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achilles A60S Operation & Maintenance Manual

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WARNING
Before operation and maintenance, the drivers
and maintenance personnel shall always read and get
understanding of the manual. Otherwise, fatal
accident may occur. This manual shall be kept
properly for future reference by the personnel
concerned.
A60S HYDRAULIC EXCAVATOR
OPERATION & MAINTENANCE
MANUAL
2025-6 VERSION 1
ACHILLES AUSTRALIA SDLG SERIES

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  • Page 1 Otherwise, fatal accident may occur. This manual shall be kept properly for future reference by the personnel concerned. A60S HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL 2025-6 VERSION 1 ACHILLES AUSTRALIA SDLG SERIES...

  • Page 3: Preface

    Excavator Operation and Maintenance Manual Preface Welcome to use hydraulic excavator produced by Shandong Lingong. The manual can instruct you to correctly use and maintain the machine, which will be placed in the cab to be read by all relevant personnel at any time. If the manual cannot be read due to loss or damage, you will immediately contact our company or distributor to ask for a new manual.

  • Page 4: Safety Matters

    Excavator Operation and Maintenance Manual Safety Matters Operators shall understand and abide by existing national and local safety provisions. If there are no national or local provisions, operators shall abide by safety instructions in the manual. Most of accidents are caused as failing to abide by provisions on operation and maintenance of the machine.

  • Page 5: Ce Labels And European Community (Ce) Directives

    Excavator Operation and Maintenance Manual CE labels and European Community (CE) directives CE label (Declaration of compliance with relevant decrees) (Only applicable to machines launched in markets within the European Community/European Economic Community) The machine is provided with CE marks. This indicates that the machine meets the “basic health and safety requirements”...

  • Page 6: Ce Statement

    Excavator Operation and Maintenance Manual CE Statement Mechanical instructions, EMC declarations The Company makes a declaration: The mechanical directive of the machine meets the requirements of 2006/42/EC, and the EMC meets the requirements of 2014/30/EU (EN ISO 13766-1 and EN ISO 13766- 2), all of which meet the European Union (EU) and European Community (CE) directives.

  • Page 7: European Safety Regulations

    Excavator Operation and Maintenance Manual European safety regulations Noise limit Noise level at the driver's position (L ): 72.8 ± 1.5 dB (A), external radiation noise level LWA: 96 dB (A), in accordance with ISO 6395: 2008. Vibration limitation The vibration value of the cab seat meets the provisions of ISO 7096:2000, and the vibration value is: 0.976 m/s²...

  • Page 9: Table Of Contents

    Excavator Operation and Maintenance Manual Table of contents PREFACE ................................I SAFETY MATTERS ............................II CE LABELS AND EUROPEAN COMMUNITY (CE) DIRECTIVES ............. III CE STATEMENT ............................. IV EUROPEAN SAFETY REGULATIONS ......................V WARNING IN NO. 65 PROPOSAL OF STATE OF CALIFORNIA ............... V CHAPTER I PRODUCT INTRODUCTION ......................
  • Page 10 Excavator Operation and Maintenance Manual THER CONTROLS ..............................62 4.1 Work equipment control handle ......................62 4.2 Multi-function control handle ......................... 65 4.3 Optional pedal (right) ..........................67 4.4 Traveling control lever ..........................67 4.5 Dozer blade control handle ........................68 4.6 Control lockout lever..........................
  • Page 11 Excavator Operation and Maintenance Manual 4.3 Working in areas with cables and pipelines buried underground ............. 81 4.4 Working in confined areas ........................82 4.5 Working in areas with insufficient lighting conditions ................. 82 4.6 Working in other hazardous areas ......................82 4.7 Avoidance of environmental damage ....................
  • Page 12 Excavator Operation and Maintenance Manual CHAPTER 4 OPERATION TECHNIQUES ....................112 ............................. 112 XCAVATION RULES Precautions ............................. 112 1.2 Precautions for loading materials ....................... 115 1.3 Precautions during slewing or reversing ................... 115 1.4 Prohibited operations ........................... 116 ACHINE VIBRATION ............................
  • Page 13 Excavator Operation and Maintenance Manual 3.3 Preventing environmental pollution ..................... 149 IRE PREVENTION ..............................151 4.1 Fire prevention measures ........................151 4.2 Measures in the event of a fire ......................154 4.3 Measures after fire is extinguished ..................... 154 ISPOSAL OF HAZARDOUS MATERIALS ........................
  • Page 14 Excavator Operation and Maintenance Manual OOLING SYSTEM ............................... 175 7.1 Checking the coolant level ........................175 7.2 Replacing the coolant........................... 176 7.3 Cleaning radiators, hydraulic oil and fuel coolers and condenser fins .......... 178 ............................180 YDRAULIC SYSTEM 8.1 Checking the hydraulic oil level ......................180 8.2 Replacing the hydraulic oil ........................
  • Page 15 Excavator Operation and Maintenance Manual 16 T RACK TENSION ..............................206 16.1 Check the track tension ........................206 16.2 Adjusting the track tension ......................... 207 17 L UBRICATION ..............................208 18 R EGULAR MAINTENANCE ........................... 209 18.1 Maintenance every 10 hours ......................209 18.2 Maintenance every 50 hours ......................

