Page 1 APPLICABLE No. E265B LQ12-06001~ E265B LL 12-05001~ READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS AND INSTRUCTIONS FOUND IN THIS MANUAL BEFORE OPERATING THE MACHINE. Book Code No. 87739538 Printed in Japan 2007.01 (KE)
Page 3: Table Of Contents
TABLE OF CONTENTS FOREWORD GENERAL ......................... 0-1 PERIODIC INSPECTIONS ....................0-1 NOTICE..........................0-1 KEEP OPERATION & MAINTENANCE MANUAL STORAGE ......... 0-2 FOR ORDERING ......................0-3 1. SAFETY PRECAUTIONS 1.1 GENERAL SAFETY INFORMATION ............... 1-2 1.2 SAFETY PRECAUTIONS..................1-3 1.3 WARNING LABELS & DECALS................1-6 1.3.1 WARNING LABELS &...
Page 4 TABLE OF CONTENTS 2.3.15 OTHER EQUIPMENT (ACCESSORY).............. 2-45 3. MACHINE OPERATION 3.1 MACHINE OPERATION................... 3-3 3.1.1 EVERYDAY CHECK-UP ................... 3-3 3.1.2 CHECKING BEFORE STARTING ENGINE ............3-4 3.1.3 ADJUSTING OPERATOR SEAT............... 3-10 3.1.4 ADJUSTING MIRROR..................3-10 3.1.5 CHECKING FUNCTION OF GAUGE CLUSTER ..........3-11 3.1.6 CHECKING WORK LIGHT ................
Page 5 TABLE OF CONTENTS 4.16 1000 HOUR (12-MONTH) INSPECTION & MAINTENANCE PROCEDURES ..4-57 4.17 2000 HOUR INSPECTION & MAINTENANCE PROCEDURES ......4-60 4.18 5000 HOUR INSPECTION & MAINTENANCE PROCEDURES ......4-67 5. TRANSPORTATION 5.1 GROUND TRANSPORTATION ................5-3 5.1.1 MACHINE PREPARATION ................5-3 5.1.2 LOADING/UNLOADING THE MACHINE ............
Page 6 TABLE OF CONTENTS...
Page 7: General
FOREWORD FOREWORD AVOID INJURY Read, understand and follow all safety precautions and procedures found in this manual before attempting any operation, inspection or maintenance of this machine, attachment or systems. Manufacturer cannot an- ticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are therefore not all inclusive.
Page 8: Keep Operation & Maintenance Manual Storage
FOREWORD KEEP OPERATION & MAINTENANCE MANUAL STORAGE For quick reference, keep this manual in the magazine box of right rear of operator’s seat. READ THIS MANUAL BEFORE OPERATING THE MACHINE Most accidents occurring during work are due to non-observance of simple safety norms and ele- mentary precautions.
Page 9: For Ordering
FOREWORD FOR ORDERING For ordering parts and service, inform an authorized Manufacturer distributor of your machine’s Serial Number and Engine Serial Number stamped in the locations, and Hour Meter read, shown on the illustrations below. For future reference, record these Serial Numbers in the spaces provided below: MACHINE TYPE MACHINE SERIAL No.
Page 10 FOREWORD...
Page 11: Safety Precautions
1. SAFETY PRECAUTIONS...
Page 12: General Safety Information
1. SAFETY PRECAUTIONS GENERAL SAFETY INFORMATION AVOID INJURY OR DEATH Do not operate or perform any maintenance on this machine until all instructions found in this manual have been thoroughly read and understood. Improper operation or maintenance of this machine may cause accidents and could result in serious injury or death.
Page 13: Safety Precautions
1. SAFETY PRECAUTIONS SAFETY PRECAUTIONS AVOID INJURY OR DEATH The proper and safe lubrication and maintenance for this machine, recommended by manufacturer, is out- lined in this operator’s manual for this machine. Improper performance of lubrication or maintenance procedures are dangerous and could result in injury or death.
Page 14 1. SAFETY PRECAUTIONS 11. Be careful when removing cover plates. Gradually back off the last two bolts or nuts located at opposite ends of the cover or device and carefully pry cover loose to relieve any spring or other pressure, before removing the last two bolts or nuts completely.
Page 15 1. SAFETY PRECAUTIONS If dust which may contain asbestos is present, there are several common sense guidelines that should be followed. a. Never use compressed air for cleaning. b. Avoid brushing or grinding of asbestos containing materials. c. For clean up, use wet methods or a vacuum equipped with a high efficiency particulate air (HEPA) filter. d.
Page 16: Warning Labels & Decals
1. SAFETY PRECAUTIONS WARNING LABELS & DECALS Warning labels and decals are affixed to the machine to remind operators and personnel of specific safety precau- tions in certain areas of the machine. The following are illustrated examples of all warning labels and decals along with their locations.
Page 17 1. SAFETY PRECAUTIONS 1. WORKING ABOVE GROUND Located on fuel tank and counterweight. Part Number - ZL11N02604 (2REQ’D) There is a danger of falling when working on areas above ground. • Do not approach edges. • Use the appropriate equipment, such as ladders or platform when working above ground.
Page 18 1. SAFETY PRECAUTIONS 5. HANDLING BATTERY Located on battery relay cover. Part Number - YN20T01356P1 PREVENT BATTERY EXPLOSION • Batteries give off hydrogen gasses that can ex- plode and cause personal injury. • Keep sparks, open flames and cigarettes away from batteries.
Page 19 1. SAFETY PRECAUTIONS 8. ADJUSTING TRACK TENSION Located on crawler frame. Part Number - YN20T01813P1 (2REQ’D) • This work must be done carefully by two people. The operator must operate the machine as in- structed by the signals of the partner. The crawler belt is changed by lifting one side of the machine at a time.
Page 20 1. SAFETY PRECAUTIONS 11. BOOSTER CABLE Located on battery relay cover. Part Number - ZL11N01104 Electric hazard may cause injury when mishandling the cable. Read operator manual for safe and proper han- dling. ZL11N 0 1104 12. MACHINE LIFTING Located on left side frame. Part Number - YN20T01833P1 •...
Page 21 1. SAFETY PRECAUTIONS 16. DO NOT INSERT HAND OR FOOT IN THE MOV- ING PART Located inside cab R.H. Part Number - ZL11M03704 Do not insert hand or foot in the moving part. There is a possibility of catching hand or foot be- tween the moving parts resulting in injury.
Page 22 1. SAFETY PRECAUTIONS 20. ELECTRICAL POWER LINES, READ OPERA- TOR’S MANUAL, LEAVING MACHINE Located inside cab R.H. Part Number - PV20T01005P1 • Contact with electrical power lines will result in severe injury or death. Keep machine and attachment a safe distance from electrical power lines as per following in- struction.
Page 23 1. SAFETY PRECAUTIONS 23. WORK MODE SELECT SWITCH CAUTION Located inside cab R.H. Part Number - YN20T01836P1 (OPT.) Improper WORK MODE selection with using NIB- BLER or HYDRAULIC BREAKER attachment might result serious failure on hydraulic system. Be sure to select WORK MODE properly as per fol- lowing switching procedure.
Page 24: Pre-Start Safety
1. SAFETY PRECAUTIONS PRE-START SAFETY A. FOLLOW THE RULE • In operating, inspecting and serving the machine, follow the precaution and procedure for the safety described in this manual. • Never operate machine when being in poor physical condition, having taken medicine (making sleepy), being un- der the influence of alcohol and being mentally unstable.
Page 25 1. SAFETY PRECAUTIONS E. PRECAUTION TO BE TAKEN WITH DEVICES FOR SAFETY • Check that all protective guard and cover, and mirror are installed properly. If the failure is found, repair it immediately. • Well understand how to use the device for safety. •...
Page 26 1. SAFETY PRECAUTIONS SIGNS, SIGNALS & ALGMEN Install signs on soft shoulders and ground areas, and have a flagman direct the operation if necessary. The operator should note marks and follow signals from the flagman. All personnel should know the meaning of the signs, marks, and signals.
Page 27 1. SAFETY PRECAUTIONS L. HOW TO HANDLE LIFE HAMMER A life hammer is provided on the right side of cab. In case of emergency, take the life hammer, break the cab glass, and escape from the cab. In addition, the life hammer is equipped with a cutter on the lever side to cut the seat belt, etc.
Page 28 1. SAFETY PRECAUTIONS Fire due to Faulty Piping Check that the clamp, guard and cushion of hose and tube are securely fixed. The loosening may cause the damage of hose due to the vibration during operation and the scrubbing in contact to other parts and is in danger of fire and accident resulting in injury and death due to the spouting out of high pressure oil.
Page 29 1. SAFETY PRECAUTIONS P. PAY ATTENTION TO THE NOISE The large noise from the surrounding might cause hard hearing and deafness. If it is unavoidably necessary to enter in noisy area for long time, do not fail to wear ear- muffs or earplugs.
Page 30 1. SAFETY PRECAUTIONS S. PAY ATTENTION TO FALLING MATERIALS AND FLYING DEBRIS At the site where there is a possibility of falling material and flying debris, provide protective guard on it as re- quired to protect operator from possible risks. •...
Page 31: Safety During Operation
1. SAFETY PRECAUTIONS SAFETY DURING OPERATION A. STARTING ENGINE When the caution tag "Do not operate" or similar warn- ing is indicated on the control lever or in the area around the cab, do not start engine and do not touch the control lever.
