DIGGERKING King 2.3 Digger Manual

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King 2.3 Digger

Manual for Operation

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Summary of Contents for DIGGERKING King 2.3 Digger

Page 1 King 2.3 Digger Manual for Operation...
Page 2: Table Of Contents
Contents Safety Warning Signs ........................5 Signal Words ..........................6 Foreword ............................6 Serial number ..........................7 Machine Description ........................8 Designated Operations ........................8 Product Features ..........................8 Operate as per the following instructions: ..................8 Notes about Reading of This Manual ....................8 Safety ............................
Page 3 Checking for Safe and Reliable Working Zone before Operations..........18 Checking of Chassis (Tracks) before Traveling ................18 Precaution for Traveling on Slopes ....................19 Precaution for Parking ........................25 Safe Lifting of Machine ........................26 Safe Transport of Machine ....................... 27 Precaution for Maintenances ......................
Page 4 Maintenances during Long-Time Parking ................. 106 Troubleshooting ........................108 Symptoms other than Malfunctions ....................108 Engine Overheating ........................108 No Battery Power ........................... 109 Burnout of Fuse ..........................111 Restart after Refueling ........................112 Flashing of Warning Lamps ......................113 Other Symptoms ..........................
Page 5: Safety Warning Signs
Safety Warning Signs WARNING! This sign denotes a safety warning. Please read and understand this information to prevent personal injuries. The machine owner or employer is responsible for instructing every operator to operate all equipment correctly and safely. All personnel operating this machine shall sufficiently understand the contents of this manual.
Page 6: Signal Words
Signal Words The safety information in this manual and machine identifications is indicated by words “Danger”, “Warning”, and “Notice”. The meanings of these signal words are as below: Danger “Danger” denotes high dangerous level, for which negligence will result in death or serious injury. Warning “Warning”...
Page 7: Serial Number
Should you have any doubt, please contact your dealer. Please be noted that the information contained in this manual and the parameters of this machine are subject to changes without further notice. Serial number Important: Do not disassemble the machine nameplate with serial number. Observe the serial numbers of machine and engine and record them in the blank area below.
Page 8: Machine Description
Machine Description Front, Rear, Left, and Right Front The front, rear, left, and right of the machine indicated in this manual are based on the status sitting in the driver seat, with the bulldozing blade visible in the front. Designated Operations This machine is mainly applied for following Left operations:...
Page 9: Safety
Safety General Precaution You are liable for abiding by the safety laws and regulations of relevant departments and fulfilling the operations, checking, and maintenances of machine. Please read and understand all safety information related to the prevention of accidents. Please ensure to operate the machine only after you have understood how to operate, check, and maintain the machine correctly.
Page 10: Wearing Appropriate Clothing And Protective Appliances
cause earlier wear or damage of machine. To operate the machine under conditions outside the above-mentioned temperature range, please consult with your sales or service dealer. Wearing Appropriate Clothing and Protective Appliances Installation of Fire Extinguisher and First-Aid Kit Do not wear loose clothing or items that may catch on any joystick or moving parts.
Page 11: Setup Of Signaler And Flagman
Setup of Signaler and Flagman Learn how to use the gestures of specific operation needs and designate the person responsible for making gestures. All personnel must completely understand all gestures. The operator must respond to the gestures of the designated person only. However, the operator must abide by the stop gesture made by anyone in all cases.
Page 12 Please be noted that, even if the safety lock handle is placed at locking position, the bulldozing blade, boom, and auxiliary hydraulic controls can’t be locked. Do not touch controls accidentally. While lifting up or lowering down the safety lock handle, take caution not to touch any joystick.
Page 13: Toxic Exhaust Gas From Engine
Remove all wastes and impurities from the machine. Ensure that there is no oil contaminated rags or other flammables on the machine. Handle all solvents and dry chemicals (Foam fire extinguisher) as per the manufacturer’s procedures indicated on the container. Operate in a well-ventilated place. Never use fuel for cleaning purpose.
Page 14: Guard Against Crushing And Cuts
Guard against Crushing and Cuts During operations, non-authorized personnel are prohibited to access the working zone. Please strictly abide by the rules and environmental standards applicable for this working zone. Never place your hand, foot, or other body parts between the superstructure and chassis or tracks, between machine body and working device, or between cylinder and motion parts.