  • Page 16: Chapter I Product Introduction

    Excavator Operation and Maintenance Manual Chapter I Product Introduction 1 Appearance and names of components This figure shows the appearance of the machine and the names of its main components. In this Manual, front, rear, left and right refer to the traveling directions viewed from the cab when the cab is facing forward and the traveling motor is at the rear of the machine.
  • Page 17 Excavator Operation and Maintenance Manual 7. Lower frame 8. Air filter 9. Upper frame 10. Traveling motor 11. Sprocket 12. Carrier roller 13. Track roller 14. Radiator 15. Tensioner 16. Hydraulic oil tank 17. Guide wheel 18. Track 19. Dozer blade 20. Connecting rod assembly 21. Bucket 22. Bucket cylinder 23.

  • Page 18: Components, Specifications, Machine And Operation Dimensional Drawings

    Excavator Operation and Maintenance Manual 2 Components, specifications, machine and operation dimensional drawings 2.1 Components and specifications Boom ER655H Description 2.8m (110.3 inch) Length (A) 2917 (114.9) Height (B) mm (inch) 984 (38.8) Width 362 (14.3) Weight* kg (lb) 324 (714.4) * Including cylinders, piping and pins Description ER655H...

  • Page 19: Overall Dimensional Drawing

    Excavator Operation and Maintenance Manual 2.2 Overall dimensional drawing...
  • Page 20 Excavator Operation and Maintenance Manual 2.8 m (110.3 inch) boom; 1.54 m (60.7 inch) arm; 0.18 m³ (6087.6 fl oz) bucket Item Unit Value Total length 5485 (216.1) Overall width 1980 (78.0) Total height 2692 (160.1) Upper assembly width 1850 (72.9) Track shoe width 400 (15.8) Tail turning radius...

  • Page 21: Operation Dimensional Drawing

    Excavator Operation and Maintenance Manual 2.3 Operation dimensional drawing...
  • Page 22 Excavator Operation and Maintenance Manual 2.8 m (110.3 inch) boom; 1.54 m (60.7 inch) arm; 0.18 m³ (6087.6 fl oz) bucket Item Unit Value Maximum excavation radius 6043 (238.1) Maximum ground excavation 5910 (232.9) range Maximum excavation depth 3492 (137.6) Maximum vertical excavation 2633 (103.7) depth...

  • Page 23: Labels

    Excavator Operation and Maintenance Manual 3 Labels 3.1 Product label The machine label is fixed on the front end of upper frame, indicating the machine model, manufacturing year, product identification code and manufacturer, etc. (The PIN code is also printed below the product label) 3.2 Engine label This label shows the engine type tab, displacement and serial number.

  • Page 24: Cab

    Excavator Operation and Maintenance Manual 3.4 Cab This machine is equipped with an anti-rollover cab, and the anti-rollover sign is shown in the left figure. 4 Applicable working conditions This machine is a professional crawler-type hydraulic excavator. It is widely used in small-scale building construction, highway maintenance, farmland transformation, underground construction of subway tunnel, hydropower trench foundation pit excavation, municipal engineering, sanitation, landscaping...

  • Page 25: Features

    Excavator Operation and Maintenance Manual 5 Features ⚫ It is equipped with a powerful and highly reliable engine, which ensures the excellent working performance of the whole machine. It has the advantages of low emissions and low noise, and is particularly suitable for operations in noise-sensitive areas and at night.

  • Page 26: Technical Performance Parameters

    Excavator Operation and Maintenance Manual 6 Technical performance parameters 6.1 Machine performance parameters Item Unit Value Machine weight kg (lb) 5900 (13009.5) Standard bucket 0.18 (6087.6) m³ (fl oz) capacity Bucket capacity range m³ (fl oz) 0.1～0.24 (3382.0～8116.8) Travel speed 2.2/4.4 (86680.0/4.4) km/h (inch/h) (low/high)

  • Page 27: Location And Content Of Safety Signs

    Excavator Operation and Maintenance Manual 7 Location and content of safety signs 7.1 Safety signs and their locations The location of the safety sign of the machine is shown in the table below. Carefully read and follow the instructions of all safety signs on the machine.
  • Page 28 Excavator Operation and Maintenance Manual 4. Signs for paying attention to the work equipment They are located at both sides of the arm. 5. Sign for no entry to the turning area It is located on both sides of the rear surface of the counterweight 6.
  • Page 29 Excavator Operation and Maintenance Manual 10. Fire extinguisher installation location sign It is located on the left rear pillar of the cab 11. Signs for paying attention to the hydraulic oil tank and oil filling Opening the right hood, it is located near the level gauge on the hydraulic oil tank 12.
  • Page 30 Excavator Operation and Maintenance Manual 15. High temperature liquid warning sign It is located near the antifreeze filling port. 16. Antifreeze filling sign It is located near the antifreeze filling port. 17. Sign for prompting to avoid high temperature burning It is located near high-temperature components 18.
  • Page 31 Excavator Operation and Maintenance Manual 19. Lubrication diagram It is located on the inside of the cab door 20. Fuel tank sign It is located on the right shield outside the cab 21. Safety lock warning sign It is located on the outside of the left control box 22.
  • Page 32 Excavator Operation and Maintenance Manual 24. Seat belt warning sign It is located on the right side glass in the cab. 25. Sign for keeping a safe distance from power lines It is located on the right side glass in the cab. 26.
  • Page 33 Excavator Operation and Maintenance Manual 28. Fire prevention warning sign It is located on the right side glass in the cab. 29. Explosion warning sign It is located on the accumulator 30. Sign for pinching warning It is located on the cover plate under the seat 31.
  • Page 34 Excavator Operation and Maintenance Manual 35. Lifting capacity sign （with quick attachment） It is located on the inside of the cab door 36. Lifting capacity sign（no quick attachment） It is located on the inside of the cab door 36 Emergency stop sign It is located near the emergency stop switch 37.
  • Page 35 Excavator Operation and Maintenance Manual 38. Articulated steering sign It is located on both sides of the boom 39. Lubrication adding sign It is located near the grease filler of the deflection cylinder 40. Emergency exit sign It is located on the rear glass in the cab. 41.
  • Page 36 Excavator Operation and Maintenance Manual 44. Sign of quick change device It is located on the inside of the cab door 45. Side cover opening sign It is located on the rear side of the right cover...

