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DIGGERKING KING 3.5 TON Operating Manual

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Summary of Contents for DIGGERKING KING 3.5 TON

  • Page 2 Thank you for your purchase of your new Digger King 3.5 ton Excavator! Our products are compact in design, with matching power, good product stability, and high performance. Digger King excavators can meet the digging and unloading requirements under different working conditions such as plains, hills, and forests.
  • Page 3 If the product does not match the pictures in this manual, the product shall prevail. Warning! This machine must not be used for the following purposes: - Lifting operations; - Lifting operations (if used for lifting operations, additional protection should be installed). - Disassembly (if used as a disassembly machine, protective devices must be installed);...

  • Page 4: Table Of Contents

    Table of contents Chapter 1 Safety Precautions And Safety Signs ................. 5 Chapter 2 Preparation Before Work ....................20 Chapter 3 Safe Operation Of The Machine ..................25 Chapter 4 Basic Parameters Of Excavators ..................41 Chapter 5 Common Faults And Solutions ..................50 Chapter 6 Maintenance And Care ....................

  • Page 5: Chapter 1 Safety Precautions And Safety Signs

    Chapter 1 Safety Precautions And Safety Signs 1.1 Safety Precautions General precautions You must comply with the safety regulations and laws of the relevant departments and operate, inspect, and maintain the machine in accordance with the manufacturer's requirements. 1.2 Safety Identification Tips Use the following warning and safety signs.
  • Page 6 △ This mark is the operation lock mechanism. After operating the machine, lower the operation lock lever to prevent the driver from operating it by mistake. (3) Direction (4) Inspection qualification mark (5) It is strictly forbidden to stand within the operating range. △...
  • Page 7 (9) Fuel filling port △ Refuel at designated locations. △ When refueling, the engine should be turned off and all open flames should be kept away. (10) No one is allowed to stand under the working device △ It is strictly forbidden to stand in the working area of the machine. △...
  • Page 8 (12) Note that the machine operating noise is 93dB △ Warning: Under certain specific operating conditions of the machine, the actual noise value may be different from the value determined using the noise test code. The measured A-weight transmitted sound power is 92 dB(A). The guaranteed sound power is 93 dB(A).
  • Page 9 (15) Excavator excavation parameters (16) Bulldozer operation (17) Wear ear protection when operating an excavator △ With ear protection warning (18) Schematic diagram of excavator operation...

  • Page 10: Safety Information

    △ Perform basic operations of the excavator according to the above diagram. Operate the excavator strictly according to the markings. 1. 4 Nameplate Nameplate location Nameplate 1. 5 Safety Information Safety Rules Only trained and instructed personnel may operate and maintain the machine. All safety rules, precautions, and instructions should be followed when operating or maintaining the machine.
  • Page 11 Exception handling If any abnormality is found (sound, vibration, odor, incorrect instrument display, smoke, oil leakage, etc., or abnormal alarm device or monitor display), it should be reported to the supervisor immediately and necessary measures should be taken. Do not operate the machine until the fault is corrected.
  • Page 12 Keep the machine clean 1. If water enters the electrical system, there is a risk of malfunction or failure. Do not flush the electrical system (sensors, connectors) with water or steam. 2. If the machine being inspected or maintained is contaminated with mud or oil, there is a risk of slipping and falling or a risk of dirt getting into the eyes.
  • Page 13 2. To ensure safety, face the machine and support yourself by maintaining three points (two feet, one hand, or two hands and one foot) of contact with the handrails and steps (including the track plate). 3. Do not hold the joysticks when getting on or off the machine. 4.
  • Page 14 Coolant To prevent heat injuries from hot water or steam jets when checking or draining the coolant, wait until the water cools down, use the radiator cap to test you can safely touch at a comfortable temperature before starting the operation. Even if the coolant has cooled, loosen the radiator cap slowly to release the internal pressure of the radiator before removing it.
  • Page 15 Fire and explosion-proof Fires caused by fuel or oil Fuel, motor oil, antifreeze, and window cleaner are extremely flammable and dangerous. To prevent fires, the following must be observed: 1. Do not smoke or use an open flame near fuel or oil. 2.
  • Page 16 2. Check the wires for looseness or damage daily. Tighten loose connectors or wire clamps, and repair or replace damaged wires. Preventing fire caused by hydraulic lines Check that all hoses and clamps, guards, and bumpers are securely in place. If it is loose, it will vibrate and rub against other parts during operation, causing damage to the hose and high-pressure oil spray, creating a fire hazard or serious injury.
  • Page 17 Digger King is not responsible for any injuries, accidents, or product failures caused by the use of unapproved attachments or parts. When installing and using selected accessories, please read the accessory instruction manual and the general instructions about the accessories in this manual. Combination of accessories Depending on the type or combination of working devices, there is a risk that the working device may hit the cab or other parts of the machine.
  • Page 18 Working on soft ground 1. Avoid walking or operating the machine near cliff edges, embankments, and deep canals. In these areas, the ground is soft and there is a risk of falling or tipping over if the ground gives way under the weight or vibration of the machine.
  • Page 19 location and all personnel should use approved dust masks. 3. During operation, other personnel are not allowed to approach. 4. Comply with job site regulations and environmental standards. Signalman's signals and gestures 1. Set up signs on the embankment or soft ground. If visibility is poor, arrange signalmen if necessary.