Page 15: Daily Checking And Maintenance
Before operations in water or driving through shallow rivers, check the water depth, ground firmness, and flow rate in advance. Understand more operation description information with reference to the “Precaution during Operations” Checking of Bridge Strength Please check the permissible load before driving on bridges or structures. If the strength is insufficient, reinforce the bridges or structures.
Page 16: Safety Measures At Start
Safety Measures at Start Support your body weight by three-point safety posture while getting on/off the machine. Do not jump on or off the machine. Do not attempt to get on or off a moving machine. Before getting on or off the cab, firstly open the door completely to locking position and check and ensure that the door can’t move further (For machine with cab).
Page 17: For Cold Weather
Start by Jumper Cable Start by jumper cable only as per the recommended method. The improper use of jumper cable may result in battery explosion or unexpected machine motions. Please refer to “In event of no battery power” to understand more operation description information.
Page 18: Checking For Safe And Reliable Working Zone Before Operations
necessary, install additional lighting devices. In event of poor visibility due to severe weather (Such as fog, snow, rain, and haze), stop the operations of machine till the visibility turns good. Clean the windows, mirrors, lamps, and camera to keep good visibility. Adjust the mirrors and camera to optimal positions to ensure that the driver sitting in the driver seat can see the rear view (Blind spot).
Page 19: Precaution For Traveling On Slopes
Safe Traveling The bulldozing blade shall be lifted during traveling. Retract the bucket working device as shown in above diagram and lift the bucket by 30~40cm off the ground. Do not slew during the traveling. If it’s necessary to operate the bucket working device during traveling, operate at sufficiently low speed to ensure complete control at all times.
Page 20 Special Caution for Operations of Machine on Ice/Snow While traveling on snowy or icy roads, drive at low speed and avoid the sudden startup, stop, and direction change. In snowy regions, the road curbs and the roadside objects are buried in the snow to become invisible. In addition, there is a danger of machine rollover or collision with covered objects.
Page 21 Keeping a Safe Distance from Overhead High-Voltage Cables No Movement of Bucket over Personnel Moving the bucket over personnel has a danger of splashing the loaded material or the sudden falling of bucket. Guarantee of Driver’s Safety during Loading Do not load before the driver reaches a safe place.
Page 22 Pay special attention to underground high- voltage cables. Close Observation on Dangerous Working Conditions Keep a safe spacing between machine and edge of digging site. Do not dig the ground ahead of machine. During the operations near a cliff or road curb, to ease the escape in any event, form a right-angle between tracks and cliff or road curb and place bulldozing blade in the front.
Page 23 Do not perform demolition operations above your head. There is a risk of damaged parts or collapse danger of building to cause serious harm or destructions. Do not perform demolition operations beneath the machine. There is a possible falling danger of machine when the ground becomes unstable.
Page 24 attachment end is heavier than that with standard bucket. For machine with such heavy end, do not face the bucket arm (boom) towards downslope direction for digging or towards lateral direction for operations. If the bucket is fully loaded with material, avoid slewing towards the downslope direction.
Page 25: Precaution For Parking
Guard against Flying Objects This machine is not installed with any protective device to guard the operator against the harm of flying objects. Do not operate this machine in any dangerous place in which the operator is probably subject to the impact of flying objects. Precaution for Towing Please refer to the section “Towing”...
Page 26: Safe Lifting Of Machine
Precaution during Transport Safe loading/unlocking of machine The machine may roll over or fall off during loading and unloading. Ensure to take the following safety measures: Select a solid and level ground and keep a sufficient spacing from the road curb. Fix the ramps of sufficient strength and dimensions to the cargo body of truck.
Page 27: Safe Transport Of Machine
Do not operate the lifting if there is any operator on the machine. Operate slowly during lifting to prevent the rollover of machine. During lifting, keep all personnel away from working zone. Do not move the machine over any person. Safe Transport of Machine During the transport of machine, understand and abide by all applicable safety rules, vehicle codes, and traffic regulations.
Page 28 No Access of Non-Authorized Personnel During operations, the non-authorized personnel are prohibited to access the working zone. Take caution during grinding, welding, and use of hammer. You may be injured by the flying fragments from the machine. Preparations of Working Zone Select a stable and level working zone.
Page 29 Keeping Away from Motion Parts Keep away from all rotating and motion parts. The entanglement of hands or tools into rotating or moving parts may cause accidents of serious injuries or even deaths. The tools or other objects fallen or inserted into the fan or fan belt will be crushed or cut.