  • Page 37: Chapter Ii Iecu And Controller

    Excavator Operation and Maintenance Manual Chapter II IECU and Controller △ ! Warnings Do not operate this machine until you are familiar with the location and function of the instruments and controllers and how to use them. Always check instruments and controllers, pay attention to unusual readings, and take necessary actions to prevent serious damage to the machine.
  • Page 38 Excavator Operation and Maintenance Manual 10 Seat 11 Travel pedal 12 USB/AUX port 13 Standby power supply 14 Rocker switch 15 Sprinkling can 16 Mobile phone box...

  • Page 39: Front Instrument (Iecu)

    Excavator Operation and Maintenance Manual 1 Front instrument (IECU) Notice Take appropriate measures to prevent damage to the machine. Read and understand the instructions in this section carefully to familiarize yourself with the front dashboard before attempting to operate the machine. Notice Multiple language modes are available on the front dashboard.
  • Page 40 Excavator Operation and Maintenance Manual ➢ Engine speed is ≥ 700 rpm, and system voltage is ≥ 15 V for 3 seconds. Engine water temperature is ≥ 110 ℃ (230 °F). ➢ ➢ Engine is faulty, GPS alarms, and oil level is low. Date display Display the current date in the format "...
  • Page 41 Excavator Operation and Maintenance Manual When the engine is overheated, the red central warning light will flash. Stop the work and find out the cause. Main display After the main display is powered on, it will be initialized, the Lingong LOGO interface will be displayed, and the main interface will be displayed after initialization.
  • Page 42 Excavator Operation and Maintenance Manual Main menu interface In the main menu interface, different secondary interfaces can be selected by receiving the operation command of Keypad, and the instrument will display the information of the machine on the secondary interface; For example, information on the engine, hydraulic system, electrical system, machine information, service, settings, A/C, radio and GPS can be displayed.
  • Page 43 Excavator Operation and Maintenance Manual DPF soot level: Show soot percent and ash percent. ➢ Hydraulics Display the hydraulic oil temperature, LS pressure and ➢ main pump current. Electrical system ➢ Display the voltage electrical system and other information.
  • Page 44 Excavator Operation and Maintenance Manual Machine information ➢ Total fuel consumption: The fuel consumption in the total working time is displayed in the format of "x.x L". ➢ Average fuel consumption: The average fuel consumption in the total working time is displayed in the format of "x.x L/h".
  • Page 45 Excavator Operation and Maintenance Manual Service In the secondary interface of "Service", you can directly contact the dealer service department of Shandong Lingong Construction Machinery Co., Ltd. through "One-click Repair- Servicing" and "One-click Repair-Repair" to obtain the corresponding service. Taking the "Engine Oil/Oil Filter" interface as an example, in the tertiary interface of "Service - Servicing"...
  • Page 46 Excavator Operation and Maintenance Manual Setting In the setting interface, you can receive the operation commands from Keypad to realize the settings of mute, handle operation mode, automatic idling, shear-hammer switching, hoisting mode, language, time/date, unit, display brightness, keypad backlight and regeneration enabling/disabling. ➢...
  • Page 47 Excavator Operation and Maintenance Manual ➢ Automatic idling time interface: In the tertiary interface of "Settings" - "Automatic Idling", as shown in the left figure, you can receive the operation instructions of the roller knob on the Keypad, set the automatic idle time and turn on or off the automatic idling function, and the setting will take effect after pressing the OK key.
  • Page 48 Excavator Operation and Maintenance Manual ➢ Hoisting mode: In the tertiary interface of "Settings" - "Hoisting mode", as shown in the left figure, the operation command of the OK key on the Keypad can be received to select the hoisting mode. When the hoisting mode is selected, and the boom pressure value exceeds the threshold, the text prompt of "Hoisting Overloaded"...
  • Page 49 Excavator Operation and Maintenance Manual ➢ Unit setting: in the tertiary interface of "Setting" - "Unit", as shown in the left figure, the operation command of the roller knob on the Keypad can be received to set the unit of measurement to metric or American system. ➢...
  • Page 50 Excavator Operation and Maintenance Manual regeneration). The operation steps of parking regeneration are as follows: ➢ After power-on, the DPF regeneration request light on the IECU is always on in yellow ➢ Move the machine to a safe area, warm up the machine for 15 minutes or until the engine coolant temperature is higher than 60 ℃...
  • Page 51 Excavator Operation and Maintenance Manual forbidden to turn off the DPF regeneration function, turn off the engine, operate the throttle knob, or conduct operation, otherwise the DPF regeneration will fail. ➢ After the DPF regeneration is completed, the DPF regeneration request light and the engine exhaust temperature indicator light are off, the regeneration is completed, the engine speed returns to idling, and the machine can resume operation.
  • Page 52 Excavator Operation and Maintenance Manual levels, namely, C4-C3-C2-C1-H0-H1-H2-H3-H4 Adjustment is carried out by moving the knob of the roller left and right; Toggle it to the left to reduce the temperature by 1 level; Toggle it to the right to increase the temperature by 1 level.
  • Page 53 Excavator Operation and Maintenance Manual increase by 1 level. Audio interface (radio) Select "Radio" under the "Main Interface" or directly press the "Audio Shortcut Button" on the Keypad to enter the "Radio" interface. Note: When the engine is not started after power-on, the radio function shall not be used for more than 30 minutes to ensure that the battery is sufficient.
  • Page 54 Excavator Operation and Maintenance Manual frequency will be saved in the corresponding position; up to 6 stations can be saved for each band, and a total of 30 stations can be saved. Press the OK button (less than 2 seconds) to directly listen to the corresponding preset radio station.
  • Page 55 Excavator Operation and Maintenance Manual a) Audio interface (USB music) Select "Radio" in the "Main Interface" or directly press the "Audio Shortcut Button" on the Keypad to enter the "Radio" interface. At this time, if you connect the USB port, you will enter the "USB Music"...
  • Page 56 Excavator Operation and Maintenance Manual ② Previous song ③ Play/Pause ④ Next song The GPS information interface can display the LNG, LAT, Altitud and signal quality of the current machine location. Indicator light group ⚫ Message indicator light (white) This light will be on when the machine is faulty. If this happens, check the specific fault through the message indicator light button at the bottom of IECU or "machine information-fault information"...
  • Page 57 Excavator Operation and Maintenance Manual ⚫ Preheating indicator light (yellow) In cold weather, the start switch is in the " " position; when the engine water temperature is lower than 15 ℃(59 °F), the preheating is enabled; When preheating, this indicator light will be on in yellow;...
  • Page 58 Excavator Operation and Maintenance Manual ⚫ Mute indicator light (yellow) When some faults occur, there will be an audible alarm; Press the Mute button on the bottom of the instrument panel or on the keypad, the audible alarm will stop and the indicator light will be on.
  • Page 59 Excavator Operation and Maintenance Manual ⚫ Select hydraulic shear indicator light When the hydraulic shear function is selected through the IECU menu "Settings-Shear and Hammer Switching" and the safety lock of the wave wheel on the right control handle is in the unlocked state, this light will be on.
  • Page 60 Excavator Operation and Maintenance Manual operation immediately and call 400 for service according to the fault prompt. ⚫ DPF regeneration prohibition light-yellow Yellow - indicating that the regeneration function of the machine is disabled. Release this state in time under safe working conditions.
  • Page 61 Excavator Operation and Maintenance Manual power of the machine will be limited after 36 h or 64 h. Rectify the fault in time.

