Fill the fuel tank. Bleed air from the fuel system. Check all fluid levels. 4. Start the engine. Run the engine at half speed for several minutes before beginning full load operation. 5. Operate all hydraulic functions several cycles. 6. Carefully check all systems before operating the machine with a full load. NOTE: When the machine has been stored for a long time, be sure to perform the following steps as well: a Check the condition of all hoses and connections. b Warm up the engine. c Stop engine. d Install new fuel filters. Replace the engine oil filter and fill the engine with oil. IMPORTANCE: If the machine is not used for a long time, oil films on sliding surfaces may have break down. Operate the travel, swing and digging functions, 2 to 3 cycles each to lubricate the sliding surfaces. 107

114 TROUBLESHOOTING ENGINE Trouble Cause Solution Engine rotates, but No fuel Improper fuel doesn t start or Polluted fuel start difficultly. Low battery power Injection pump Improper preheating cable & glow plug Faulty cable connection Starter motor failure Improper engine oil Clogged air filter Clogged fuel filter Engine compression ratio Fuel injection nozzle dirty or working failure Fuel cut-off leakage device Leakage in fuel system Air in fuel system Fuel supply pump bounced Dirty strainer of supply pump Refuel and discharge air. Drain the fuel and use proper fuel. Drain the fuel and refill clean fuel. Charge or install new batteries Clean and tighten the connections of battery & starter motor. Replace starter motor. Drain the oil and use recommended oil. Replace the filter. Exhaust air from fuel system. Clean fuel tank strainer. Adjust or repair linkage device. Check for fuel system connection. Exhaust the air. Press the pump and tighten the handwheel. Clean or replace. Engine makes a noise, runs abnormally or stops. Low engine oil level Air suction system clogged Dirty strainer of supply pump Fuel injection timing delay Clogged fuel filter Low coolant temperature Water, deposit or air in fuel system Fuel injection nozzle dirty or faulty Fuel cut-off leakage device Refill engine oil. Clean the filter and system. Clean or replace. Install a new fuel filter. Thermostat does not work properly or too "cold" Exhaust air from fuel system. Clean outlet strainer of fuel tank. Adjust or repair linkage device. 108

115 TROUBLESHOOTING ENGINE Trouble Cause Solution Engine does not Clogged air filter Clogged fuel hose develop full power. Polluted fuel Clogged fuel filter Clogged air vent of fuel tank cover Fuel injection nozzle dirty or faulty Adjustment of leakage device of fuel injection pump Improper fuel Improper oil Turbocharger failure Fuel injection timing delay Exhaust blocked Engine overheating or under cooling Engine failure Valve clearance Leakage of air suction or exhaust system Replace air filter. Repair or replace fuel hose. Drain the fuel and clean the outlet strainer. Then refuel. Replace fuel filter. Clean or install a new cover. Use recommended fuel Use r8ecommended oil Remove the muffler and run the engine. See the following troubles. Check and adjust the valves. Engine overheats. Low coolant level Thermostat Engine overloading Radiator cap failure Clogged cores of radiator & oil cooler Radiator net cover clogged Fuel injection timing delay Fan damaged Clogged air cleaner Loose belts of alternator & fan Belt pulley groove abrasion Dirty piping of cooling system Thermometer or feeding unit Add coolant. Check hydraulic relief valve Install a new cap. Clean the radiator & oil cooler. Clean the net cover. Replace the fan. Clean air cleaner filter Tension or install new belts. Replace the belt pulley. Flush cooling system. 109

116 TROUBLESHOOTING ENGINE Trouble Cause Solution Coolant Thermostat Thermometer or temperature is too feeding unit low. Low engine oil pressure Engine oil pump or pump drive device Low engine oil level Engine oil pressure adjusting valve Clogged suction net cover of oil pump Clogged engine oil filter Oil leakage Engine oil is diluted with fuel or coolant. Engine overheats. Improper engine oil. Add engine oil. Install a new oil filter. Check for oil leakage. Check cooling system. Drain the oil. Replace with recommended oil. Excessive engine oil consumption Improper engine oil. Engine oil leaks. Engine overheats. Air cleaner clogged Engine inner parts abrasion Drain the oil. Replace with recommended oil. Check engine oil drain plug. Check cooling system. Clean the filter or replace with a new filter. Contact with your authorized dealer. Excessive consumption fuel Air suction system is clogged or dirty. Improper fuel Fuel injection nozzle Fuel injection timing delay Clean air suction system. Use recommended fuel. Black or gray exhaust smoke Improper fuel Air intake or exhaust system is clogged or dirty. Fuel injection timing delay Fuel injection nozzle dirty or faulty Engine frame failure Drain the fuel. Use recommended fuel. Clean air intake & exhaust system. 110