Page 30 Precaution for Refueling Smoking and open fire are prohibited during refueling and near the refueling point. Do not disassemble the fuel tank cap or refuel while the engine is running or is not cooled down. Do not splash fuel to any high temperature surface of machine.
Page 31 The high pressure of hydraulic oil can penetrate skin and eyes which amy cause serious injuries and blindness or even death. Please bear in mind that the hydraulic oil permeating from orifices is nearly invisible to naked eyes. While checking for leakage, wear goggles and thick gloves and protect the skin by paper boards or plywood to protect against the harm of spraying hydraulic oil.
Page 32: No Disassembling Of Track Tensioner
No Disassembling of Track Tensioner The track tensioner is installed with a high strength spring. If the track tensioner is disassembled carelessly, the spring will spring out to cause serious injuries. Do not disassemble the track tensioner. Operations of Additional Devices Take special caution while handling the high- pressure nitrogen stored in the tank.
Page 33: Jumper Start With Battery Charging Cable
Use a flashlight to check the electrolyte level. Ensure to turn off the starter switch and stop the engine before checking or handling battery. Never touch the electrodes by any metal tool or object, in order to prevent short- circuit. The loose electrodes can generate electric spark.
Page 34: Asking Your Service Dealer For Welding Repair
Never touch the positive (+) and negative (-) electrodes of battery charging cable with each other or with the machine. During connection, firstly connect the positive electrode of battery charging cable to positive (+) terminal. During disconnection, firstly disconnect the negative (-) terminal (grounding terminal) from the negative cable.
Page 35: Safety Signs (Markings)
Operate all joysticks and check machine for normal operations. Waste Disposal Ensure to collect the drained oil of machine into a container. The improper treatment of waste oil will pollute the environment. While disposing harmful objects, including lubricating oil, fuel, coolant, solvent, filter, and battery, please abide by the applicable laws and regulations.
Page 36: Safety Sign (Markings)
Safety Sign (Markings)
Page 37: Warning Signs
Warning Signs Carefully read and understand the manual before operations, checking, and repairs of machine. Safe distance. Never approach to or stand in the working zone of machine. Danger from underbody bolts thrown from track roller adjuster. To guarantee the safe and correct operations, ensure to read the operation manual before adjusting the track roller adjuster...
Page 38 This sign denotes not to touch any hot part during operations or just after operations. Do not touch before these parts, including engine, pump, and exhaust pipe, are cooled down. This sign denotes that the entanglement into steering belt can cause injury danger.
Page 39 Take special caution while driving over a slope or during operations on rugged road. If the lateral angle is >10°, the machine will roll over. During the operations of machine, always adjust the tracks to the outer position. The inner position of the track WARNINGS If the machine is installed with an enlarged bucket, the cab may be impacted when the boom is at the maximum leftward deflection position.
Page 40: Controls
Controls 1. Top cover Tracks Bucket cylinder 2. Seat Drive wheel Bucket arm 3. Engine hood Track roller Bucket arm cylinder 4. Fuel tank Traveling motor Boom 5. Hydraulic oil tank Bucket Boom cylinder Auxiliary hydraulic pipeline Bulldozing blade Bulldozing blade cylinder...
Page 41 Electric control panel Solenoid valve selector switch Start switch Boom swing pedal Bulldozing blade joystick 10. Traveling joystick Accelerator joystick 11. Traveling high/low speed switch Safety lock handle 12. Auxiliary hydraulic pedal Right joystick 13. Left joystick Horn button 14. Lighting switch...
Page 42 Starter Key The starter key is used to start the engine. Fuse Case This case is functioned to protect the electric system against over-current. Access Panel Opening Before opening the access panel, ensure that the safety lock handle is at locking position and the engine is stopped.
Page 43 Fuel Tank Cap Loosen the butterfly nut for several turns (but do not disassemble it). Rotate upward this bolt. While opening and closing the fuel tank cap, guard your hands against being pinched by the fuel tank cap. Please open this cap for refueling. Opening Insert the key and rotate counterclockwise to unlock the fuel tank cap.
Page 44 Seat and Seat Belt Seat Tilting of Seat Warning Adjustment and Fixing of Seats (For high-end seats only) Backrest angle adjustment Sit upright against the seat. Use the rotary handle (1) to adjust the backrest to desired angle. Longitudinal adjustment Pull up the adjustment handle (2) and slide the seat longitudinally to the position you desired for operations of machine.