Page 32 1. SAFETY PRECAUTIONS E. PRECAUTION TO BE TAKEN WHEN STARTING ENGINE • Lock it with the safety lock lever. • Sound the horn before starting the engine to alert people that the machine is being started. • Start engine from the operator’s seat. •...
Page 33 1. SAFETY PRECAUTIONS K. DO NOT HIT CAB WITH ATTACHMENT Check clearance between bucket and cab before oper- ation. Slowly cycle bucket, check for interference with arm and cab, particularly if a lifting eye is welded on bucket bottom. Exercise care when operating the buck- et near the cab.
Page 34 1. SAFETY PRECAUTIONS M. TRAVELING ON SLOPE The traveling up and down on a slope 30 degree in an- gle or more is not allowed because there is a possibility of rollover. • When traveling up and down on a slope, keep the at- tachment at the height of 20~30 cm (0.7 to 1 ft) from the ground so as to make the urgent stop possible at the time of emergency by putting the attachment...
Page 35 1. SAFETY PRECAUTIONS O. OPERATING ON INCLINES OR SLOPS • Operation of this machine on an incline or slope may cause the machine to become unstable or unbal- anced. Work up and down inclines or slopes, do not across. Do not swing or turn machine around on a slope.
Page 36 1. SAFETY PRECAUTIONS R. WORKING AROUND UNDER GROUND UTILITY LINES During operation it is likely that you will be working around or near buried utility lines which may include, but are not limited to: • Electrical Power Line • Gas Line •...
Page 37 1. SAFETY PRECAUTIONS U. CHECK THAT NO PERSON IS UNDER THE BUCKET There is a possibility of accident resulting in injury or death and the damage of machine due to the fall of sand/earth and the direct contact with bucket when the bucket and attachment pass through over the worker and the driver’s seat of dump truck.
Page 38 1. SAFETY PRECAUTIONS X. WORKING AROUND UTILITIES If it is suspected that utility lines such as, gas, water, phone or electrical power are in the work area, contact the local utility authority for line location BEFORE be- ginning work in the area. Use extreme caution around electrical power lines.
Page 39 1. SAFETY PRECAUTIONS AB.SLIPPERY OPERATION SURFACE Use caution when operating machine on boards or steel plates. Boards and steel plates become very slip- pery when wet. Pay special attention when working on inclined areas. Provide a device to prevent skidding and operate with extra care.
Page 40: Inspection & Maintenance Safety
1. SAFETY PRECAUTIONS INSPECTION & MAINTENANCE SAFETY A. READ CAREFULLY OPERATING/MAINTENANCE PROCEDURES Incorrect maintenance may cause not only damages on the machine, but also injury. Read and fully understand the maintenance proce- dures and safety precautions described in the opera- tion and maintenance manual before performing any maintenance in this machine.
Page 41 1. SAFETY PRECAUTIONS G. AVOID HOT SURFACES & AREAS Immediately after the machine is operated, the temper- ature and pressure of the engine coolant, engine oil and hydraulic oil are very high. Burns may result if caps are removed, or oil, water, or filters are changed under these conditions.
Page 42 1. SAFETY PRECAUTIONS K. VENTILATION PRECAUTIONS Operation of the machine indoor or in a place with poor ventilation may cause poisoning by gas. Ventilate any exhaust gas, fuel, cleaning oil, paint or similar articles. Make sure there is proper ventilation in the working area when the machine is operated indoors.
Page 43 1. SAFETY PRECAUTIONS N. WORKING ABOVE GROUND There is a danger of falling when working on areas above ground. • Do not approach edges. • Use the appropriate equipment, such as ladders or platform when working above ground. In addition, strap yourself to the proper equipment accordingly.
Page 44 1. SAFETY PRECAUTIONS P. GENERAL GUIDELINES FOR WELDING Welding work must be performed by a certified welder with sufficient experience. In addition, safety practices must be followed by any personnel involved in such work. Identify all cracks to be repaired or areas to be welded by thor- oughly cleaning the suspected surface, remove paint, and check with dye penetrant or magnetic particle testing.
Page 45 1. SAFETY PRECAUTIONS Q. CRAWLER SHOE TENSION • Grease in track tensioning mechanism is under ex- treme pressure and can penetrate skin causing se- vere injury. Keep face and body away from grease fitting area. • Do not loosen grease fitting more than one turn. If grease does not release after one turn of the fitting, call our dealer/distributor for assistance.
Page 46 1. SAFETY PRECAUTIONS U. DO NOT HEAT HYDRAULIC EQUIPMENT OR PIPING Do not apply heat to hydraulic equipment or piping, such as welding, soldering, heating with torch, etc. Heating of hydraulic components or piping will cause gas expansion, which can easily catch fire and/or ex- plode.
Page 47: Battery Safety
1. SAFETY PRECAUTIONS BATTERY SAFETY A. WEAR PROPER PROTECTIVE CLOTHES Wear long sleeve shirt, gloves and approved safety glasses or face shield when working with or around bat- teries. Battery electrolyte (acid) will cause severe burns if allowed to make contact with clothing, skin or eyes. Should electrolyte (acid) come in contact with clothes, skin or eyes, immediately remove effected clothing, flush area with clean water for 15 minutes and get...
Page 48 1. SAFETY PRECAUTIONS D. USING BOOSTER CABLES Cable connecting order • If using another machine or vehicle to boost dis- Cable disconnecting order charged batteries, make sure that the machine or ve- hicle DOES NOT TOUCH the disabled machine. (Red) •...
Page 49: Prohibited Machine Operation
1. SAFETY PRECAUTIONS PROHIBITED MACHINE OPERATION The following examples of machine abuse and misuse should never be attempted by even the most experienced operator. Such abuse and misuse of this machine and its attachments can result in serious injury, death, severe equipment damage and shortened service life of the machine.
Page 50 1. SAFETY PRECAUTIONS E. DO NOT OVER EXERT THE MACHINE’S CA- PACITIES Know the limitations of the machine and its attachments and operate the machine within those specifications. Do not exceed lift charts. Do not tip or raise the machine to obtain power to move material.
Page 51: End Of Work Shift Safety
1. SAFETY PRECAUTIONS END OF WORK SHIFT SAFETY Perform all of the following procedures after each shift is complete to insure the machine it in optimal operating condition for the next shift or job site. 1. Move the machine to a firm, level surface. 2.
Page 52: Towing The Machine
1. SAFETY PRECAUTIONS 1.10 TOWING THE MACHINE 1. If the machine should become stuck in soft soil ar- eas it may be necessary to tow the machine. Attach a wire rope or chain, with the capacity to pull the machine out, to the lower frame. 2.
Page 53: Machine Familiarization
2. MACHINE FAMILIARIZATION...
Page 54 2. MACHINE FAMILIARIZATION...
Page 55: Basic Components Of The Machine
2. MACHINE FAMILIARIZATION BASIC COMPONENTS OF THE MACHINE NAME NAME NAME HINO Engine 12 Arm 23 Track Guide Hydraulic Pump 13 Bucket Cylinder 24 Upper Roller Engine Muffler 14 Idler Link 25 Slewing Ring Main Control Valve 15 Bucket Link 26 Travel Motor Hydraulic Oil Tank 16 Bucket...
Page 56: Operator Cab Nomenclature
2. MACHINE FAMILIARIZATION OPERATOR CAB NOMENCLATURE The operator cab nomenclature, see Figure below, points out locations of operator controls of the hydraulic excava- tor operator cab. Study these areas and locate these components on the machine. Specific information regarding these components are explained on the following pages of this section. DETAIL A NAME NAME...
Page 57: Component & Controls Nomenclature
2. MACHINE FAMILIARIZATION COMPONENT & CONTROLS NOMENCLATURE The following information provides a brief description and function of the components and controls of the hydraulic excavator. All personnel associated with this machine should read and understand this information BEFORE beginning any work with or on this equipment.
Page 58 2. MACHINE FAMILIARIZATION 2. FUEL METER This indicates the amount of fuel. F : Full tank is about 460 L {122 gal} This gauge indicates the remaining volume of fuel in the fuel tank. Re- fuel when the indicator is approaching to the "E" point. Refill the fuel tank with diesel fuel only.
Page 59 2. MACHINE FAMILIARIZATION 2. BUZZER STOP SWITCH In case where warning is displayed on the multi-display (LCD), press buzzer stop switch (1) and buzzer shown below stops sounding. DATA COMMUNICATION ERROR The level shown in the table is based on the following contents. 1.
Page 60 2. MACHINE FAMILIARIZATION 3. WORK MODE SELECT SWITCH The initial setting (default) of work mode had been set to "S" mode at factory. Select proper work mode from 4 modes shown below according 10:25 to the work condition and the purpose. The work mode is switched in order of "S"...
Page 61 2. MACHINE FAMILIARIZATION 6. TRAVEL SPEED SELECT SWITCH 10:25 Slow speed traveling is necessity to load and unload the machine on to a trailer. During loading or unloading, do not change the trav- el speed. The travel speed select switch is located on the gauge cluster switch panel.
Page 62 2. MACHINE FAMILIARIZATION 8. SELECT SWITCH This switch is usually set to "OFF", but this switch (8) is available for auto warming up, clock setting, contrast adjust- ment, and flow rate setting of attachment/breaker mode. For the how to use select switch, see pages 2-10 to 2-14. Press screen change switch (1) during the above adjustment and setting operations and the screen returns to the previous screen.