117 TROUBLESHOOTING ENGINE Trouble Cause Solution White exhaust Improper fuel gas Cold engine Thermostat failure or too cold Fuel injection timing delay Coolant leaks into the engine cylinder. Drain the fuel. Use recommended fuel. Run the engine until it warms up. High noise or much vibration of turbocharger Leakage at turbocharger connector Too much resistance on the rotating part of turbocharger No lubricant on bearing Worn bearing Air leakage of engine, suction or exhaust pipe Improper clearance between turbo & turbo box Breaking turbo blade Damaged or worn bearing and (or) seal High crankcase pressure Carbon blocked at the exhaust pipe where turbocharger oil return pipeline getting through Carbon blocked, at turbocharger rear part, caused by burning sediment Dirt blocked, at rear of compressor pulley, caused by air leakage when sucking into the pipe Bearing jammed, dirty or worn caused by too high temperature, unbalanced blade pulley, dirty oil, lack of oil or inadequate lubrication Lack of oil pressure; Check the clogged turbocharger oil pipe Check & repair. Remove the air exhaust pipe and air inlet hose and check. Check and clean air cleaner. Check whether the engine maintenance intervals is appropriate or whether there is any dirt entering into the engine Check ventilation pipes to ensure that they are not blocked. And clean them. Remove the pipe. Check & clean. Check & clean. Check & clean. 111

118 TROUBLESHOOTING ELECTRICAL SYSTEM Trouble Cause Solution Electrical system doesn t work. Battery Charge or replace the battery. Electrical system doesn t work (excepting for clock). Lack of battery power Battery relay Replace battery relay. Loose or corroded terminals Alternator belt is loose. Alternator doesn t charge. Fuse Ignition key switch failure Clean and tighten the terminals or replace the battery. Tension or install a new belt. Replace the fuse. Replace ignition key switch. Starter motor does not rotate. Starter electromagnetic vibration Starter motor operates, but engine doesn t start. Engine starts slowly. Lack battery power or damaged battery Bad battery cable connections Fuse link Ignition key switch Starter relay Starter solenoid Starter Starter pinion gear was stuck in the flywheel gear. Engine frame failure Bad connections on battery or starter Low battery power Starter solenoid holding coil turning on Starter pinion not meshing with the gear on flywheel ring Position-changing mechanism of the pinion jammed or failure Pinion tooth fracture Flywheel gear tooth fracture Damaged or faulty battery cable Loose cable connection or corrosion at terminals of battery or starter wires Charge or replace the battery. Clean the connections. Replace fuse link. Repair or replace starter motor. Repair or replace starter Clean the connections Charge or replace the battery Check and replace the cable. Clean and retighten the terminals. 112

119 TROUBLESHOOTING ELECTRICAL SYSTEM Trouble Cause Solution Engine starts The battery is flat or does Replace the battery. slowly. not keep power Starter dragging Low battery voltage Charge or replace the battery. Starter motor goes on operating after engine starting. Starter relay energized Starter solenoid energized Starter not disconnecting Ignition key switch Charge indicator stays on when engine is running. Loose or slipping alternator belt Low engine speed Excessive electrical load caused by additional accessories Loose or corroded electrical connections on battery, grounding strip, starter or alternator Low battery voltage Alternator or adjuster Indicator circuit Check the belt. If the belt is slipping, replace it. If it s loose, tension it. Adjust engine speed to the specified value. Remove the additional accessories or install a higher output alternator. Check, clean or retighten electrical connections. Charge or replace the battery. Engine makes noise. Worn drive belt Worn belt pulley Improper belt adjustment Alternator bearing. Replace the belt. Replace the belt pulley or belt. Adjust the alternator installation. Loosen alternator belt and rotate the pulley with hand. If you feel any rough, repair the alternator. All of the indicators on monitor don t come on. Some indicator on the monitor does not turn on. Fuse Electrical wiring Bulb Fuse Electrical wiring Replace the fuse. Replace the bulb. Replace the fuse. 113