Page 45 Please pull the seat belt to check for secure locking and place the seat belt around your waist. Release of Seat Belt Hold the seat belt tab (A) and then push down the button (C) on the seat belt buckle. The seat belt retracts to its original position.
Page 46 S/N Name Description Water temperature When the water temperature is >105℃, the warning lamp starts to warning lamp flash and at the same time the buzzer sounds. Fuel warning lamp When the fuel level reaches 10%, the warning lamp starts to flash and at the same time the buzzer sounds.
Page 47 Precaution This instrument is a water-proof instrument, featuring stable performance and high conciseness and elegance, and is an intelligent instrument developed specially for small excavators. To guarantee the stable data and prolong the life of instrument, please notice the following issues: Do not disassemble the instrument without permission.
Page 48 Traveling Speed Switch The high/low speed switch is located beneath the right joystick support. It indicates the high-speed mode when the indicator lamp turns on. It indicates the low-speed mode when the indicator lamp turns off. This device is functioned to lock the operations of bucket working device and machine slewing. When the handle is pulled up, the lock handle bracket pops up to lock the controls.
Page 49 Traveling Joystick/Pedal Before operating the traveling joystick/pedal, ensure that the bulldozing blade is in front of the driver seat. Please bear in mind that the operation direction of the traveling joystick/pedal with bulldozing blade behind the driver seat is reverse to that with bulldozing blade in front of driver seat.
Page 50 Solenoid valve selector switch This joystick has two buttons to switch over between change of track width and operations of bulldozing blade cylinder. When pushed down, this joystick controls the telescoping of tracks. When not pushed down, this joystick controls the lifting and lowering of bulldozing blade. Auxiliary hydraulic pipeline Disconnecting the pipelines before the pressure relief of hydraulic system may result in out-spray of hydraulic oil.
Page 51 After the stop of engine, depress the auxiliary hydraulic pedal from one side to other side for several times. Before Start of Operations Getting on/off Machine Warning Do not jump on or off the machine. Do not attempt to get on or off a moving machine. Before getting on or off the cab, firstly open the door completely to locking position and check and ensure that the door can’t move further.
Page 52 Start of Engine Keep all personnel away from working zone. Sound the horn to alert the personnel around machine. Important: Do not run the starter motor continuously for >15s. If the engine fails to start, wait for 60s and then attempt to restart the engine. Important: If the engine stops due to shortage of fuel, please add fuel, rotate the key to ON for 60s, and then rotate it to START position.
Page 53 and then rotate the key to START. After the engine is started, release the key. The key will automatically return to ON position. Return the accelerator joystick and then run the engine at low idling speed under no-load condition for 5min. Stop of Engine Important: Do not stop the engine suddenly under heavy load or during high-speed running.
Page 54 Completely lower down the safety lock handle to unlock and lift the bucket from the ground. Important: When the hydraulic oil temperature is <20℃, do not operate any joystick quickly. During the operations, the appropriate hydraulic oil temperature is 50~80℃. If it’s necessary to operate under low temperature, warm up the hydraulic oil to at least 20℃.
Page 55 Change of Track Width Always operate the machine with extended track width of 1,240mm, in order to improve the machine stability to the maximum extent. Operating the machine with narrow track width (990mm) may result in rollover of machine due to poor stability. If it’s necessary to operate the machine with narrow track width (990mm), retract the bucket working device and lower the boom to reduce the gravity center and face the machine towards front before traveling.
Page 56 Longitudinal Movement of Machine Pull the accelerator joystick to increase the engine speed. Completely lower down the safety lock handle to unlock. Retract the bucket working device and lower to 30~40cm off the ground. Lift the bulldozing blade. Operate the traveling joystick as per following procedure.
Page 57 In-situ Turnaround Left turn under stopped status: To turn left the head: Push forward the right joystick. To turn left the tail: Push backward the right joystick. To turn backward, operate the right joystick by same operation method of left joystick. In-situ left turn: Pull backward left joystick and push forward right joystick.
Page 58 Slewing Before slewing, check the surrounding area for safety. Lower boom: Push forward the right joystick. Upper boom: Push backward the right joystick. Operations of Bucket Arm Slew leftward superstructure: Push leftward the left joystick. Slew rightward superstructure: Push rightward the left joystick. Operations of Boom Retract bucket arm: Push backward the left joystick.