Page 63 2. MACHINE FAMILIARIZATION 4. After switching from "OFF" to "ON" in operation of Washer switch (4), set it by pressing the select switch. 5. Turn starter key switch off once and have the auto warming up setting memorize. When the engine is started with starter key and then if it is in low temperature, the automatic warming up oper- ation starts.
Page 64 2. MACHINE FAMILIARIZATION 8.2 Clock Adjustment Switches Switches Screen Change Switch Buzzer Stop Switch Work Mode Select Switch Washer Switch Wiper Switch Travel Speed Select Switch Auto Accel Switch Select Switch Main screen SWITCH STATUS 10:25 13:15 CLOCK/CONTRAST Enter SWITCH STATUS ADJUST CLOCK CLOCK/CONTRAST ADJUST CONTRAST...
Page 65 2. MACHINE FAMILIARIZATION 8.3 Contrast Adjustment Switches Switches Screen Change Switch Buzzer Stop Switch Work Mode Select Switch Washer Switch Wiper Switch Travel Speed Select Switch Auto Accel Switch Select Switch Main screen SWITCH STATUS 10:25 CLOCK/CONTRAST SWITCH STATUS ADJUDT CLOCK 10:25 CLOCK/CONTRAST ADJUST CONTRAST...
Page 66 2. MACHINE FAMILIARIZATION 8.4 Pump Flow Rate Adjustment (A mode/ B mode) According to some kind of attachment, it is required to change the flow rate for service circuit. Change the flow rate in accordance with the procedure mentioned below. In this machine, last set flow rate has been stored and the initial flow rate is 246 L/min.
Page 67 2. MACHINE FAMILIARIZATION C. LCD MULTI-DISPLAY When the warning is displayed on the multi-display, stop the work immediately and check failure cause and service the trouble. For checking and service, refer to the section of "Maintenance". The gauge cluster processes signals received from various sensors and switches and outputs the signals to LCD display and lamp display, and makes the buzzer sound.
Page 68 2. MACHINE FAMILIARIZATION C.2 DISPLAY BY SWITCH OPERATION When using it by selecting switch on the switch panel provided on the gauge cluster, the selected mode is displayed on the lower part of multi- display. 22:00 1. Work mode display The mode changes in order of "S"...
Page 69 2. MACHINE FAMILIARIZATION C.3 Display for maintenance This screen displays the remaining time to the end of recommended replacement interval specified for filter/oil. After reaching to the end of replacement interval, check and serve them following to section "Maintenance". The recommended replacement interval is the accumulated time which is counted by controller when the engine is running.
Page 70 Procedure Operating Procedure Display on Multidisplay After several seconds, 10:25 display is changed to NEW HOLLAND Turn starter key switch on. KOBELCO clock autmatically. Press " " switch press once display 10:25 200 Hr change switch on the switch panel once. And...
Page 71 2. MACHINE FAMILIARIZATION C.5 WARNING DISPLAY The warning is displayed in order of priority, and when many troubles occurred at the same time, for levels 1 and 2 in order of priority (A) level 1 is displayed in priority to level 2. When these warning are displayed, there is a possibility of serious trouble.
Page 72 2. MACHINE FAMILIARIZATION Displays Level Warning Contents Remedy Stop engine, lower the coolant temperature at low idling of engine speed, and cool down the engine. Displayed when coolant tempera- When the warning does not cancelled after HIGH ENG ture is raised to the specified tem- an elapse of several minutes, stop engine WATER TEMP.
Page 73: Location Of Switches And Meters
2. MACHINE FAMILIARIZATION 2.3.2 LOCATION OF SWITCHES AND METERS Detail A NAME NAME Starter Key Switch Horn Switch Throttle Potentiometer Power Boost Switch Working Light Switch (Boom, Deck) 10 Potentiometer for Emergency Mode Conflux/Single Flow Change Switch (Option) 11 Swing Parking Brake Release Switch Air Conditioner Control Panel 12 Hour Meter Cap (For Opt.
Page 74 2. MACHINE FAMILIARIZATION 1. Starter Key Switch The starter key switch is located on the right hand op- erator console and has 4 operating functions. • OFF : When starter key switch (1) is turned to this position, the engine stops and electrical power to the ma- chine’s electrical systems is stopped after approxi- mately 3 seconds.
Page 75 2. MACHINE FAMILIARIZATION 4. Conflux/Single Flow Change Switch (Option) This switch is used to switch the single flow and conflux hydraulic circuit. • Symbol mark (two marks side) : Select this side when carrying out the demolition work with the nibbler which requires the conflux flow. •...
Page 76 2. MACHINE FAMILIARIZATION 9. Power Boost Switch Located on the right hand control lever, this switch should only be used for increased break out force dur- ing digging. Use of it is prohibited where an arm longer than the standard is installed. 10.
Page 77 2. MACHINE FAMILIARIZATION 12. Hour Meter This indicates the total time the engine has run. Even if the excavator is not moving, the meter continues to count as long as the engine is running. 13. 12 Volt Power Supply The 12 volt power supply (1) is located beside the rear side cover.
Page 78: Levers And Pedals
2. MACHINE FAMILIARIZATION 2.3.3 LEVERS AND PEDALS 1. Safety Lock Lever 2. Control lever (ISO Control Pattern) 3. Travel lever 1. Safety Lock Lever The safety lock lever is provided to prevent any unexpected operation due to the unexpected movement of control levers.
Page 79 2. MACHINE FAMILIARIZATION 2. Operating Levers (ISO Operating Pattern) These two levers activate each operation as illustrated in the right. • Confirm for safety around the working area. Also ensure that each lever operation is in accor- dance with the operating pattern indicated on the labels.
Page 80 2. MACHINE FAMILIARIZATION 3. Left and Right Travel Lever & Pedal The travel lever & pedal are located in front of operator seat. They are used to move the left or right track of the machine either forward or backward. •...
Page 81: Fuses & Relay Box
2. MACHINE FAMILIARIZATION 2.3.4 FUSES & RELAY BOX Make sure the starter key switch is in the "OFF" position when replacing fuses. The fuses protect the electrical system from excess current. If operation is not normal, a fuse may be blown. Replace blown or faulty fuses with the spare fuses as follows.
Page 82 2. MACHINE FAMILIARIZATION Fuses 10 11 12 13 14 15 16 AMPS FUNCTION AMPS FUNCTION Cab Work Light DC-DC Converter Cab Work Light Option (Bucket Control) Gauge Cluster Option (Roof Wiper) Wiper, Washer Flasher, Alarm, One Way Call Option 1 Safety Lever Lock Option 3 Mechatro Controller...
Page 83: Fusible Link (For Starter)
2. MACHINE FAMILIARIZATION 2.3.5 FUSIBLE LINK (FOR STARTER) In case power does not come when the starter key switch is turned "ON", a disconnection of the fusible link is suspected. Inspect and replace the fusible link. The fusible link is of a fuse wiring of big size provided in the electric wiring Checking and replacing procedure 1.
Page 84: Handling Of Antenna
2. MACHINE FAMILIARIZATION 2.3.7 HANDLING OF ANTENNA To prevent interference, retract the antenna in before transportation and storing. 2.3.8 AIR CONDITIONER The air conditioner provides the comfortable indoor at- mosphere and freely controls the room temperature and also removes the moisture resulting in prevention of blur on the glasses.
Page 85 2. MACHINE FAMILIARIZATION Control Panel Description NAME NAME Auto Control Switch Power Switch Fresh and Recirculate Air Selector Switch Temperature Setting Switch (°C ←→ °F Selector Switch) Compressor Switch Fan Speed Selector Switch Air Outlet Mode Selector Switch LCD Display Defroster Switch •...
Page 86 2. MACHINE FAMILIARIZATION B. CONTROL PANEL FUNCTIONS 1. Main Power Switch and Display a. LCD display is illuminated (5) when the climate con- trol-AC is operating. When the climate control-AC is stopped, LCD will be tuned off. b. Press main power switch (6), and all functions for the climate control-AC switch ON or OFF.
Page 87 2. MACHINE FAMILIARIZATION 3. Temperature Setting Switch and Display a. The set temperature is indicated in digits on LCD display (5). Temperature set range is 18.5°C (65.3°F) to 31.5°C (88.7°F). b. Press the two temperature set switches (7) simulta- neously for 5 seconds to change the display from Centigrade (°C) to Fahrenheit (°F) or viceversa in the LCD display.
Page 88 2. MACHINE FAMILIARIZATION 6. Recirculate and Fresh Air Selector Switch and Display Fan Speed a. Suction (fresh air intake) mode is indicated on LCD Display display (5). b. Each time recirculate and fresh air capacity selector switch (2) is pressed, the mode is switched to air re- circulate or fresh air intake.
Page 89 2. MACHINE FAMILIARIZATION 10. Treatment of Season In and Off (1) Season in Contact our dealer/distributor for checking and ser- vice of air conditioner before air-cooling season (season in) so that the air conditioner is used in good condition for a long time. (2) Season off Operate air conditioner for several minutes once a week in the period of out of season (season off).