  • Page 62: Keypad

    Excavator Operation and Maintenance Manual 2 Keypad Roller knob Return button Menu/Confirm button Audio shortcut button Heating and A/C button Work light switch Travel speed selector switch Warning light switch Alarm mute Roller knob Rotation-adjust the throttle gear of the engine; Front, rear, left, right - line feed, page turning.
  • Page 63 Excavator Operation and Maintenance Manual the corresponding indicator light will also be on (or off) in turn. When it is rotated to the highest gear, all lights are on. When it is rotated to any gear, the corresponding LED light on the display will be on and show the current gear.
  • Page 64 Excavator Operation and Maintenance Manual Position 0 The light is off (OFF). Position 1 The cab light is on. Position 2 The boom work light and the cab light are on at the same time. Travel speed selector switch This switch is a two-position switch. When this switch is pressed, the traveling speed will be switched between two positions, and the corresponding indicator light of the selected traveling speed will go on.
  • Page 65 Excavator Operation and Maintenance Manual pressed again, the radio is unmuted; when it is pressed again, the instrument is unmuted. When this button is pressed when the radio is off, the instrument is muted; when it is pressed again, the instrument is unmuted.

  • Page 66: Switch

    Excavator Operation and Maintenance Manual 3 Switch ⚫ Rocker switch 1) Quick-change power switch Position 1 The quick-change power supply is on, the two quick-change button switches on the left control handle are in working condition, and the safety locking/unlocking indicator light goes on.
  • Page 67 Excavator Operation and Maintenance Manual Position 2 The wiper stops operating. Notice: The wiper switch is located at the upper right corner of the front windshield.
  • Page 68 Excavator Operation and Maintenance Manual ⚫ Start switch This switch is located at the rear of the right control box and is used to turn on or off the machine's electrical system and start engine. Position O The key can be inserted or removed in this position, and 1 Stop position when the key is rotated to this position, the starting circuit is 2 Power-on (preheating)
  • Page 69 Excavator Operation and Maintenance Manual ⚫ Emergency stop switch This switch is located at the lower left of the left control box of the seat. Open the red protective cover and toggle the switch upward to stop the engine. When this switch is in the downward condition, the machine can be used normally, and the red protective cover can be closed normally.