Page 59 Swing of Boom Lower bulldozing blade: Push forward the joystick. Upper bulldozing blade: Push backward the joystick. Swing leftward the boom: Depress the left side of pedal. Swing rightward the boom: Depress the right side of pedal. Prohibited Operations Do not operate on a bed rock (Hard or soft). Do not slew during the traveling.
Page 60 Do not extend any hydraulic cylinder to the end. Reserve an allowance during operations. When the machine body is lowered and the bucket arm cylinder is completely extended, do not support the machine body by bucket working device. Otherwise, the load will be concentrated on the bucket arm cylinder to probably damage the bucket arm cylinder.
Page 61 Careful Retraction of Bucket Working Device While retracting the bucket working device, take caution not to impact the bucket with bulldozing blade. For deep digging operations, if the bulldozing blade is in the front, take caution to prevent impacting the boom and bucket with bulldozing blade.
Page 62 Precaution for Operations of This Machine in Water Immersing the rear of machine in the water as shown in above diagram will result in the rotation of radiator fan in the water to damage the fan. It's prohibited to immerse the rear of machine in the water.
Page 63 slope. Downslope Traveling While driving down a 15° or higher slope, reduce the engine speed and maintain the machine posture shown in above diagram. Braking during Downslope Traveling While driving down a slope, the brake applies braking automatically after the traveling joystick returns to neutral position.
Page 64 Swing the bucket towards the track entrapped in the mud. Set the angles at 90~110° for bucket arm and boom. Push the bucket bottom (Not bucket teeth) onto the ground. Place a wood plate or similar object beneath the lifted track. Lift the bucket and drive out the machine from the mud slowly.
Page 65 Parking of This Machine Parking Before leaving the seat, lift up the safety lock handle to the locking position and stop the engine. Meanwhile, ensure to withdraw the key, close the doors and hoods, and carry the key with you. Stop the machine on a level, solid, and safe ground.
Page 66 Precaution after Operation Please abide by the following precaution to prevent the movement failure of machine due to frozen mud, water, or underframe. Remove all mud and water from machine body. Especially, wipe clean the hydraulic cylinder rod to prevent the ingress of rod surface mud and dusts into the seals along with water drops from damaging the seals.
Page 67 adhered onto the tracks shall be immediately removed by water. Driving the machine on irregular surfaces, such as new asphalt pavement and hot steel plates exposed to campfire or burning sun will result in irregular wear or damage of tracks. Do not move the rubber tracks to possibly Do not slew the underframe (The superstructure is not slewed) when the bucket working device is lifted in the front of machine body.
Page 68 Please avoid driving the machine with one track on a slope or protrusion and the other track on level surface (In such case, this machine is inclined by 10° or more). Please drive the machine with both tracks on level surface. Do not change the direction when the tracks are loose.
Page 69 with center of tracks. Ensure that the bulldozing blade will not touch the ramps. Lower the bucket working device as low as possible and take caution not to impact it with the transport truck. Reduce engine speed. transport truck. According to the signaler’s signals, drive the machine straightly up or down along the ramps in 1st gear (low speed).
Page 70 If the boom swings leftward or rightward, adjust it to neutral position. Raise the safety lock control lever to the locking position. Stop the engine, withdraw the starter key, and leave the machine. Install the ropes as shown in diagram below. Install the ropes and lifting appliance and take caution to keep them away from machine body.
Page 71 Fixing of Machine After loading the machine to designated position, fix as per following requirements. Lower the bulldozing blade. Sufficiently extend the bucket cylinder and bucket arm cylinder and then lower the boom. Lift up the safety lock handle to the locking position. Stop the engine, withdraw the starter key, and lock all locks.
Page 72: Maintenance
Maintenance To maintain the good status and long-term serviceability of the machine, please fulfill the checking and maintenances correctly and safely abide by the procedures recommended by this manual. Based on the total operating time of the machine, the checking and maintenance items can be divided into several groups: Every 10h (Walk-around checking and daily routine checking), every 50h, and every 250h.
Page 73 working area and clean the parts to guard against ingress of dusts. Cleaning of Mounting Surfaces Keep clean the contact surface of parts during the installation and disassembling. If the sealing grooves of the contact surfaces are damaged, please contact your sales or service dealer for repairs or breakup.
Page 74 Please refer to following table to select appropriate fuel, lubricating oil, and grease based on the temperature. Regardless of the specified periods, replace the oil when the oil is too dirty or already deteriorated. Never mix the oils of different trademarks while adding fuel/oil. To replace with fuel/oil of another trademark, please replace completely.