120 TROUBLESHOOTING ELECTRICAL SYSTEM Trouble Cause Solution All of the Circuit board Electrical wiring indicators on Fuse Replace the fuse. gauge don t come on. Some indicator on the gauge does not come on. Bulb Fuse Transmitter Electrical wiring failure Replace the bulb. Replace the fuse. Check the transmitter. Coolant gauge does not operate. Fuse Temperature gauge Coolant temperature gauge transmitter Electrical wiring Replace the fuse. Check the sensor of coolant temperature gauge. Automatic idle indicator does not come on. Fuse Bulb Automatic idle switch Replace the fuse. Replace the bulb. Fuel gauge does not operate. Fuse Fuel gauge Electrical wiring Replace the fuse. 114

121 TROUBLESHOOTING MODE SELECT Trouble Cause Solution Working mode Working mode switch Electronic connector select switch Bad pilot pressure switch does not wiring operate. Main controller Solenoid valve unit Travel mode does not shift from fast mode to slow mode. Travel mode switch Pilot pressure switch (travel) Wiring of pump delivery pressure sensor Main controller Solenoid valve Damaged travel motor Automatic idle switch does not operate. Fuse Switch panel Electric connector Electrical wiring Engine control motor Pressure switch (travel, front-end) Main controller Replace the fuse. 115

122 TROUBLESHOOTING CONTROL LEVER Trouble Cause Solution Control lever moves difficultly No movement Control lever can t return to neutral position Joint rusts Worn pusher Worn pusher Pilot valve Pilot valve Too loose Worn rotating joint Control lever can t keep in neutral position vertically. Pilot valve HYDRAULIC SYSTEM Trouble Cause Solution Hydraulic Low hydraulic level function is slow Cold hydraulic Improper hydraulic oil Low engine speed Pilot circuit Worn pump Pump suction pipeline blocked Add oil to the hydraulic oil tank to the maximum mark. Press the hydraulic preheating button. Drain the oil tank & use recommended oil. Increase the speed or contact with your appointed dealer. Hydraulic oil is overheating. Improper hydraulic oil Pump suction pipeline leakage Hydraulic oil pipeline blocked Low oil level Filter clogged Worn pump Radiator or oil cooler clogged Oil cooler bypass Relief valve Polluted oil Travel motor Hydraulic components being adjusted improperly Use proper oil. Add oil to the hydraulic oil tank to the maximum mark. Install a new filter. Clean and straighten the blades. Drain the oil and fill the tank. 116

123 TROUBLESHOOTING HYDRAULIC SYSTEM Trouble Cause Solution Frothing oil Leakage of pipeline from Repair the oil tank or contact with oil tank to pump your appointed dealer. Pipeline deformation or Check the pipeline. sag Improper oil Use the recommended oil. There is water in oil. Replace hydraulic oil. High or low oil level Correct the oil level. Low or no oil pressure Improper oil Hydraulic components being adjusted improperly No oil in system Worn padding of hydraulic cylinder Relief valve Use the recommended oil. Fill proper oil. No hydraulic functions (Pump makes noise.) Worn Hydraulic pump Decrease the setting pressure of main relief valve in control valve Low hydraulic oil level Damaged suction pipeline or hose Clogged suction filter Air being sucked into the oil suction port Add oil. Clean Hydraulic cylinder operates but can t lift any load. Worn Hydraulic pump Low pressure of main relief valve Low hydraulic oil level Clogged suction filter Pump suction pipeline leakage Add oil. Clean the filter and system. Check suction pipeline. 117

124 TROUBLESHOOTING HYDRAULIC SYSTEM Trouble Cause Solution One control Low pressure of relief valve lever does not Pipe or hose damaged Repair or replace. operate. Hydraulic joint loose Retighten. Damaged O-ring inside Fit a new O-ring. the joints Hydraulic pump Pilot valve Pilot pipeline Repair or replace. One cylinder does not operate. The control valve rod is damaged or polluted by dirt. Damaged Hydraulic pipeline Loose joints Pilot valve Pilot pipeline Repair or replace. Retighten. Fit a new O-ring. Repair or replace. One cylinder does not operate or almost no power. Leak of cylinder seals Damaged cylinder rod Pilot pipeline Pilot valve Wiring failure Repair or replace. Both of the two travel motors don t operate. Damaged center joint One travel motor does not operate. Travel motor Brake does not release. Pilot valve. Pilot pipeline Repair or replace. Machine not smoothly. does travel Track adjusting Damaged idler or track roller Bend track frame Adjust the tension. 118