Page 90: Handling Of Seat Belt
2. MACHINE FAMILIARIZATION 2.3.9 HANDLING OF SEAT BELT Install the seat belt properly or the fundamental performance may not be achieved. • Make sure that there is no abnormality on the belt attaching bracket and bolts before fastening the belt. •...
Page 91: Operator Seat
2. MACHINE FAMILIARIZATION 2.3.10 OPERATOR SEAT The operator seat incorporates several adjustment mechanisms to insure operator comfort, ease of operation and operator safety. The adjustment areas are as follows. When adjusting the operator seat, pay attention to hands in order not to be caught between handle and seat. A.
Page 92: Arm Rest Adjustment (4 Inch)
2. MACHINE FAMILIARIZATION 2.3.11 ARM REST ADJUSTMENT (4 INCH) The height of right/left arm rests is adjustable in 4 steps. 1. Loosen knob (1) slightly and move it forward slight- 2. Adjust arm rest (2) to preferable height and match it to aligning hole of bracket (3).
Page 93: Operator Cab
2. MACHINE FAMILIARIZATION 2.3.12 OPERATOR CAB When necessary to leave from the operator seat, lock the safety lock lever. After the control lever is unexpectedly touched without the safety lock lever locked, this may cause serious accident resulting in injury and death. A.
Page 94 2. MACHINE FAMILIARIZATION D. Opening and Closing Front Window • The front window should be opened and closed in the condition where the machine is parked in level and locked securely. If the lock is released in the forward tilting position of machine there is a possibility of falling of the front window.
Page 95: Fuel Pump
2. MACHINE FAMILIARIZATION F. Opening and Closing Glass Window on the Right Rear Side Release the quarter lock and the glass window opens slightly. G. Cab Room Lamp Quarter a. Turn cab room lamp "ON" by pushing the lamp Lock switch downward.
Page 96: Emergency Escape From Cab
2. MACHINE FAMILIARIZATION 2.3.14 EMERGENCY ESCAPE FROM CAB If it is impossible to open the cab door in an emergency, escape from the cab by the following way. 1. Open the front window and escape through the front window. For how to open the front window, see item "Opening and closing front upper window".
Page 97: Other Equipment (Accessory)
2. MACHINE FAMILIARIZATION 2.3.15 OTHER EQUIPMENT (ACCESSORY) A Tool Box Use this box for tools and accessory. This box is located on the right front side of machine. Release lock (1) of the cover with starter key and sup- port it with stay (2). After using tools, release the stay and close the cover, and then lock it with starter key.
Page 98 2. MACHINE FAMILIARIZATION 2-46...
Page 99: Machine Operation
3. MACHINE OPERATION...
Page 100 3. MACHINE OPERATION...
Page 101: Everyday Check-Up
3. MACHINE OPERATION MACHINE OPERATION 3.1.1 EVERYDAY CHECK-UP A. DAILY INSPECTION Before starting the engine, walk around the machine to check for any loose nuts and bolts, any oil, fuel or coolant leakage, and the condition of attachment and hydraulic system. Check for any looseness in the electrical wiring and for any accumulated material (leaves, dirt , etc.).
Page 102: Checking Before Starting Engine
3. MACHINE OPERATION 3.1.2 CHECKING BEFORE STARTING ENGINE The following checkup should be performed once before the first engine startup in a day. A. Checking Coolant Level for Shortage and Making Up • Do not open radiator cap if not required. Check coolant level of the reserve tank (1) when LOW ENG WATER LEVEL...
Page 103 3. MACHINE OPERATION B. Checking Oil Level of Engine Oil Pan and Making Up Immediately after engine is stopped, there is a pos- sibility of getting burn with heated parts and oil. Start working after the temperature is not hot •...
Page 104 3. MACHINE OPERATION C. Checking Fuel Level and Making Up • Use diesel fuel only and stop engine before refill- ing. • Do not overflow fuel while refilling. It may cause damage to the fuel system and cause oil spout- ing.
Page 105 3. MACHINE OPERATION D. Fuel Filter Drain Draining water collected in fuel filter the fuel filter is used to separate water contaminated in fuel. When warning "DRAIN WATER SEPA" is displayed, or water is collected in fuel tank, drain water. 1.
Page 106 3. MACHINE OPERATION F. Check Hydraulic Oil Level Hydraulic Oil Level Check Position It is very danger because the inside of hydraulic tank is heated and pressurized. When removing filler port plug, stop engine and re- move breather top end cap (1) and then release pressure from hydraulic oil tank by pressing the valve head.
Page 107 3. MACHINE OPERATION G. Checking Belt Tension Rotating parts can cause injury. Keep away from fan and belt when engine is run- ning. Stop engine before servicing. Check the fan and alternator belt for insufficient ten- sion, wear, and damage. Insufficient belt tension may cause battery charge failure, engine overheating, or ab- normal belt wear.
Page 108: Adjusting Operator Seat
3. MACHINE OPERATION 3.1.3 ADJUSTING OPERATOR SEAT • Adjust the operator seat before starting opera- tion or at the time when operator was changed. • Be careful not to put hands between handle and seat stand. Adjust the operator seat position so that the control le- ver, each control pedal and switch can be easily manip- ulated in the condition where operator takes seat and has his back fitted to the back seat.
Page 109: Checking Function Of Gauge Cluster
3. MACHINE OPERATION 3.1.5 CHECKING FUNCTION OF GAUGE CLUSTER Before starting the engine, check the warning display and gauge according with the following procedures: 1. Make sure the safety lever is in the "LOCKED" (Up) position. LOW ENG WATER LEVEL 2.
Page 110: Starting Engine
3. MACHINE OPERATION 3.1.7 STARTING ENGINE After making sure that no one is stayed and no obstruction is left around the machine, sound horn and start the engine. • Do not hold the starter key switch in the "START" position for more than 15 seconds. If the engine does not start, return the starter key switch to the "OFF"...
Page 111 3. MACHINE OPERATION B. Start-Up in Cold Conditions In cold weather, due to the increase in oil viscosity and decrease in battery performance, starting the engine may be difficult. Use the preheater to start the engine easily under these conditions. 1.
Page 112 3. MACHINE OPERATION C. Using Booster Cables Observing the following precautions when using boost- er cables to start a disabled machine. AVOID BATTERY HAZARDS • Flammable gas (hydrogen gas) is generated in the battery. Do not allow sparks or flames to come in con- tact with batteries to avoid triggering an explosion.
Page 113 3. MACHINE OPERATION D. Connecting/Disconnecting Booster Cables Make sure the starter key switch is in the "OFF" position before connecting the booster cables. Proceed as fol- Cable connecting order Cable disconnecting order lows to connect and disconnect the booster cables. (Red) AVOID EXPLOSION •...
Page 114: Stopping Machine Engine
3. MACHINE OPERATION 3.1.8 STOPPING MACHINE ENGINE Run the engine for at least 5 minutes at low speed be- fore stopping. Avoid damage to engine. Stopping the engine while running at high speed will cause damage from in- creased engine temperature affecting seals and oil. 1.
Page 115: Inspection After Starting Engine
3. MACHINE OPERATION 3.1.9 INSPECTION AFTER STARTING ENGINE Check and ensure the following items after starting the engine. • Careless movement of any control levers may cause unexpected movement of the machine. Set the safe- ty lock lever to the "LOCKED" (up) position before leaving the cab. •...
Page 116 3. MACHINE OPERATION B. Checking Function of Engine and Multi-Display When warning was displayed on the multi-display, stop the engine immediately and investigate the cause of er- CHARGE ERROR ror. 1. Check leak for oil and water around the engine. 2.
Page 117: Machine Warming-Up
3. MACHINE OPERATION 3.1.10 MACHINE WARMING-UP • The proper hydraulic oil temperature for this machine is about 50°C. The abrupt operation when the hydraulic oil temperature is 25°C or less may cause serious trouble for hydraulic equipment. Warm up the hydraulic oil before starting the work. •...
Page 118 3. MACHINE OPERATION B. Warming Up Hydraulic Oil 1. Make sure that safety lock lever (1) is set to the "UNLOCKED" (DOWN) position. 2. Move throttle control to "HI" idle position. 3. Move right control lever slowly to the stroke end of bucket digging side, and execute relief action for about 2 minutes.
Page 119: Work Mode Select Switch
3. MACHINE OPERATION 3.1.11 WORK MODE SELECT SWITCH ) in order, and "S" → "H" → "B" → "A" mode can be selected. Press the work mode select switch ( Select the effective work mode according to the work condition and working target from the table shown below. For the selected work mode, refer to the table shown below.
Page 120: Controls Decal
3. MACHINE OPERATION 3.1.12 CONTROLS DECAL A. Operating Pattern The operating and travel controls of this machine are factory set to ISO standard operating patterns for optimum performance of the machine and its systems. Check and make sure that operating pattern control matches the decal provided inside the right side win- dow.
Page 121 3. MACHINE OPERATION 3.1.13 MACHINE OPERATION The following instructions are aimed at providing an operator with the basic function of each hydraulic control. Use these instructions, and practice with a machine, will allow a given operator to become more efficient in the operation of this equipment.
Page 122 3. MACHINE OPERATION B.1 Forward/Reverse Travel 1. Make sure the safety lock lever is in the "UN- LOCKED" (down) position. Operate the boom, arm, and bucket control levers to raise the attachments from the ground. 2. To move the machine forward, push both (right and left) travel levers toward the front of machine.