Page 75 To maintain the performance and life of engine, please always use clean and high-quality fuel. To prevent freezing in cold weathers, please choose diesel still suitable when the actual temperature is less by at least 12℃ than the expected minimum outside temperature. Please use diesel with cetane number at 45 or higher.
Page 76 system 30% coolant mixture 1000h SAE: J814C or J1034 Traveling Gearbox API: GL-4 First 250h reducer gear SAE 90 Afterward Slewing Every 50h motor gear Lithium-base grease EP-2 MLGI 2# Slewing Every 50h bearing Working Daily or device every 10h necessary *: If the traveling time accounts for a high ratio of the total operating time, replace the gear oil ahead of the specified periods.
Page 77 Replacement period (Hour) Hydraulic device replacement period Filter replacement period Breaking hammer operating ratio (%) (): For the use of common anti-wear hydraulic oil. Item Hydraulic oil Filter element 1 st time 2 nd time Periodic 1200(600)
Page 78 List of Wearing Parts Periodically replace the wearing parts, including filters and filter elements, as per the table below. System Item Part name Replacement period Hydraulic Hydraulic oil return Replace after first 50 hours, then Filter element system filter every 500 hours Hydraulic Ventilator Every 1000h...
Page 79 Combination wrench 13mm Piece Combination wrench 14mm Piece Combination wrench 15mm Piece Combination wrench 16mm Piece Combination wrench 17mm Piece Combination wrench 18mm Piece Combination wrench 19mm Piece Socket head, 10mm Piece Socket head 11mm Piece Socket head 12mm Piece Socket head 13mm Piece Socket head 14mm...
Page 80 Table of Tightening Torques Nuts and Bolts (Grade ISO10.9) Unless otherwise specified, tighten the nuts and bolts to the torques listed in table below. The tightening torques for installation of plastic caps are not listed in the table below. To understand more details, please consult with your sales or service dealer.
Page 81 Critical Safety Parts To operate the machine safely, please fulfill the periodical checking and maintenances. The following critical safety parts shall be replaced periodically to improve safety. These parts can cause serious injuries or fire accident if they are damaged. List of Critical Safety Parts Vehicle body Periodically replaced critical safety part...
Page 82 detection of any deformed or cracked pipe clamp, immediately replace it together with hose. Please consult with your sales or service dealer for the replacement of safety parts. Except the critical safety parts, check and tighten the hydraulic pipes and when necessary, replace.
Page 83: Maintenance List
Maintenance List Checking and maintenance item Date Completed Walk-Around Checking Opening of engine hood and machine hood for checking Walk-around checking of machine Checking in driver seat Daily routine checking (Every 10h) Checking and adding of coolant Checking and adding of engine oil Checking of Fuel-Water Separator Checking of fuel level Checking of hydraulic oil tank oil level and adding of oil...
Page 84: Walk-Around Checking
Walk-Around Checking Fulfill the following checking before the first start of engine each day. Before operations, fulfill the walk-around checking and when necessary, repair immediately. Before operations within the machine, please securely fix the engine hood or machine hood. Keep the engine hood and machine hood closed under windy weather or while parking the machine on a slope.
Page 85: Daily Routine Checking (Every 10H)
Check hydraulic oil pipes, hydraulic devices, hoses, and connectors for oil leakage. Walk-around checking of machine Check lamps for presence of dusts and damages and check lamp bulbs for burnout. Check hydraulic accessories and hoses for damage. Check bucket, bucket teeth, and side teeth for wear, damage, and looseness. Check hook, anti-slip stop block, and hook seat on bucket for presence of damage.
Page 86 Install the cap (2). Note: Add clean water (soft water) only to compensate the lost coolant due to evaporation. Add the coolant (antifreeze) and clean water (soft water) of specified mixing ratio only to compensate the lost coolant due to leakage. Checking and adding of engine oil Please stop the engine and wait for the machine to cool down before maintenance.
Page 87 Check the fuel level by fuel gauge (1). F: Full tank. E: Empty tank. If the fuel level is low, open the fuel tank cap. Checking of Fuel-Water Separator Checking of Fuel-Water Separator (1). Open the engine hood. If the red indicator ring (6) submerges to the bottom, there is no mixture of water.