  • Page 70: Other Controls

    Excavator Operation and Maintenance Manual 4 Other controls 4.1 Work equipment control handle Left control handle (ISO) ⚫ When the ISO operation mode is selected through the IECU-Settings sub-interface, this handle is used to rotate and operate the arm. 1 Arm extended (unloading) 2 Arm retracted (excavating) 3 Left swing 4 Right swing...
  • Page 71 Excavator Operation and Maintenance Manual ⚫ Left control handle (BHL) When the BHL operation mode is selected through the IECU-Settings sub-interface, this handle is used to rotate and operate the boom. 1 BOOM lower 2 BOOM RAISE 3 Left swing 4 Right swing...
  • Page 72 Excavator Operation and Maintenance Manual ⚫ Right control handle (ISO) When the ISO operation mode is selected through the IECU-Settings sub-interface, this handle is used to operate the boom and bucket. 1 Bucket in (digging) 2 Bucket out (unloading) 3 BOOM lower 4 BOOM RAISE Right work equipment control handle This handle controls the boom and bucket...

  • Page 73: Multi-Function Control Handle

    Excavator Operation and Maintenance Manual ⚫ Right control handle (BHL) When the BHL operation mode is selected through the IECU-Settings sub-interface, this handle is used to operate the arm and bucket. 1 Bucket in (digging) 2 Bucket out (unloading) 3 Arm extension (unloading) 4 Arm retraction (digging) 4.2 Multi-function control handle A Left control lever...
  • Page 74 Excavator Operation and Maintenance Manual vibrates; Roll the thumbwheel to the right, and the hydraulic shear opens. Thumbscrew opening and closing - roll the thumbwheel to the left, the thumbscrew clamps/the breaker vibrates; Roll the thumbwheel to the right, and the thumbscrew opens. (with thumbscrew)

  • Page 75: Optional Pedal (Right)

    Excavator Operation and Maintenance Manual 4.3 Optional pedal (right) This pedal is used to operate the swing cylinder of the work equipment. When operating the swing cylinder of the work equipment, first turn up the cover plate, and then step on the left end of the pedal to make the work equipment swing counterclockwise;...

  • Page 76: Dozer Blade Control Handle

    Excavator Operation and Maintenance Manual 4.5 Dozer blade control handle This control handle is located on the right control box. Position 1: backward - dozer blade lifting Position 2: forward - dozer blade lowering Position N: middle (neutral) The traveling speed selector switch is integrated at the top of this control handle.
  • Page 77 Excavator Operation and Maintenance Manual the work equipment control handle is accidentally touched, serious personal injury can be caused. Notice! When pulling up or pushing down the control lockout lever, do not touch the control handle of the work equipment.

  • Page 78: Seat Adjustment

    Excavator Operation and Maintenance Manual 4.7 Seat adjustment △ ! Warning When adjusting the seat, park the vehicle in a safe places and shut down the engine. Before changing the driver or starting to operate the machine, adjust the driver seat to the most comfortable seating position.

  • Page 79: Fire Extinguisher

    Excavator Operation and Maintenance Manual 4.9 Fire extinguisher The mounting holes for the fire extinguisher bracket have been reserved in the right rear of the cab of this machine. Please install a fire extinguisher that meets the national laws and local requirements. Warning! Be sure to prepare a fire extinguisher and read the instructions on the fire extinguisher before operating the machine.

  • Page 80: Closing Of Front Window

    Excavator Operation and Maintenance Manual into the lock pin at the rear side of the cab top, and confirm that it is locked. Warning If the window is not locked in the Open position, machine movement may cause it to drop. Warning When opening or closing the front upper window, front lower window or door, place the control lockout lever in the Lock...

  • Page 81: Removal Of Front Lower Window

    Excavator Operation and Maintenance Manual 4.12 Removal of front lower window 1 Open the front window. 2 Pinch the upper edge of the lower window with both hands, and pull it up. 3 Store the removed window in the cab. Notice! Ensure that the lower window is properly placed to prevent it from being damaged.

  • Page 82: Emergency Exit

    Excavator Operation and Maintenance Manual 4.14 Emergency exit If the doors and windows of the cab cannot be opened, the rear window can be broken with a safety hammer as an emergency escape exit. The safety hammer is located on the left pillar in the cab.

  • Page 83: Placement Of The Operation And Servicing Manual

    Excavator Operation and Maintenance Manual 4.16 Placement of the Operation and Servicing Manual There is a storage bag behind the driver's seat, in which the Operation and Servicing Manual shall be placed for use when necessary. Notice Do not place tools or heavy objects in the storage bag, which may damage the storage bag.

  • Page 84: Chapter Iii Operation Instructions

    Excavator Operation and Maintenance Manual Chapter III Operation Instructions 1 Introduction This chapter contains regulations on operation and safety. In ensure the correct and safe operation/operation of the machine, you must comply with these regulations, and also fulfill the responsibilities and obligations of national, provincial and municipal laws and regulations on transportation safety, traffic safety, industrial safety and labor welfare.

  • Page 85: Safety Rules During Operation

    Excavator Operation and Maintenance Manual 3 Safety rules during operation 3.1 Obligations of operators Warning When operating the machine, the operators and the management department have the right to let the unauthorized personnel leave the site. The operators shall carefully observe the surroundings of the machine to ensure safety.