125 TROUBLESHOOTING HYDRAULIC SYSTEM Trouble Cause Solution Machine does There are rocks or soil stuck in track frame not travel Travel brake does not smoothly. release. Machine not swing. does Swing brake release valve Swing motor. Pilot valve Machine not smoothly. does swing Swing inner teeth Swing bearing Lack of lubricant Add lubricant. Engine stops when moving travel or control level. Poor joint connection Electrical wiring failure Damaged main controller Repair or replace. 119

126 TROUBLESHOOTING MEMO 120

127 OVERALL DIMENSIONS OVERALL DIMENSIONS A. Upper structure width 2622mm B. Undercarriage width 2800mm C. Overall height (to top of cap) 2926mm D. Rear-end length 2800mm Rear-end swing radius 2828mm E. Engine cover height 1983mm F. Counterweight ground clearance 1053mm G. Shaft distance (sprocket center to idler center) 3354mm H. Undercarriage Length 4148mm I. Track shoe width 600mm J. Height of track mechanism 920mm K. Min. ground clearance 478mm L. Overall Length 4854mm M. Track gauge 2200mm N. Front-end swing radius 1298mm Ground pressure: 48kPa Operating weight: 20500kg 121

128 TRANSPORTATION DIMENSIONS TRANSPORTATION DIMENSIONS 122

129 WORKING RANGES UNIT: M Item Standard arm A. Max. digging reach 9925mm B. Max. digging reach at ground level 9762mm C. Max. digging depth 6643mm D. Max. vertical digging depth 6064mm E. Max. cutting height 9631mm F. Max. dumping height 6864mm G. Min. front-end swing radius 3554mm 123

130 LIFTING CAPACITY LIFTING CAPACITY Boom length: 5.68m, Arm length: 2.912m Equipped with 0.80m 3 (PCSA heaped) bucket and 600mm (24") track shoes Load Point height Load radius Unit: 1000kg At max. reach m * * * * * * * * * *7.41 * * * NOTE: 1. Ratings are based on SAE J Lifting capacity of the Series does not exceed 87% full hydraulic capacity or 75% of tipping load with the machine on firm, level ground. 3. The load point is a hook (not standard equipment) loaded on the back of the bucket. 4. *Indicates that loads are limited by hydraulic capacity m=ground 124

131 TECHNICAL INSTRUCTONS excavator is a full hydraulic crawler excavator. Its platform can swing 360 and length of rear-end is 2800mm. The engine is a ISUZU six cylinders water cooled diesel engine with total power 114kw/2100rpm and mounted on a flexible support at platform tail. The safety elements on air filter make air cleaning safe and reliable and easy to maintain. Outside cool air inhaled by the lower noise axial flow fall flows by both sides of engine and is exhausted through the vent on counterweight. Engine can work well in high environment temperature without overheating due to its safe and reliable cooling system. Full power variable displacement double pump and the engine are joined directly by a flange and the highest working pressure is 32Mpa. The main pump is driven by tile flexible coupling mounted inside the diesel engine flywheel, and thus the impact of engine vibration on the main pump can be eliminated effectively. The counterweight covers the platform tail entirely in both width and height orientations, and thus prevents all units fixed in the platform rear from being damaged effectively. Hydraulic system and pilot system The oil tank, which volume is 219L, provides oil pump hydraulic oil. Hydraulic oil is supplied by the oil pump to all operating mechanism and comes back to oil tank through oil cooler and magnetized paper filter. The pilot valve mounted in cab ensures the movements of monoblock valve. A gear pump mounted directly on the diesel engine by a flange provides pilot piping lines with hydraulic oil and makes the excavator operate safely even in case of the diesel engine speed dropping. A high-pressure filter with high accuracy is fixed in pilot piping lines to prevent the excavator from outside disturbance. The pressure accumulator in pilot piping lines makes the excavator operating in emergency, and thus the attachment can be lowered down to ground when engine stops working suddenly. Hydraulic oil cooling An air-oil swap aluminum cooler is fixed in the machine and cooling effect is very good. The cooler fan is driven by hydraulic motor. Fuel oil unit Diesel engine sucks oil from the oil tank, which volume is 376L. A shut-off valve is mounted between inlet piping lines and outlet piping lines for convenience of changing oil and cleaning. Swing drive Swing hydraulic motor drives internal gear swing bearing with a planetary reduction gear. A normal close brake is fixed in drive unit to keep excavator operating safely. 125