Page 123 3. MACHINE OPERATION C. Changing Travel Speed (1st, 2nd Speed) The travel speed change (1st, 2nd speed) switch (1) on the switch panel is available to change the travel speed from/to low speed (1st speed) to/from high speed (2nd speed). 10:25 When starting engine, the switch is automatically set to low speed (1st speed).
Page 124 3. MACHINE OPERATION E. Machine Operation in Water Be careful not to immerse the slewing bearing, slewing pinion and swivel joint into the water or mud. If the ma- Water depth chine is operated in water or mud, the slewing bearing and others may be worn abnormally.
Page 125 3. MACHINE OPERATION F. Getting Out of Soft Ground AVOID INJURY Attempting to free a machine that is stuck can be hazardous. Avoid operating on soft ground. The machine operator must be careful to avoid injury to himself and others while attempting to free the machine. If possible, avoid traveling on a soft ground.
Page 126 3. MACHINE OPERATION G. Machine Attachment & Swing Controls The following instructions are to be used with hoe bucket attachment only. If other attachments are being used, con- sult the operator’s manual for the particular attachment. Read, understand and follow all safety precautions during all operations of this machine and its attach- ment(s).
Page 127 3. MACHINE OPERATION G.4 Swing Operation PUSH LEFT TO SWING LEFT PUSH LEFT TO SWING LEFT Swing operation is performed by moving the L.H. con- trol lever to the right and left. Swing speed is deter- mined by the amount the lever is moved. 1.
Page 128: Practices To Improve Efficiency
3. MACHINE OPERATION 3.1.14 PRACTICES TO IMPROVE EFFICIENCY A. Use Arm in Action Operate the bucket at shallow depths and use the arm use arm in action as much as possible in action to fill the bucket. Setting the bucket too deep will decrease the machine’s efficiency.
Page 129 3. MACHINE OPERATION E. Cleaning Sand & Soil from Bucket Operate arm to a near level position and bring the buck- et to a dumping position. If sand and soil do not fall out, move the bucket lever right and left a few times. Avoid shaking out soil using shocks at the end of the bucket cylinder stroke.
Page 130 3. MACHINE OPERATION H. Operating The Shovel Grade at 2 ~ 3 slope for drainage Digging with the shovel differs slightly from digging with backhoe. 1. Using the arm cylinder, scrape the ground. 2. Scrape the ground at 2 ~ 3° to improve draining in areas near the groundwater level.
Page 131: Flagman Hand Signals
3. MACHINE OPERATION 3.1.15 FLAGMAN HAND SIGNALS The following is a compilation of the hand signals to be used when a flagman is required for excavator operation. All personnel associated with the operation of the excavator should know these signals and their meaning before at- tempting to operate this machine.
Page 132 3. MACHINE OPERATION E. Raise Boom Face machine operator, extend right arm out horizon- tally from shoulder, make a fist with thumb up. F. Lower Boom Face machine operator, extend right arm out horizon- tally from shoulder, make a fist with thumb down. G.
Page 133 3. MACHINE OPERATION Arm In Face machine operator, bend at elbows with arms fac- ing operator, make fists and point thumbs in toward each other. J. Arm Out Face machine operator, bend at elbows with arms fac- ing operator, make fists and point thumbs out away from each other.
Page 134 3. MACHINE OPERATION M. Travel Forward Face machine operator, bend both elbows in, make fists and rotate fists one over the other in a reverse cir- cular motion. N. Travel Reverse Face machine operator, bend both elbows in, make fists and rotate fists one over the other in a forward cir- cular motion.
Page 135 3. MACHINE OPERATION Q. Turn Left Face machine operator, raise right forearm up, make fist with right hand and hold stationary, bend left arm in, make fist with left hand and rotate left fist in a small re- verse circular motion. R.
Page 136 3. MACHINE OPERATION U. Stop Face machine operator, raise left arm out horizontally from shoulder with hand open and facing down, move arm in a horizontal motion back and forth. V. Emergency Stop Face machine operator, raise both arms out horizontal- ly from shoulders with hands open and facing down, move arms in a horizontal motion back and forth.
Page 137: Parking The Machine
3. MACHINE OPERATION 3.1.16 PARKING THE MACHINE AVOID INJURY • Always park the machine on a hard level, sur- face. • When parking on a slope is unavoidable, posi- Block tion the machine as shown in the figure. Block the crawler track, dig bucket teeth into ground, lower dozer blade (if equipped) to the ground.
Page 138: Precautions After Operation
3. MACHINE OPERATION 5. Pull up safety lock lever (4) to "LOCKED" (UP) po- sition. 6. When necessary to leave from the machine, close windows, cab door and each door, and then lock it. 3.1.17 PRECAUTIONS AFTER OPERATION Check engine coolant level, engine oil pressure and fuel level for shortage through the use of multi-display.
Page 139: Machine Operation In Adverse Weather Conditions
3. MACHINE OPERATION 3.1.18 MACHINE OPERATION IN ADVERSE WEATHER CONDITIONS 1. Operation in Extreme Cold a. Follow procedures on page 3-13 as starting engine may be difficult due to extremely cold temperatures. b. Use an engine oil, hydraulic oil and diesel fuel designed for use in cold climates. See maintenance section, page 4-10 for reference.
Page 140 3. MACHINE OPERATION 4. Operation in Sandy and Dusty Areas a. Check the engine air cleaner elements frequently in sandy or dusty conditions. b. When air cleaner restriction lamp is lit, change filters immediately regardless of time intervals. c. Service fuel filter, water separator, and all hydraulic filters frequently. 5.
Page 141: Maintenance
4. MAINTENANCE...
Page 142 4. MAINTENANCE...
Page 143: General Information
4. MAINTENANCE GENERAL INFORMATION Read, understand and follow all safety precautions contained in this manual before performing any inspec- tion or maintenance procedures on this machine, it's systems or components. For the adjustment, disassembling and repair of the engine, reduction gear and electronic equipment (controller, etc.), contact the dealer/distributor.
Page 144: General Safety & Precautions
4. MAINTENANCE GENERAL SAFETY & PRECAUTIONS • Do not attempt any other inspection or maintenance procedures other than those specified in the manual. Carry them out parking the machine at a flat and conveniently situated place. • Do not attempt any MAINTENANCE with engine running. Stop the engine and allow machine to cool to avoid injury.
Page 145 4. MAINTENANCE D. STOP ENGINE Do not attempt any MAINTENANCE with engine run- ning. Always stop the engine and allow machine to cool to avoid injury. Otherwise, there is a possibility of danger that your hand may be caught in the cooling fan or fan belt result- ing injury.
Page 146 4. MAINTENANCE H. WARM ENGINE OIL Engine oil should have a temperature of between 20 to 40°C {68 to 104°F} before the oil is changed. If necessary run engine until the oil is warm within the recommended oil change temperature. PRESSURIZED SYSTEM HAZARDS Release the internal pressure before removing the hy- draulic system or fuel system, piping or coupling of the...
Page 147 4. MAINTENANCE L. CAUTION FOR OIL FILLING When a strainer is provided on the filling port, do not re- move it while refilling fuel, oil or fluid. M. DISPOSAL OF HAZARDOUS WASTE Dispose of waste oils, fluids, lubricants, filters and other hazardous waste properly.
Page 148 4. MAINTENANCE P. CAUTION WHILE CHANGING BUCKET/ATTACHMENT Do not insert your finger, hand or arm into the pin bore. The alignment must be carried out visually or by using a tool. Q. OPERATION IN DUSTY CONDITIONS When the machine is operated in dusty operating con- ditions, do the following.
Page 149 4. MAINTENANCE T. WELDING SAFETY 1. Turn starter key switch to "OFF" position. Wait 4 seconds for electrical power to disconnect. 2. Remove negative (–) cable from battery terminal. 3. Attach welder ground cable with 1 m {3’3"} away from component being welded. 4.
Page 150: Lubricant, Fuel & Coolant Specifications
4. MAINTENANCE LUBRICANT, FUEL & COOLANT SPECIFICATIONS The following chart provides information on the specification of oils, grease, fuels and coolant to be used in various climates and working conditions. Climate Zone Type of Capacities Components Specified Lubricant Lubricant (When changed) (KOBELCO BRAND) 170 Liters Long life hydraulic oil...
Page 151 4. MAINTENANCE Handling method of long life hydraulic oil When changing and replenishing hydraulic oil, make sure to use oil specified by us. The use of unspecified hydraulic oil or the use of mixed oil causes deterioration of oil resulting in shortening life of oil. The above hydraulic oil change time is 5,000 hours.
Page 152: Use Of Bio-Degradable Oils
4. MAINTENANCE USE OF BIO-DEGRADABLE OILS When using Bio-degradable Oil (BIO OIL), refer to the following information. A. Recommended Oil Maker Mobil Brand MOBIL EAL Envirosyn 46H B. Precaution for the Use of Oil 1. When filling the former machine in which mineral oil is charged with BIO oil, try to flush the machine three times. The mineral oil will be left in the circuit of the machine without flushing, resulting in the reduction of effect of bio- degradation ability.
Page 153: Maintenance Parts
4. MAINTENANCE MAINTENANCE PARTS A. Filters & Elements, and Bucket Replace parts, such as filters and elements, during the periodical maintenance or before the service life. The machine can be used economically if the parts are changed properly and timely. When you place an order of parts, confirm the parts number on parts manual.