  • Page 86: Safety Regulations

    Excavator Operation and Maintenance Manual abnormal display on the alarm device or monitor) is found during operation or servicing, report it to the supervisor and take necessary measures. Do not operate the machine until the fault is rectified. 3.2 Safety regulations ⚫...
  • Page 87 Excavator Operation and Maintenance Manual ⚫ Select the smoothest operating surface (level the surface if necessary). ⚫ Adjust the machine speed. ⚫ When traveling on uneven ground, the machine shall not tilt to one side by more than 10°. ⚫ There are two escape routes in the cab: the door and rear window.

  • Page 88: Working In Hazardous Areas

    Excavator Operation and Maintenance Manual 4 Working in hazardous areas Notice: The machine is not suitable for environments that are harmful to human body, such as toxic gas, dust, etc. 4.1 Working in areas close to overhead high-voltage power lines If the machine is close to a high-voltage wire, ⚫...

  • Page 89: Working In Areas Where Overhead Cables For Electric Trains Are Used

    Excavator Operation and Maintenance Manual 4.2 Working in areas where overhead cables for electric trains are used ⚫ Before loading or unloading the machine, contact the railway authority to obtain the operation permit. ⚫ After the operation is interrupted, the railway authority must be contacted again before continuing the operation.

  • Page 90: Working In Confined Areas

    Excavator Operation and Maintenance Manual ⚫ When the position of the cable or pipeline is complex and difficult to be handled, or the operator cannot see the actual operation point at the operation place, a signalman shall be appointed. For hand signals, please refer to "8 Hand signals"...

  • Page 91: Avoidance Of Environmental Damage

    Excavator Operation and Maintenance Manual 4.7 Avoidance of environmental damage Care shall be taken to protect the environment during maintenance and servicing. The discharge of oil harmful to the environment will pollute the environment. Oil degrades very slowly in water and sediment. 1 litre of oil can contaminate millions of litres of drinking water.
  • Page 92 Excavator Operation and Maintenance Manual environmental protection policies.

  • Page 93: Starting The Machine

    Excavator Operation and Maintenance Manual 5 Starting the machine 5.1 Inspection before starting the engine IMPORTANT!! Always walk around the machine before starting to make sure there is no one in the place nearest to the machine. Place the machine in the repair position. Refer to "1 ⚫...

  • Page 94: Operation Before Starting The Engine

    Excavator Operation and Maintenance Manual plate are closed. 5.2 Operation before starting the engine ⚫ Window cleaning or defrosting ⚫ When starting the engine, always sit on the operator seat. Refer to "5.3 Starting engine" of this chapter. ⚫ Fasten the seat belt before all operations. ⚫...

  • Page 95: Operation And Inspection After Starting The Engine

    Excavator Operation and Maintenance Manual state, otherwise the engine cannot be started. See "3.6 Control lockout lever of Chapter II". ⚫ Turn the engine speed control lever to the low throttle position. Refer to "3.5 Engine speed control lever" of Chapter II.
  • Page 96 Excavator Operation and Maintenance Manual Refer to "3.6 Control lockout lever" of Chapter II, and lift the bucket from the ground. ⚫ Operate the control lever slowly, move the bucket and arm cylinders to their stroke ends for 30 seconds and 5 minutes respectively in turn to rise the hydraulic oil temperature.
  • Page 97 Excavator Operation and Maintenance Manual ⚫ Place the control lockout lever in the Lock position and confirm that the slewing and work equipment cannot be operated with the left and right work equipment control levers.

  • Page 98: Operating The Machine

    Excavator Operation and Maintenance Manual 6 Operating the machine 6.1 Operating the work equipment For the operation method of the work equipment, please refer to "4.1 Work equipment control handle" and "4.2 Multi- function control handle". 6.2 Dozer blade control handle For the operation method of the dozer blade, please refer to "4.5 Dozer blade control handle".
  • Page 99 Excavator Operation and Maintenance Manual Ground Operation conditions Do not travel continuously for more than 2 hours. If it is to travel at high speed for more than 2 hours, stop it for at least 20 Flat, normal or minutes, and the traveling must be in the soft soil forward direction.
  • Page 100 Excavator Operation and Maintenance Manual slowly pull the traveling control lever backward, or slowly step on the rear part of the pedal; ⚫ When the traveling motor is at the front of the machine, slowly push the traveling control lever forward, or slowly step on the front part of the pedal.
  • Page 101 Excavator Operation and Maintenance Manual same time to make the machine switch direction quickly to the right; ⚫ When the traveling motor is at the front of the machine, operate the traveling control lever in the opposite direction to the above.

  • Page 102: After Operation

    Excavator Operation and Maintenance Manual 7 After operation 7.1 Steps for parking the machine △ Warning When entering or leaving the cab, always face the machine and use the pedal or handrail to prevent slipping. Always use three-point contact when getting on and off the machine, that is, two hands and one foot or two feet and one hand.

  • Page 103: Operation And Inspection After Shutting Down Engine

    Excavator Operation and Maintenance Manual position (the Off position). 7.2 Operation and inspection after shutting down engine ⚫ Conduct walkaround inspection work equipment, the exterior of the machine and the chassis, and check for water or oil leakage. If any abnormality is found, repair it.

  • Page 104: Parking The Machine

    Excavator Operation and Maintenance Manual 8 Parking the machine IMPORTANT!! Park the machine on level ground. Place the bucket and dozer blade flat on the ground. If it must be parked on a slope, place cushion blocks under the track to prevent the machine from moving, adjust the bucket to the downhill side, and insert the bucket teeth into the ground.
  • Page 105 Excavator Operation and Maintenance Manual may shorten the service life. Do not shut down the engine immediately unless there is an emergency. In case of engine overheating, cool the engine at low speed, and then shut down the engine. If the machine is to be parked for a long time, the following points must also be observed: ⚫...