Page 88 Adding Important: While adding oil, the oil level shall not be above the upper limit (H). Otherwise, it will damage the hydraulic circuit or cause oil spray. If the oil level is too high due to carelessness, stop the engine, wait for the hydraulic oil to cool down, and drain the excessive oil from oil drainage port.
Page 89 Lubrication of Working Device Maintain the machine under the status shown in above diagram, lower the working device to the ground, and then stop the engine. Lubricate the grease fitting by a grease gun. Wipe away excessive grease. Records After first 50h (For new machine only) Checking and adjustment of fan belt Please stop the engine and wait for the machine to cool down before maintenance.
Page 90 Checking Open left side gate of machine. Check the tension (Approximately 98N) based on the centers of fan pulley (1) and alternator pulley (2). Check the fan belt (3). Upon detection of any of following conditions, replace. Rupture or cracking. The belt is worn to touch the bottom of pulley V-grooves.
Page 91: Every 50H
Disassemble the right covering part. Slowly loosen the bleeding plug (1) to relieve the internal pressure and then take out the plug. Loosen the hose band and take out the hose (2) from the flange (3). Loosen the bolt and take out the flange (3).
Page 92 Lubricate the slewing bearing Do not slew during lubrication. Otherwise, you may be entangled into the machine. Take out the cover plate (1). Use a grease gun to inject lubricating grease via the grease fitting (3) of grease Stop the machine as per the posture shown in above diagram and stop the engine.
Page 93: Every 100H
Checking of battery electrolyte level and adding of electrolyte The battery can generate flammable hydrogen which can cause explosion. Keep away from fire sources including open fire, spark, and ignited cigarette. Do not clean by a dry cloth, otherwise it can cause electrostatic accumulation and combustion or explosion.
Page 94: After First 250H (For New Machine Only)
After first 250h (For new machine only) Replacement of traveling motor gear oil Please stop the engine and wait for the machine to cool down before maintenance. The traveling motor is hot after operation. Touching it can cause scalding. The gear oil is also high temperature and under high pressure after operation.
Page 95 Rotate the filter (4) counterclockwise by a filter wrench to take it out. Clean the mounting surfaces of filter housing. Apply a thin film of oil to the washer of new filter. Manually install new filter. After the washer of filter comes into contact with the mounting surface, tighten the filter further for one turn (by oil filter wrench).
Page 96 Cleaning of radiator fins and oil cooler fins Clean primary filter element (3) by dry compressed air (294~490kPa). Firstly, blow along the wrinkles from the inside of filter element. Then blow from outside and finally blow from inside. Illuminate the inside of primary filter element (3) by a lamp to check.
Page 97: Every 500-Hour
Every 500-hour Replacement of Hydraulic Oil Tank Return Filter Replacement of Water Separator Filter Opening of Side Gate Close valve (2). Loosen the ring (3) and take out the box (4). Take out the spring (7) and indicator ring (6) from the box (4).
Page 98 Install new filter element. Install the dust collector (2) by facing upward the “↑TOP↑” and then secure it by clamp (1). Checking and Adjustment of Engine Valve Clearance These operations require experiences. Please ask your sales or service dealer for operations. Cleaning of Engine Cooling System Please stop the engine and wait for the machine to cool down before maintenance.
Page 99: Every 1500-Hour
Stop the engine, wait for the coolant to cool down, and then take out the drainage plug (4) to drain the water. After water drainage, clean the cooling system by detergent. Use the detergent as per the attached operation instructions of the detergent. Repeat steps 4~8 to clean the cooling system.
Page 100 Lift up the safety lock handle to the locking position. Open the engine hood. Slowly loosen the bleeding plug (1) to relieve the internal pressure of hydraulic oil tank. Loosen the hose band and take out the hose (2) from the flange (3).
Page 101 Cylinders Start the engine and run at low idling speed for 10min. Keep the engine running at low idling speed, extend and retract all cylinders for 4~5 times, but take caution not to telescope any cylinder to the end. Run the engine at high speed, extend and retract all cylinders for 4~5 times, but take caution not to telescope any cylinder to the end.
Page 102 Disassembling Clean the bucket and park the machine on a level, firm, and safe ground. Place level the bottom face of bucket and cushion it with cushion block to ease the disassembling of bolts (1). Withdraw the starter key and check bucket for steady placement.
Page 103 Disassembling Disassemble the bucket. Check the pin seal ring (3). Upon detection of deformation or damage, replace. Installation Lower the bucket steadily onto the ground as shown in above diagram. Note: While disassembling the tooth pin, adjust the bucket position in such manner that the bucket barely comes into contact with the ground.