Page 154: Torque Values For Specified
4. MAINTENANCE TORQUE VALUES FOR SPECIFIED Follow the table below and tighten or retighten every bolt and nut. Check for any loose or missing bolts or nuts before daily operation and during periodical inspections. Retighten or supply new parts for missing ones as required. Tightening Opposing Size...
Page 155 4. MAINTENANCE Tightening Opposing Size torque Recommended Q’ty flats Location N•m sealant {lbf•ft} 5/8- • Idler adjuster grease nipple mounting • 59±10 {44±7.4} 18UNF The figures in ( ) show the specification for long crawler. The counterweight attaching bolts may be loosened by hitting the counterweight against solid obstructions during swing operation.
Page 156: Torque Specifications For Bolts & Nuts
4. MAINTENANCE TORQUE SPECIFICATIONS FOR BOLTS & NUTS The following torque specifications are provided for use when actual torque value of a fastener is not known. Check the machine for loose bolts and nuts daily before starting work and at the scheduled maintenance interval. Replace missing bolts and nuts with equal specification as the original parts.
Page 157 4. MAINTENANCE 2. Metric fine thread standard tightening torque values. Tighten all bolts and nuts to proper torque values. Metric Fine Thread (Not plated) Torque value Unit : N•m {lbf•ft} Classification 4.8T 10.9T Nominal size No lubrication Oil lubrication No lubrication Oil lubrication No lubrication Oil lubrication 11.3±1.1 9.5±1.0 24.5±2.0...
Page 158: Torque Specifications For Joints & Hydraulic Hoses
4. MAINTENANCE TORQUE SPECIFICATIONS FOR JOINTS & HYDRAULIC HOSES A. Ors Joint (O-Ring Sealing Type) Wrench Size Torque Value Nominal Size Connector O-ring Nipple (mm) N•m {lbf•ft} 1–14 UNS 137±14 {101±10} Hose mouth ring and 177±18 {130±13} coupling 1–3/16–12 UN 206±21 {152±15} 1–7/16–12 UN 206±21 {152±15}...
Page 159 4. MAINTENANCE E. Split Flange Working Pressure MPa {kgf/cm Working Pressure MPa {kgf/cm 20.6 {210} 41.2 {420} Size Torque Value Torque Value Bolts Size (M) Bolts Size (M) N•m {lbf•ft} N•m {lbf•ft} 3 / 4 33.9±5.6 {25±4.1} 39.5±5.6 {29±4.1} 42.4±5.6 {31±4.1} 62.2±5.6 {46±4.1} 1 –...
Page 160: Inspection & Maintenance Chart
4. MAINTENANCE INSPECTION & MAINTENANCE CHART Follow the chart below for recommended intervals of regular inspection and maintenance procedures. Perform in- spection and maintenance according to the calendar time or operation time shown by the hour meter, whichever comes first. See the inspection and maintenance procedure mentioned below for details.
Page 161 4. MAINTENANCE Lubricant, When Interval (Hours on Hourmeter) etc. REF. Maintenance to Perform (Replacing page # quired 50H 120H 250H 500H 1,000H 2,000H 5,000H part) Checking of engine mount bracket 4-58 for tightening *2 Checking and adjustment of — valve clearance (First) *2 Checking and adjustment of —...
Page 162 4. MAINTENANCE Lubricant, When Interval (Hours on Hourmeter) etc. REF. Maintenance to Perform (Replacing page # 50H 120H 250H 500H quired 1,000H 2,000H 5,000H part) Check/fuel level Drain water and de- 4-35 Fuel tank posits Clean cap and strain- 4-53 Check oil level Hydrau-...
Page 163 4. MAINTENANCE Lubricant, When Interval (Hours on Hourmeter) etc. REF. Maintenance to Perform (Replacing page # quired 50H 120H 250H 500H 1,000H 2,000H 5,000H part) Check idler wear Check roller wear Check track tension Grease for pins 4-31 EP grease Grease bucket pins 4-31 Replacement of backhoe bucket...
Page 164: When Required
4. MAINTENANCE 4.10 WHEN REQUIRED Thoroughly read and understand the Section 1 "SAFETY PRECAUTIONS" of this MANUAL before operating or servicing the machine. A. Radiator and Oil Cooler Debris Screen Hot fluids and surfaces can burn. Wear goggles, safety shoes, hard hat, work clothes, and work gloves to perform inspection and maintenance on this machine.
Page 165 4. MAINTENANCE B. Cleaning or Replacement of Radiator Cap To avoid being burned, be careful when removing the radiator cap. Coolant is under high pressure when hot. • Do not remove the radiator cap when the system is hot. • Allow enough time for the machine to cool down before removing the radiator cap.
Page 166 4. MAINTENANCE D. Wind Washer Fluid Reservoir The use of wiper without washer fluid discharged may cause damage to the motor equipped with the washer fluid reservoir. Washer fluid reservoir (1) is located back of cab and is positioned in left side door of machine. 1.
Page 167 4. MAINTENANCE E.2 Installing Bucket 1. Clean each pin and pin hole and grease sufficiently. 2. Move the bucket cylinder to match the pin bores or the bucket (6) and bucket link (8) with each other, then insert the pin (4). 3.
Page 168 4. MAINTENANCE F.1 Replacing the Tooth Points Short Damaged Rubber Good Wear, goggles, safety shoes, hard hat, work clothes Good and work gloves to perform inspection and mainte- The ball push in nance on this machine. if it is pressed by hand Alight the bottom Replace the bucket tooth in the following cases.
Page 169 4. MAINTENANCE G. Reversing Backhoe Bucket The backhoe bucket which is reversed 180° is available for shoveling work. When working in team, follow the signals exactly and pay particular attention to the safety. 1. Move the machine to a firm level surface and place the bucket on the ground, making certain that the bucket is stable.
Page 170 4. MAINTENANCE H. Adjusting Bucket Mount Gap • Unexpected movement of attachment, while adjust- ing the bucket mounting gap is quite dangerous. Place the bucket on the ground in a stable condition, and set the safety lock lever to "LOCKED" position, then stop the engine.
Page 171: Pre-Start (Every 8 Hours) Inspection & Maintenance
4. MAINTENANCE 4.11 PRE-START (EVERY 8 HOURS) INSPECTION & MAINTENANCE Thoroughly read and understand the "1.SAFETY PRECAUTIONS" of this MANUAL before operating or servicing the machine. The following inspection and maintenance shall be carried out before starting/after starting and after work.
Page 172 4. MAINTENANCE 2. Boom foot pin (2), (3). 3. Boom cylinder rod pins (4), (5). 4. Arm cylinder head pin (6). 5. Boom foot (Center) pin (7). 6. Arm cylinder rod pin (8). 7. Arm to boom pin (9). 8. Bucket cylinder head pin (10). 9.
Page 173 4. MAINTENANCE B. Batteries • Wear hard hat, approved safety glasses or face shield, gloves and other safety equipment when working with batteries. • Flammable gas (hydrogen gas) is generated in the battery. Do not allow sparks or flames to come in contact with batteries to avoid triggering an explosion.
Page 174 4. MAINTENANCE • Clean battery terminal and apply grease or commer- cial lube oil rust preventive spray. • Call in licensed specialty company for the disposal of used battery. • Be careful not to use the old battery together with new battery.
Page 175 4. MAINTENANCE C. Fuel Tank Drain Loosen the drain valve (1) to drain the water and de- posits in an empty container. Since the water is deposited during the night, it is effec- tive to drain before starting up the engine in the morn- ing.
Page 176 4. MAINTENANCE D. Track Tension 1. Operate swing, arm, bucket and boom controls until machine is set up as shown in. Support lower frame with suitable blocks. 2. In center of track, measure the distance between the bottom of frame rails and surface of shoe. Slack 320~350 mm Proper Tension (A)
Page 177: Hour Inspection & Maintenance Procedure
4. MAINTENANCE 4.13 120 HOUR INSPECTION & MAINTENANCE PROCEDURE Thoroughly read and understand the "1.SAFETY PRECAUTIONS" of this MANUAL before operating or servicing the machine. Perform together with daily and 50-hour inspection and maintenance. A. Swing Motor Reduction Oil Never change oils on a machine that has just fin- ished working.
Page 178 4. MAINTENANCE B. Travel Reduction Unit Oil • Travel reduction unit could be under pressure. Carefully loosen plug and remove slowly filled air pressure. Where the plug was loosened abruptly, there is the danger of spouting out of plug and oil. Do not face the plug to prevent from flying plug etc.
Page 179 4. MAINTENANCE C. Checking for Intake Rubber Hose • Don't touch the rubber hose to avoid burns. Immediately after stopping the machine or dur- ing the operation, the temperature of the rubber hose is very high. • When the rubber hose is replaced, fill the inlet of air intake with clean cloth to prevent the dust from entering.
Page 180: Hour (3-Month) Inspection & Maintenance Procedure
4. MAINTENANCE 4.14 250 HOUR (3-MONTH) INSPECTION & MAINTENANCE PROCEDURE Thoroughly read and understand the "1.SAFETY PRECAUTIONS" of this MANUAL before operating or servicing the machine. Perform together with daily, 50-hour and 120-hour inspection and maintenance. A. REPLACING ENGINE OIL AND ENGINE OIL FILTER Wear the proper safety equipment when working around hot areas.