  • Page 106: Transportation Of The Machine

    Excavator Operation and Maintenance Manual 9 Transportation of the machine △ Warning ➢ Observe the regulations on weight, height, length and load safety when transporting the machine. ➢ Pay special attention to the loading and unloading of the machine. ➢ Run the engine at low speed, and set the running speed of the vehicle at low speed.

  • Page 107: Securing The Machine

    Excavator Operation and Maintenance Manual of the loading platform are safe for loading. ⚫ Ensure that the angle of the loading platform is 15° or less. ⚫ Ensure that the distance between the loading platforms matches the center of the track. ⚫...

  • Page 108: Unloading

    Excavator Operation and Maintenance Manual Refer to the section of master power switch of "3 Switch" of Chapter II. ⚫ Lock the driver door and all covers and hoods with locks. Refer to "4.11 Covers/hoods with lock" of Chapter II. ⚫...
  • Page 109 Excavator Operation and Maintenance Manual right loading platforms is the same. ⚫ Remove the chains or wire ropes that fasten the machine. ⚫ Start the engine for warm-up. ⚫ Place the control lockout lever in the "Unlock" position. Refer to "3.6 Control lockout lever" of Chapter II. ⚫...

  • Page 110: Lifting The Machine

    Excavator Operation and Maintenance Manual 9.4 Lifting the machine △ Warning! If there is a person in the cab or on the machine, do not lift the machine. Proper steel ropes, chains and hooks with sufficient load capacity shall be used. Always lift the machine as shown in the figure below.
  • Page 111 Excavator Operation and Maintenance Manual ⚫ As shown in the figure, properly connect and firmly lock the lifting cable or chain with sufficient strength relative to the weight of the machine at the lifting position. ⚫ After installing all lifting equipment, adjust the lifting angle of the sling rope to 30°~40°, and lift the machine slightly to check the balance.

  • Page 112: Disassembly During Transportation

    Excavator Operation and Maintenance Manual 9.5 Disassembly during transportation Notice In case of transportation, the local, provincial and national regulations on the weight, width, height and length of the machine shall be observed. In case of selection of the transportation route, the clearance of the passageway, the width limit, height limit and load limit of the bridge and road, as well as the passing time shall be considered.
  • Page 113 Excavator Operation and Maintenance Manual transportation to avoid damage due to overheight.

  • Page 114: Lifting Items (Optional)

    Excavator Operation and Maintenance Manual 9.6 Lifting items (optional) If the machine is used to lift items, the following safety work equipment must be provided: ⚫ A load hook. ⚫ The explosion-proof valve on the boom or the explosion-proof valve on the boom and arm in some countries shall be evaluated in accordance with the risk.
  • Page 115 Excavator Operation and Maintenance Manual Load hook The hook 1 on the quick-change device cannot withstand the lateral load force. The load force must be applied longitudinally to this hook. The following items shall be strictly observed in case of lifting with quick-change device: ⚫...

  • Page 116: Traction Of The Machine

    Excavator Operation and Maintenance Manual 10 Traction of the machine 10.1 Precautions Use a cable with sufficient strength to tow the ⚫ machine, and do not use a towing rope with broken strands, reduced diameter or twisting. Do not tow the machine on a slope. ⚫...

  • Page 117: Light Load Traction

    Excavator Operation and Maintenance Manual 10.3 Light load traction ⚫ To tow light objects, use the shackles on the lower frame.

  • Page 118: Explosion-Proof Valve (Optional)

    Excavator Operation and Maintenance Manual 11 Explosion-proof valve (optional) Warning Do not remove the explosion-proof valve by yourself. When the pressure valve is disassembled, the internal components will pop out with great force under the action of spring tension, causing injuries. If there is a problem with the explosion-proof valve, please contact the authorized dealers of Shandong Lingong Construction Machinery Co., Ltd.
  • Page 119 Excavator Operation and Maintenance Manual allows the operator to lower the boom and arm in the usual way. It takes a long time to lower the boom and arm, and the control pressure will be released. Collect the oil in the explosion-proof valve hose into a suitable container.

  • Page 120: Chapter 4 Operation Techniques

    Excavator Operation and Maintenance Manual Chapter 4 Operation techniques This chapter provides instructions and suggestions on the operation of machine, including the operation method of the most common working devices, so that operators can operate the machine safely and effectively. 1 Excavation rules 1.1 Precautions △...
  • Page 121 Excavator Operation and Maintenance Manual material may fall, and the bucket may hit the dump truck, causing serious injury or damage. ⚫ Never use a bucket for cutting and chiseling. ⚫ Never use dozer blade as a support. ⚫ Never use this machine as a crane for lifting. ⚫...
  • Page 122 Excavator Operation and Maintenance Manual ⚫ When working on the top of building or other structure, check the strength of the structure at first, as such operation poses a risk of buildings collapse, causing serious injury or damage thereafter. ⚫ Do not perform demolition to structures above the head, as this poses a risk of debris falling or building collapse, causing serious injury or damage thereafter.

  • Page 123: Precautions For Loading Materials

    Excavator Operation and Maintenance Manual digging, place the dozer blade on the ground and do not lift it, so as to avoid contact with the boom cylinder. ⚫ Always ensure that the machine is stable enough for excavation. For operation on a level ground, always place the dozer blade flatly on the ground;...