  • Page 20: Chapter 2 Preparation Before Work

    Chapter 2 Preparation Before Work Before operation, you should fully understand the vehicle's condition and operating area to ensure safety. 2.1 Fuel quantity check Fuel quantity inspection Before operation, the fuel capacity of the vehicle should be checked. When the fuel is insufficient, the fuel should be replenished in time to avoid the exhaustion of fuel and the air entering the machine, and the machine may not be able to ignite after refueling.
  • Page 21 is too low or the machine is tilted, the oil pump will not be able to suck oil and the vehicle will not move (the movement will be stagnant, the oil pump and hydraulic pump will be severely worn or even damaged).

  • Page 22: Oil Leakage Inspection

    the hydraulic system rises. Oil and oil level check Check the engine oil before the operation to see if it is sufficient (because the machine may work in various situations such as climbing, descending, and tilting, the oil should be close to the dipstick limit to prevent the pump from draining oil).
  • Page 23 2.7 Check the operating area 1. Check terrain and ground conditions in the area of operation. 2. Check the building structure and take safety measures if necessary. 3. Avoid walking in places such as ditches, underground pipes, trees, cliffs and shelves. 4.

  • Page 24: Daily Inspection And Maintenance

    2.9 Always keep the machine clean 1. Wipe off oil, grease, dirt, snow, or ice to prevent accidents. 2. Clear all loose objects and unnecessary equipment from the machine. 3. Remove dust, oil, or grease from engine parts to prevent them from catching fire. 4.

  • Page 25: Chapter 3 Safe Operation Of The Machine

    Chapter 3 Safe Operation Of The Machine 3.1 Starting the engine If there is a warning sign on the joystick, do not start the engine or touch the joystick. NOTE: Personnel must receive the necessary training, be familiar with potential hazards, and have the skills to solve problems.

  • Page 26: Operation

    cylinder to get stuck or an internal short circuit, damaging the starter motor. Therefore, avoid leaving the key out in the rain or in humid or dusty environments. If you need to leave the key, you must take protective measures and store in a cool dry place. Special attention: If the diesel engine still cannot start after 10 seconds, please wait for 15 seconds before starting it (starting the power supply continuously for a long time will cause a large amount of battery power consumption and the starter may burn out).

  • Page 27: Workstation Setup

    Always wear your seat belt. Check that the machine motion is consistent with that shown on the control mode card. If not, use the correct control immediately. Check the operation of instruments and equipment, and check the operation of the bucket, dipper arm, boom, traveling system, swing system, and steering system.
  • Page 28 by leaning forward or backward to adjust the desired sitting position. The backrest should be adjusted in such a way that the joystick can be safely operated with the operator's back fully resting on the backrest. Note: The maximum RMS value of whole-body vibration is 0.5 m/s2. The uncertainty of whole-body vibration measurement is 0.1 m/s2.
  • Page 29 3.7 Other equipment on the driver's seat The cab is described below. Command Box The command box is located directly in front of the console. Gauge adjustment button If the excavator is equipped with a track gauge adjustment device, the excavator's crawler track telescopic range is 990 mm ~ 1300 mm.
  • Page 30 Put away the bucket Open bucket Left joystick Lower the stick Raise the arm Rotate the cab left Rotate the cab right Boom Operation When the excavator encounters an overload condition, always lower the boom until the load reaches the ground. To raise the boom, pull back using the right joystick. To lower the main boom, push forward using the right joystick.
  • Page 31 Take note while lowering to ensure that there are no personnel or cargo under the boom. Stick Operation To raise the stick, push the left joystick forward; to retract the stick, pull the left joystick backward. The joystick moves as shown. To raise the bucket, use the right joystick to pull to the left.
  • Page 32 state. 2. Remove the fixing screws around the cab. 3. Operate the equipment and slowly raise the cab. 4. Move the cab to the left /right and slowly place it to complete the disassembly work. Installation Steps 1. Secure the ropes to the lashing points on top of the cab. 2.
  • Page 33 7. When the machine is running or rotating, be especially careful not to hit other machines or people. 8. Even if the machine is equipped with a rearview mirror, the above precautions must be followed. 3.11 Travel safety precautions 1. When walking on level ground, the working device should be 40~50cm (16~20 inches) off the ground.
  • Page 34 3.12 Walking on a slope To prevent the machine from tipping over or sliding, follow these requirements. When walking on a slope, keep the working device 20 to 30 cm (8 to 12 inches) off the ground. In an emergency, the working device can be quickly lowered to the ground to stop the machine from working.