Page 181 4. MAINTENANCE 5. Remove oil filter (3) with filter wrench and replace it with new one. Filter wrench parts No. : 2421R171 In this machine, the engine oil filter is located at the separate position from engine. And the engine oil filter is placed on the inside of door on the machine right rear side.
Page 182 4. MAINTENANCE B. Fan, Alternator, A/C Belt Wear and Tension Rotating parts can cause injury. Keep away from fan and belt when engine is running. Stop engine before servicing. This machine is equipped with belts for alternator, fan and air-con. Check these belts for wear and damage and check the belt tension for slack, and adjust it properly in order to maintain the engine in high performance and the spec-...
Page 183 4. MAINTENANCE C. Adjustment for Alternator and Fan Belt Be careful of the alternator and fan belts so that grease and oil are not adhered. The service life may be short- ened due to slipping with oil. 1. Release bonnet catch, open engine hood and sup- port it with stay.
Page 184 4. MAINTENANCE E. Checking the Radiator Hoses The hose replacement before trouble occurs provides economical and good maintenance. The hose replacement before the hose is damaged will result in cutting costs and minimize the unexpected in- terruption of work. Replace the hose (2) and clamp (1) immediately if the crack, permanent set in fatigue and water leakage is found.
Page 185 4. MAINTENANCE E.2 Replacing the Radiator Hoses Avoid being burned by hot liquid and steam. Do not loosen the radiator cap when the coolant is hot. The cooling system is under pressure. Stop the engine and allow enough time for system to cool. 1.
Page 186 4. MAINTENANCE F. Air-Conditioner Filters Service The flying debris due to compressed air may cause accident resulting in injury or death. Wear safety goggles and respirator when cleaning the filters of air-conditioner. Cleaning recirculate and fresh air filters Recirculate air filter : Every 500 hours Fresh air filter : Every 250 hours Replacing inside and outside air filters Recirculation air filter : After cleaning about 10 times...
Page 187 4. MAINTENANCE G. Air Cleaner Maintenance • Direct contact of the body with compressed air, steam and high pressure water can cause injury. Wear protective glasses, mask, safety cap, safety shoes, etc., to avoid injury. • Stop engine first and clean and replace the air clean- er element.
Page 188 4. MAINTENANCE 5. After cleaning, check on element (1) and if pin hole and excessively thinned part were found, replace it with new one. O-ring (4) is attached around the rim of cover, do not lose this O-ring. The water intrusion due to loss of O-ring (4) may cause failure of engine.
Page 189: Hour Inspection & Maintenance Procedures
4. MAINTENANCE 4.15 500 HOUR INSPECTION & MAINTENANCE PROCEDURES Thoroughly read and understand the "1.SAFETY PRECAUTIONS" of this MANUAL before operating or servicing the machine. Perform together with daily, 50-hour 120-hour and 250-hour inspection and maintenance. A. Replacing Fuel Filter The fuel filter is placed on the area where the inside of door on the machine right rear.
Page 190 4. MAINTENANCE 8. Fit bowl (4) to new element (3) by hand securely. 9. Apply light oil thinly to new O-ring (6) and set it to sealing face on element upper surface. 10. Attach element (3) with bowl (4) to filter body (7) by hand securely and tighten it with filter wrench (Parts number: 2421R171).
Page 191 4. MAINTENANCE B. Replacing Pre-Filter The pre-filter is placed on the area where the inside of door on the machine right rear. 1. Prepare container for drain oil. 2. Close fuel cut valve placed on the halfway of fuel fil- ter line.
Page 192 4. MAINTENANCE C. Bleeding Air from the Fuel System After replacing the fuel filter or if you have run out of fu- el, air might have entered the fuel system and a simple supply of fuel cannot start the engine. Bleed the air ac- cording to the following procedure: •...
Page 193 4. MAINTENANCE D. Cleaning Fuel Tank Cap and Strainer 1. Remove cap with starter key. 2. Check cap seal for damage, and if damaged re- place it with new one. 3. Clean strainer with light oil and attach it in place. If damaged, replace it with new one.
Page 194 4. MAINTENANCE F. Checking Slewing Ring Fitting Bolts for Loosening Check that bolts (1), (2) securing slewing ring are not loosened. If loosened, remove bolts (1), (2) once, apply Loctite #262 or equivalent, and tighten them again. Torque specification N . m {lbf . ft} Location Inner race 56 {416...
Page 195 4. MAINTENANCE H. Checking the Air-Conditioner Refrigerant Sight Sight • Do not loosen parts in the refrigerant circuit be- Glass Glass cause there is a hazard of losing sight by getting coolant in eyes and being frostbitten hands by touching it. •...
Page 196 4. MAINTENANCE • Keep the air conditioner ready for use all year round. Operate the air conditioner at least once every week for several minutes to rotate the compressor regard- less of the season. This will prevent the refrigerant gas from leaking from the compressor sealing. •...
Page 197: 1000 Hour (12-Month) Inspection & Maintenance Procedures
4. MAINTENANCE 4.16 1000 HOUR (12-MONTH) INSPECTION & MAINTENANCE PROCE- DURES Thoroughly read and understand the "1.SAFETY PRECAUTIONS" of this MANUAL before operating or servicing the machine. Perform together with daily, 50-hour 120-hour, 250-hour and 500-hour inspection and maintenance. A. Replacing Return Filters The return filter needs delicate treatment because they role important part for removal of contaminant in hy- draulic oil to and preventing trouble of hydraulic compo-...
Page 198 4. MAINTENANCE 9. Replace element, and assemble element assy (A) disassembled in procedure "6." again. 10. Attach element by the reverse procedure of that shown in items "3." and "4.". 11. Attach cover (3) with bolts (2). Tightening torque: 46.1±4.9 N•m (34±3.6 lbf•ft) 12.
Page 199 4. MAINTENANCE C. Checking Voltage • Wear hard hat, approved safety glasses or face shield, gloves and other safety equipment when working with batteries. • Flammable gas (hydrogen gas) is generated in the battery. Do not allow sparks or flames to come in contact with batteries to avoid triggering an explosion.
Page 200: 2000 Hour Inspection & Maintenance Procedures
4. MAINTENANCE 4.17 2000 HOUR INSPECTION & MAINTENANCE PROCEDURES Thoroughly read and understand the "1.SAFETY PRECAUTIONS" of this MANUAL before operating or servicing the machine. Perform together with daily, 50-hour 120-hour, 250-hour, 500-hour and 1000-hour inspection and maintenance. A. Changing Engine Coolant Avoid being burned by hot liquid and steam.
Page 201 4. MAINTENANCE 4. Remove undercover under the radiator, and pre- pare container for coolant under drain valve (2) and drain plug (3) on the engine side face. 5. After draining, close drain valve (2) and drain plug (3) and fill it with clean soft water. 6.
Page 202 4. MAINTENANCE B. Changing Oil in Swing Reduction Unit • Immediately after operation, there is a hazard of getting burn because oil is hot. Start working af- ter being cooled. • Swing reduction unit could be under pressure, carefully loosen plug and remove slowly till air pressure is released.
Page 203 4. MAINTENANCE C. Change Oil in Travel Motor Reduction Units • Immediately after operation, there is a hazard of getting burn because oil is hot. Start working after being cooled. • Travel reduction unit could be under pressure, carefully loosen plug and remove slowly till air pressure is released.
Page 204 4. MAINTENANCE D. Cleaning Suction Strainer • Use extreme caution when removing the cover. The oil is under high pressure when hot. Stop en- gine first, remove breather cap, press valve, re- lease the pressure from tank, and then remove cover.
Page 205 4. MAINTENANCE E. Swing Reduction Lubrication Immediately after operation, there is a hazard of getting burn because oil is hot. Start working after being cooled. 1. Park machine on firm level ground, and place the attachment to the ground. Stop engine and move safety lock lever to "LOCKED"...
Page 206 4. MAINTENANCE G. Cleaning of Pilot Line Filter Immediately after operation, there is a hazard of getting burn due to hot hydraulic oil gushed. Clean the filter af- ter being cooled. Carry out the replacement of filter after completely re- leasing internal pressure from hydraulic system.
Page 207: 5000 Hour Inspection & Maintenance Procedures
4. MAINTENANCE 4.18 5000 HOUR INSPECTION & MAINTENANCE PROCEDURES Thoroughly read and understand the "1.SAFETY PRECAUTIONS" of this MANUAL before operating or servicing the machine. Perform together with daily, 50-hour 120-hour, 250-hour, 500-hour and 1000-hour inspection and maintenance. A. Change Hydraulic Oil •...
Page 208 4. MAINTENANCE 7. Drain the hydraulic oil into container using oil pump. Dispose of all hazardous waste in accordance with gov- ernment environmental regulations. 8. Place container for drain oil under drain plug (1) of the hydraulic tank bottom. 9. Loosen drain plug (1) on the bottom of hydraulic tank slowly and drain hydraulic oil completely.
Page 209: Transportation
5. TRANSPORTATION...
Page 210 5. TRANSPORTATION...
Page 211: Ground Transportation
5. TRANSPORTATION GROUND TRANSPORTATION 5.1.1 MACHINE PREPARATION 1. Know the total weight, length, width and height of the machine being transported. 2. Know route to be traveled. Investigate bridges, overpasses, height of road signs on route. 3. Obtain any permits required from proper government agencies for machine transportation. 4.