132 TECHNICAL INSTRUCTONS Chassis The chassis is a steel assembly with high distortion rigidity and strengthen. The guide roller and drive roller, which aye large in size, provide the best travel performance on bad road conditions and good track self-cleaning ability. The elements on track, such as guide roller, sprocket rollers and track rollers, are characterized by long lubrication intervals and need not to be maintained in a general way. The track can be loosed or tensioned easily by hydraulic tension unit. The spiral springs made of spring steel provide the guide roller great pre-tension, and guide wheel guides the tracks effectively and avoids it coming off. Track shoes are made of high strength alloy steel and characterized by good adhering performance, excellent stability and long life. Travel Drive Travel mechanism is driven by a axial hydraulic piston oil motor and driving force is magnified by a planetary gearbox, and thus the drive roller gains great drive torque. It is characterized by built in and compact structure, good traveling ability and novel external appearance. Travel Brake A GFT36T3 planetary gearbox and an insert-in axial piston motor drive travel brake. A Hydraulic brake together with a spring pressure multi-plates brake (normal close) is used, and thus excavator can operate, especially operate on slops with reliable braking ability. Hydraulic brake valve in this drive mode can prevent excavator from over speed travel. Cab Cab is mounted flexibly on platform and accords with the current international specification in height, width and structure. Front door is designed to have good accessibility and easy to pass through. The large glass around and adjustable front window provides operator a good field of vision. The operator's seat, designed according to the up to date technology of anthropometrics engineering, is very comfortable with its backrest and height adjustable and can meet needs of different operators. Seat with safety belt and backrest cushion can be provided on demand. Operation lever is combined concordantly with suspended rack near the lower part of seat. It is well positioned and easy to be operated, and thus operator will not feel very tired after a long operating hour. Travel drive is controlled by a dual-action pedal commonly and else by lever if necessary. Panel is positioned within the vision Of operator. On the panel are mounted all the important instruments and indicators which are used to monitor diesel engine and electrical units. They are easy to be seen and accord with SAE. There is radio recorder and heater in cab. 126

133 TECHNICAL INSTRUCTONS Hood and Sound Insulation Hood consists of a firmly installed side door and a coping for maintenance. They protect diesel engine and pumps, and have a lining of noise proof material. excavator is one of the excavators with lowest noise due to its good cooling system and lower speed of hydraulic cooling fan. Measured according to ISO/DIS 6395:2006, the equivalent continuous A-weighted sound power level of exterior noise emitted by cab equipped excavator while the excavator is in a dynamic test condition shall not exceed 103dB (80+11lgP, P is the engine rated power-114kw), the actual measured value is 102dB(A). Measured according to ISO/DIS 6396:2006, for excavator equipped with a cab, the equivalent continuous A-weighted pressure power level at the operator s position while the excavator is in a dynamic test condition shall not exceed 85dB(A), the actual measured value is 78dB(A). Bucket Teeth A combinatorial bucket teeth is used on the machine. Its teeth and adapters are all made of wearable alloy. Teeth and adapters are joined by pins and elastic parts and easy to be replaced. Instead of special teeth on the two ends of bucket, there are side blades with back angle on both sides of bucket for helping digging. 127