  • Page 35: Operating On A Slope

    If the engine stalls while the machine is traveling on a slope, immediately move the joystick to the "neutral" position to restart the engine. 3.13 Operating on a slope When working on a slope, the machine will lose balance and tip over when operating the rotating or working device.
  • Page 36 3. When digging, adjust the crawler tracks to a right angle with the shoulder or cliff. The sprocket is at the rear, making it easy to withdraw the machine in any situation. 4. Do not perform disassembly operations under the machine as this will make the machine unstable and there is a risk of it tipping over.
  • Page 37 truck, causing serious injury or damage. 3.15 Snow Day Operation 1. Snow-covered or icy roads are slippery. When walking or operating the machine, be especially careful not to operate the joystick suddenly. Even a small slope can cause the machine to slip, so be especially careful when working on a slope.
  • Page 38 1. Only install and unload on hard, level ground. Keep a safe distance from roadsides or cliff edges. 2. Do not install or uninstall the machine together with working equipment. There is a risk of the machine falling or tipping over. 3.
  • Page 39 to support the weight of the machine. When traveling on a highway, the relevant management agency should first check and follow its instructions. Machine Recovery: If the excavator is trapped, use a crane to lift the entire excavator for recovery, following the lifting procedures and taking care to use the correct lifting points.

  • Page 41: Chapter 4 Basic Parameters Of Excavators

    Chapter 4 Basic Parameters Of Excavators 4.1 Basic parameters Serial Name Main Tooth Side Teeth Bucket Link Joystick Bucket Cylinder Stick Stick Cylinder Boom Boom Cylinder Bulldozer Drive Sprocket Track Roller Sprocket Travel Motor Rubber Tracks Upper Plate Counterweight Shield Seats Side Swing Cylinder Air Conditioner Indoor Unit...
  • Page 42 4.2 Hinge pins for machine working devices Machine pin position indicator (King 3.5 ton) Serial Pin Connection Bucket and connecting rod connecting pin Connecting pin between rocker and arm Connecting pins between rocker, connecting rod and bucket cylinder Bucket cylinder and bucket arm connecting pin...
  • Page 43 4.3 Main dimensions and specifications Main digging range direction of the excavator King 3.5 ton : mm Unit Working scope King 3.5 ton Maximum ground excavation height 4295 Maximum unloading height 2932 Maximum digging depth 2927 Maximum range of ground activities...
  • Page 44 Maximum sinking height of bucket teeth Overall height 2357 Overall width 1350 Height of vehicle body Width of push shovel 1300 Track width 4.4 Hydraulic schematic diagram and detailed information As an important part of hydraulic system design, the hydraulic schematic diagram clearly shows the working principle, structure, and control method of the hydraulic system.
  • Page 46 4.5 Electrical schematics and details Electrical Schematic As an important part of circuit design, electrical schematics are used to clearly show the working principle, structure, and control method of the circuit. Based on electrical schematics, we can have a comprehensive understanding of the electrical layout of the machine and can also be used to troubleshoot electrical problems.
  • Page 48 4.6 Excavator parameter table Model information configuration status King 3.5 ton ● Standard 〇 Optional Kubota Machine working Engine Model 2578.5 V1505 weight (kg) Maximum Bucket capacity 0.08 (m³) horsepower(hp) Walking speed 0-1.5 Maximum power (Kw) 18.5 low/high (km/h) Climbing ability...
  • Page 49 (bandwidth*pitch*num Tension form Grease tightening ber of sections) ● air conditioner ０ -Steel Piston pump / 230 * 90 * (bandwidth*pitch*num Main pump TFA10VS028DFLR ber of sections) type/model -31R-PSA12N00 Taifeng Main pump brand Rubber block (piece) Hydraulics Main pump 64.4 maximum flow (L/min) 8-way hydraulic...