Page 104 Align the anti-rotation holes, install the lock bolts (2), and install and tighten 2 nuts. Adjust the pin seal ring (3) to the orientation shown in above diagram. Use a small wood hammer to press in the pin seal ring lightly. Take caution not to damage the seal ring.
Page 105 Checking of Rubber Tracks For detailed repair or replacement, please consult with your sales or service dealer. If any track is stretched and non-adjustable, please replace the track. If the height (A) is ≤5mm, replace. If two or more segments of the wire rope are exposed, please replace. If more than half of the side face of wire rope is cut, please replace.
Page 106: Maintenances During Long-Time Parking
Disassembling Completely loosen the tension of rubber tracks. Lift the machine body by working device. Place a steel tube (1) in the rubber track and rotate the sprocket slowly towards opposite direction. Rotate the sprocket till the steel tube (1) closes to the tensioner and the rubber track is lifted off the tensioner and then stop the rotation of sprocket.
Page 107 Check for oil/water leakage and cracking and check for any loose nut or bolt. Refuel and replace hydraulic oil and lubricating oil. To prevent rusting and freezing, replace the engine coolant with long-life coolant (LLC). Lubricate the grease fitting by a grease gun. Fully retract the bucket and bucket arm cylinders and lower the bucket and bulldozing blade onto the ground.
Page 108: Troubleshooting
Troubleshooting Symptoms other than Malfunctions The following symptoms are not malfunctions. With engine running at low speed, when the bucket arm reaches a nearly vertical position, its retraction speed will drop shortly. With engine running at low speed, when the bucket teeth reach a nearly horizontal position, its movement speed will drop shortly.
Page 109: No Battery Power
Remedy procedure Park the machine on a safe place. Check whether the steam overflows from the closed engine hood or machine hood. If the steam overflows from engine compartment, immediately stop the engine and contact your sales or service dealer for repair. If no steam overflows, run the engine at low idling speed to cool down the coolant.
Page 110 Connection of Jumper Cable Important: Place the starter keys of both rescue machine and malfunctioned machine to OFF. The booster machine and the machine with depleted battery are prohibited for mutual contact. The positive (+) and negative (-) clamps of the jumper cable are prohibited for mutual contact. During connection, firstly connect the jumper cable to positive (+) terminal.
Page 111: Burnout Of Fuse
Burnout of Fuse If a lamp fails to turn on or the electronic system fails to work, the fuse is probably burnt. Check the fuse. Checking and Replacement of Fuses Warning: If a fuse is burnt again shortly after replacement, the electronic system is probably malfunctioned.
Page 112: Restart After Refueling
Checking of Fuses If the engine fails to start after the starter switch is rotated to ON, the filter cartridge fuse (1) is probably burnt. Open the access panel to check. If the fuse is already burnt, please contact your sales or service dealer.
Page 113: Flashing Of Warning Lamps
Flashing of Warning Lamps If a warning tone is heard or a warning lamp starts to flash during operations, park the machine in a safe place and take the following remedy measures. Warning lamp Lamp name Cause and solution The fan belt or charger is malfunctioned.
Page 114: Other Symptoms
Other Symptoms For the symptoms not listed in table below or the further existed problems after appropriate solutions, please consult with your sales or service dealer. Symptom Main cause Solution Track tension adjustment Adjust tracks to specified tension. malfunction Impossible change of Burnout of fuse Replace fuse.
Page 115 Symptom Main cause Solution Inflexible motion of Shortage of grease for Lubricate joystick. ● ● left/right joystick left/right joystick Adjust or replace (Please consult with ● Inflexible motion of Loose wires ● your sales or service dealer). bulldozing blade Operation failure of Lifted (locked) safety Lower down (Unlock) safety lock ●...
Page 116: Towing
Towing During towing, the improper operations, the incorrect use of rope, or the improper checking can cause serious injuries or deaths. Use ropes compatible with the towing force. Do not use any kinked, twisted, or damaged rope. Do not suddenly apply heavy load onto the rope. Please wear safety gloves during the handling of rope.
Page 117: Support
Support: For parts, support, or warranties, please call: 1300 676 996 Or email: office@diggerking.com.au Manufactured by: Digger King Unit 9, 103-109 Quarry Road SOUTH MURWILLUMBAH NSW https://diggerking.com.au...