134 OPTIONAL EQUIPMENTS HYDRAULIC BREAKER Select a hydraulic breaker with proper dimensions and weight for machine. Consult your appointed dealer for some related information. Before installing a hydraulic breaker to the arm of machine, please read the Excavator & Breaker Operation Manual carefully and conduct the required verification or inspection. IMPORTANCE: PRECAUTIONS FOR INSTALLING HYDRAULIC BREAKER PIPE LINES Take care not to allow dust to enter the hydraulic system when disconnecting the bucket and connecting the hydraulic breaker. When the hydraulic breaker is not installed, be sure to put caps or plugs to the arm tip pipe open ends and the hydraulic breaker side hose ends to prevent the hydraulic system from being contaminated by dust. Be sure to keep the spare caps and plugs in the toolbox in order to access them at any time. Check that the pipe clamp bolts are tight, and no oil is leaking from the pipe and hose joints after connecting the hydraulic breaker. HYDRAULIC BREAKER OPERATION Using the attachment pedal located at operator s right foot as illustrated to the right can perform the hydraulic breaker operation. ATTENTION: Be sure to lock the attachment pedal when it is no longer used. Don t step on the attachment pedal even though it is unlocked to avoid damaging any hydraulic parts. Fig

135 OPTIONAL EQUIPMENTS PRECAUTIONS FOR HYDRAULIC BREAKER OPERATION CAUTION: Machine stability is reduced as the breaker is much heavier than the bucket. When the hydraulic breaker is used, machine is more easily tipping over. In addition, flying debris may be scattered to the cab or other parts of machine during breaker operation. Observe the precautions described below to prevent accidents occurring or machine being damaged. Avoid crashing the breaker onto hard materials. The breaker is heavier than the bucket, causing the lowering speed of the breaker to become faster. Be careful not to attempt to do this, otherwise, damage to the breaker, the front attachment and/or the upper structure may result. Always move (or lower) the breaker onto objects to be broken slowly. Fig.105 Do not move crushed materials using the breaker unit and the swing function. Damage to the boom, arm or breaker may result. Fig.106 Do not operate the breaker with the hydraulic cylinders fully extended or retracted. Failure to do so may result in damage to the hydraulic cylinders and/or machine. Fig.107 Should the hydraulic hoses begin to surge vibrate abnormally during operation of a breaker, immediately stop operation. This problem often is a result of pressure variation in accumulators or the damaged accumulators and can also result in breaker and (or) machine failure. If this occurs, contact your appointed dealer immediately. Fig

136 OPTIONAL EQUIPMENTS Do not operate the breaker in water. Otherwise, it may rust and the seals may become broken due to rusting of the breaker. Also damage to the hydraulic components may result. Fig.109 Do not use the breaker to lift objects. Serious accidents may result due to tipping over of the machine and (or) damage of breaker. Fig.110 Do not operate the breaker over the side of the machine. The machine stability is reduced, possibly resulting in tipping over of the machine. In addition, the service lifetime of the undercarriage may become shorter. Fig.111 Do not allow the breaker chisel to come in contact with the boom when rolling in the arm and the breaker. Fig

137 OPTIONAL EQUIPMENTS 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. Fig.113 When beginning break operation, lower the breaker, place the chisel onto objects vertically and push in. Fig.114 Do not operate the breaker for more than one minute. Otherwise, it may cause excessive abrasion of the breaker chisel. If the object cannot be crushed within one minute, operate the breaker onto another position. Operation of each position should not be longer than one minute at a time. Fig.115 To raise the front part of machine undercarriage by depressing the breaker may damage the front attachments. While it is allowed to raise the front edge of machine undercarriage off the ground no more than 150mm. However, if it s unnecessary, do not use this method. Never raise the front edge of machine undercarriage off ground more than 150mm. Fig

138 OPTIONAL EQUIPMENTS REPLACE HYDRAULIC OIL & OF HYDRAULIC OIL TANK FILTER Hydraulic breaker operation may cause hydraulic system to become contaminated and hydraulic oil to be deteriorated more quickly than bucket operation. Change hydraulic oil and replace the filter element at the regular intervals. Failure to perform proper maintenance of hydraulic oil may cause the breaker, the hydraulic oil pump and other components of hydraulic system to malfunction. Be sure to change hydraulic oil and replace the filter element at the intervals as shown in the table below. (Refer to the Hydraulic System group in the Inspection and Maintenance Section.) REPLACEMENT INTERVALS (HOURS) Breaker Equipped Machine General Bucket Equipped Machine Hydraulic oil 600* 1500 or 2500 or 4000 Filter element 100* 1000 NOTE: *The replacement interval in the above table is recommended for the 100% average operating availability of breaker. When the average operating availability of breaker decreasing, extend the replacement intervals as shown in the following chart. Be sure to replace the filter after continuous operating the breaker for 100 hours. 132