  • Page 50: Chapter 5 Common Faults And Solutions

    Chapter 5 Common Faults And Solutions 5.1 Common faults of excavators and their solutions Common faults Cause Solution The machine has The overflow valve is clogged Dismantle the cleaning device or tighten weak power and or too loose the relief valve moves slowly Pump damage Replace the hydraulic pump...
  • Page 51 The relief valve is too tight Adjust the loose relief valve Engine misfire Battery voltage loss Rechargeable or with an external battery Diesel cannot be output to the Unplug the diesel engine pipe on the pipeline because there is air in engine, exhaust the air, and install or the pipeline press the oil pump to exhaust...
  • Page 52 and the computer Damaged parts Replacement parts or display does not work Battery not Generator disconnection Check engine wiring and reconnect charging Fuse failure Replace the fuse Regulator damage Replace the regulator Battery damage Replacement battery Tracks fall off Mechanical tension relaxation Support the machine, put the track into the tension wheel, start the machine, and use the rotation force of the drive wheel...
  • Page 53 returned or stem are loose or fallen off pushed back Valve core stuck Remove the valve core and reinstall it 5.2 Clean the overflow valve (safety valve) and adjust the system pressure As one of the core components of the hydraulic system, the overflow valve plays a decisive role in the system pressure.

  • Page 54: Chapter 6 Maintenance And Care

    Chapter 6 Maintenance And Care 6.1 Maintenance precautions Engine maintenance As the main power system of the excavator, the engine needs to be maintained in accordance with the "Engine Operation Manual" carried on the vehicle. Strict maintenance in accordance with the provisions of the engine operation manual can effectively increase the service life of the engine and reduce the occurrence of failures.
  • Page 55 Regular replacement of safety-critical components 1. To ensure the long-term safe use of the machine, refuel and inspect and maintain it regularly. To improve safety, please regularly replace safety-critical components such as hoses and seat belts. 2. "Safety-critical parts that are replaced regularly" are parts that age, wear, and degrade after repeated use, and whose performance changes over time.

  • Page 56: Fuel Recommendation

    Hydraulic pipe (bulldozer cylinder pipe) Hydraulic pipe (pilot valve) Hydraulic pipe (auxiliary pipe) 6.2 Fuel Recommendation Diesel fuel should meet the following standards. This table lists several fuel specifications currently used in the world. Diesel Specifications area Diesel area Specifications GB252 China BS2869-A1 or A2...
  • Page 57 7. Use compliant biodiesel, the engine warranty is void for non-compliant machines or spoiled biodiesel. 6.3 Description of machine lubrication parts Lubrication area diagram The details of the 20 fuel filler ports for the King 3.5 ton model are as follows: Grease fitting position quantity (1) Bucket, rocker and arm connection...
  • Page 58 The user must add sufficient grease to the above refueling point every 4 to 8 hours of work. ※ 6.4 Maintaining the Directory Excavator maintenance catalog: Excavator Repair Catalog First Conventional Model Remark Filter Name Maintenance Maintenance Cycle Cycle Methods Methods Oil Filter 50 Hours...
  • Page 59 Hydraulic Replace 300 Hours Replace Return Filter Hours Oil maintenance schedule: First Conventional Maintenan Name Maintenance Model Remark Cycle Cycle Methods Methods Choose The Right Oil Type Cd 15w-40 Engine Oil 50 Hours Replace Replace According To The Local Hours (Pc10 Model) Temperature Cannot Be Mixed With...

  • Page 60: Changing The Engine Oil

    3. Fill oil close to the upper limit of the dipstick but do not exceed the upper limit. The oil filter must be replaced when changing the engine oil. King 3.5 ton model oil change method: As shown in the figure below, unscrew the oil outlet screw, drain the oil, and collect it in a container.
  • Page 61 6. 6 How to replace the filter element Below, to replace the filter element of the Kubota engine, you need to open the rear cover of the excavator first, and then you can see all the filter elements. First, use a wrench to remove the protective cover on the filter element, and then remove the filter element for replacement.

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