Page 212: Loading/Unloading The Machine
5. TRANSPORTATION 5.1.2 LOADING/UNLOADING THE MACHINE • The machine loading and unloading work should be carried out on the firm and level ground. • Use ramps which have sufficient width, length, thickness and strength. • Slow speed traveling is necessity to load and un- load the machine.
Page 213 5. TRANSPORTATION 5. Since machine is tend to be unstable when going over the rear wheel, travel slowly and carefully. 6. Since the machine is bent-forward when traveling over the rear wheel, travel forward slowly to the re- quired position giving particular attention to the at- tachment so as not to touch the bed of trailer.
Page 214 5. TRANSPORTATION B. Use of Platform or Earth Banking 1. Make the width of the earth banking (raising the ground level) enough to the machine width. 2. Make the earth banking strong enough in order no to turn over the machine during loading/unloading due to broken side slope of the earth banking.
Page 215: Securing The Machine
5. TRANSPORTATION 5.1.3 SECURING THE MACHINE • Retract the antenna of radio during transport. And re- move mirror when required. Keep the removed parts surely. • To protect the bucket (attachment) cylinder from damage during transport, place a wood block at the end of the bucket link to keep the cylinder from con- tact with the truck bed.
Page 216 5. TRANSPORTATION A. Unloading the Machine AVOID INJURY OR DEATH • Slow speed traveling is necessity to load and un- load the machine. • Be prepared for a change in the machine position as the machine travels up or down the ramp. The machine may rock forward or rearward as the machine center of gravity changes when travel- ing on the ramp or on the border between the...
Page 217: Lifting Machine
5. TRANSPORTATION LIFTING MACHINE The following procedures are for lifting the machine, as built by NEW HOLLAND. These procedure do not take into account modifications made to the machine that affect machine weight or center or gravity. Expander Center of Grabitiy...
Page 218: Installing And Removing Mirror
5. TRANSPORTATION INSTALLING AND REMOVING MIRROR The mirror is attached on the position shown in the fig- ure. Remove and attach mirror when transporting machine by the following procedure. The machine is shipped with both right deck mirror and cab mirror removed. Adjust mirrors according to instruction in the section "ADJUSTING MIRROR"...
Page 219: Specifications
6. SPECIFICATIONS...
Page 220 6. SPECIFICATIONS...
Page 221: General Specifications
6. SPECIFICATIONS GENERAL SPECIFICATIONS Item Unit E265B E265BLC Working Weight 24,400 24,900 Bucket Heaped (cu•yd) 1.0 (1.31) 1.0 (1.31) HINO MOTORS J05E-TB Engine Maker – Water-cooled, 4 cycle 4 cylinder direct injection type diesel en- gine with intercooler turbo-charger Engine Output-Rating kW/min 131 / 2,100 131 / 2,100...
Page 222: Shoe Types
6. SPECIFICATIONS SHOE TYPES A. E265B Grouser Shoes Type 600 mm (23.6") 700 mm (27.6") 800 mm (31.5") For General Soil For Soft Soil For Soft Soil (Optional) (Optional) (Standard) Working Weight (kg) 24,400 24,700 24,900 Height to Top Cab (mm) 3,060 3,060...
Page 223: Working Ranges
6. SPECIFICATIONS WORKING RANGES A. Backhoe Attachment Unit : mm Attachment 2.5 m (8’-2") Arm 2.98 m (9’-9") Arm 3.66 m (12’-0") Arm + 1.2 m (1.57 cu•yd) Bucket + 1.0 m (1.31 cu•yd) Bucket + 0.81 m (1.06 cu•yd) Bucket Item A Maximum digging reach 9,890...
Page 224 6. SPECIFICATIONS B. Face Shovel Attachment Unit : mm Attachment 2.5 m (8’-2") Arm 2.98 m (9’-9") Arm 3.66 m (12’-0") Arm Item + 1.2 m (1.57 cu•yd) Bucket + 1.0 m (1.31 cu•yd) Bucket + 0.81 m (1.06 cu•yd) Bucket A Maximum digging reach 10,040 10,460...
Page 225: Bucket And Arm Combinations
NEW HOLLAND's warranty does not cover any damages resulting from theses combinations. Do not use these combinations. Install only genuine attachment recommended by NEW HOLLAND on the machine. NEW HOLLAND is not liable for any damages to the machine or attachment arising from the installment of attachment other than the specified at-...
Page 226 6. SPECIFICATIONS...
Page 227: Optional Equipment
7. OPTIONAL EQUIPMENT...
Page 228 7. OPTIONAL EQUIPMENT...
Page 229: Operation Of Hydraulic Breaker And Nibbler
7. OPTIONAL EQUIPMENT OPERATION OF HYDRAULIC BREAKER AND NIBBLER 7.1.1 SELECTION OF HYDRAULIC BREAKER AND NIBBLER When installing a hydraulic breaker or nibbler to the machine, select the optimal breaker or nibbler taking the matters into consideration such as stability, hydraulic system pressure, required hydraulic oil volume. 7.1.2 BEFORE OPERATING BREAKER OR NIBBLER •...
Page 230: Work Mode Selection And Selector Valve
7. OPTIONAL EQUIPMENT 7.1.4 WORK MODE SELECTION AND SELECTOR VALVE A. Work Mode Selection The work mode in use should be switched according to each attachment in use. 10:25 • When operating machine with hydraulic breaker or nibbler attached, check that the work mode selected is proper through multi display.
Page 231 7. OPTIONAL EQUIPMENT Work mode and hydraulic circuit Set pressure of overload re- Attachment Work mode Hydraulic circuit lief valve ATT of single flow circuit like Return circuit does not pass When shipping: 24.5 MPa B mode breaker through control valve automatically. (3550 psi) ATT of conflux circuit like nib- Return circuit pass through control...
Page 232: Setting Stop Valve
7. OPTIONAL EQUIPMENT 7.1.5 SETTING STOP VALVE Stop valve (1) on arm top end is used to stop hydraulic oil flowing. Free : Hydraulic oil flows Stop : Hydraulic oil stops flowing Before removing attachment, set stop valve to "STOP" position.
Page 233: Basic Operation
7. OPTIONAL EQUIPMENT 7.1.7 BASIC OPERATION This machine is provided with breaker or nibbler single circuit and nibbler and breaker conflux flow circuit. To use breaker or nibbler, select circuit appropriate to the specification through switch (1) on the rear side of driver’s seat.
Page 234 7. OPTIONAL EQUIPMENT B. Operating Pedal Release pedal lock on the right front side of driver’s seat to operate pedal. ATTACHMENT OPERATION BY FOOT PEDAL Always check the foot pedal control pattern before op- eration. Always read operator’s manual before operating ma- chine.
Page 235: Prohibited Work In Use Of Breaker
7. OPTIONAL EQUIPMENT 7.1.8 PROHIBITED WORK IN USE OF BREAKER The following safety precautions should be used in conjunction with all other safety precautions found in this MAN- UAL. Read, understand and follow all safety precautions and operating procedures found in this manual before operating the machine or any attachment.
Page 236 7. OPTIONAL EQUIPMENT D Cylinders Do not operate boom, arm or bucket cylinders at stroke ends when using a breaker attachment. Doing this can cause undue load on the cylinder rods and result in damage. E Use for Intended Purpose Use the attachment only for its intended purpose.
Page 237 7. OPTIONAL EQUIPMENT H Do Not Use Dropping Force Do not use the dropping force of the attachment to break or drive objects. This will cause extensive damage to the attachment and machine structure. Do Not Lift Do not use an optional attachment to lift or transport objects or material.
Page 238: Periodic Inspection And Maintenance Interval
7. OPTIONAL EQUIPMENT Do Not Hit Chisel Against Boom To avoid interference of chisel with boom, operate control lever of arm and boom carefully. M Precaution When Lifting Up Machine Press the ground by attachment Unnecessary machine lifting up is not allowed. It may cause damage of attachment.
Page 239: Prohibited Work In Use Of Nibbler
7. OPTIONAL EQUIPMENT 7.1.11 PROHIBITED WORK IN USE OF NIBBLER The wrong nibbler operating method may cause damage of attachment and excavator or result in dangerous work condition. To prevent these trouble, learn correct and safety operating method. The precaution during operation is explained here with operative examples including similar behavior to prevent trouble.
Page 240 7. OPTIONAL EQUIPMENT E. Do Not Travel while Nibbler is Holding Object Do not pull building and structure by the use of trav- eling force while nibbler is holding the top side of object. F. Attention to the Falling Debris Take position to prevent from debris.
Page 241: Precaution To Be Exercised On Breakers Of Different Manufac- Tures7
7. OPTIONAL EQUIPMENT 7.1.12 PRECAUTION TO BE EXERCISED ON BREAKERS OF DIFFERENT MANUFACTURES There are some differences between manufactures as to the piping to breakers and the handling of breakers. For this reason, consult with the manufacturer when mounting a breakers in the field. The following is a summary of how breakers should be handled that is extracted from manufacture's catalog use and operation manuals.
Page 242 7. OPTIONAL EQUIPMENT Low pressure : Measure the inlet pressure of the line side filter on the breaker side by actuating the breaker at full engine revolution in the H mode, and in case the maxi- mum pressure exceeds 5.4 MPa {55 kgf/cm } (780 psi), install a low pres- sure accumulator.

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