  • Page 124: Prohibited Operations

    Excavator Operation and Maintenance Manual ⚫ Before starting the machine, activate the horn or signal to warn all personnel to leave the machine. ⚫ Check that there is no one in the blind corner at the rear of the machine during reversing. 1.4 Prohibited operations ⚫...
  • Page 125 Excavator Operation and Maintenance Manual ⚫ Operation using bucket lowering force Do not use the lowering force of the machine for digging or the lowering force of the bucket as a pick, breaking hammer or pile driver. Hammer digging or continuous hammering may overload the rear of the machine or damage the working device.

  • Page 126: Machine Vibration

    Excavator Operation and Maintenance Manual 2 Machine vibration Vibration on construction machinery is influenced by many factors, such as working mode, ground conditions, speed, etc., and the operator can also affect the actual vibration level to a large extent. 2.1 Guiding principles for reducing machine vibration levels ⚫...

  • Page 127: Guiding Principles For Effectively Minimizing Back Pain

    Excavator Operation and Maintenance Manual ⚫ Check and maintain the seat suspension and adjust the device of machine. ⚫ Fasten the seat belt and adjust it correctly. ⚫ Perform steering, braking, acceleration, gearshifting and movement of working device steadily. ⚫ Minimize vibrations caused by long work cycle or long-distance travel.

  • Page 128: Operation Under Special Working Conditions

    Excavator Operation and Maintenance Manual 3 Operation under special working conditions 3.1 Travel The working device must be retracted and lifted so ⚫ that it is 40cm (15.8 inch) to 50cm (19.7 inch) above the flat ground. ⚫ Prevent the machine from tilting for more than 10° on the uneven ground.
  • Page 129 Excavator Operation and Maintenance Manual ⚫ For travel upwards a slope of 15° or above, keep the posture of the machine as shown in the figure. If the track shoes slip on slopes, insert the bucket into the ground and pull the stick move the machine up with the power of the working device.
  • Page 130 Excavator Operation and Maintenance Manual ⚫ If the engine is suddenly shut down during travel on a slope, please place the travel control lever in "N" and lower the bucket to the ground, then restart the engine. ⚫ If the engine is shut down on a slope, turn the ignition switch to the "I"...

  • Page 131: Moving Out Of Muddy Ground

    Excavator Operation and Maintenance Manual 3.3 Moving out of muddy ground Be very careful when working on muddy ground. △ ! WARNING When the boom or stick is used to support the machine, be sure to use the bottom of the bucket (instead of the bucket teeth).

  • Page 132: Travel In Water

    Excavator Operation and Maintenance Manual 3.4 Travel in water IMPORTANT! When the machine is driven out of the water, and the angle of the machine exceeds 15°, the rear of the upper structure body will enter the water, and the water will be kicked up by the radiator fan, which will cause damage to the radiator fan, so take special care in this case.

  • Page 133: Working On Sites With Debris

    Excavator Operation and Maintenance Manual suggestions on startup. ⚫ Remove ice and snow on the window before operation. ⚫ The snow-covered or frozen surface is very slippery. Therefore, when driving or operating the machine on such a surface, be extremely careful, and do not operate the control lever suddenly.
  • Page 134 Excavator Operation and Maintenance Manual work lights and reflectors. ⚫ Be more careful during excavation at night, as it is more difficult to determine distance and height in the dark. ⚫ Set up a road warning sign or turn on the top warning lamp (optional) in case of operation on roads.

  • Page 135: Recommended Operations

    Excavator Operation and Maintenance Manual 4 Recommended operations Excavator is a multi-functional machine that can be installed with various professional working devices to complete various types of operations. The following are some simple operations allowed by the excavator. Backhoe ⚫ Backhoe is suitable for excavation in a position lower than the machine.
  • Page 136 Excavator Operation and Maintenance Manual When parking the dump truck, minimize the slewing radius and ensure a good visibility for the operator to improve the work efficiency. In addition, perform loading at the rear of the dump truck instead of on the side, which makes the operator's work easier and improves work efficiency.

  • Page 137: Track

    Excavator Operation and Maintenance Manual 5. Track Track Application Safety precautions shoe Stony Be sure to drive the machine ground, slowly on the ground with pits general or many obstructions. soil High-speed traveling is only Soft possible on flat ground. If it is inevitable to cross obstacles ground during traveling, reduce the...
  • Page 138 Excavator Operation and Maintenance Manual Spec. Category 350mm (13.8 inch), 380mm (15.0 inch) steel track shoes 400mm (15.8 inch) steel tracks & rubber block track shoes...

  • Page 139: Optional Multi-Functional Working Devices

    Excavator Operation and Maintenance Manual 6 Optional multi-functional working devices IMPORTANT! Select other working devices, if required, that are suitable for the machine. 6.1 Precautions for selecting working devices When installing and using optional work devices, please read the operation manual for the relevant working devices and the relevant information in this manual.
  • Page 140 Excavator Operation and Maintenance Manual Main applications ⚫ Stone breaking ⚫ Blasting ⚫ Road repair Hydraulic hammer is widely applicable for building demolition, road surface breaking, tunnel excavation, slag crushing, and stone breaking and cutting. Install a protective equipment when a hydraulic hammer is installed for use.
  • Page 141 Excavator Operation and Maintenance Manual Press the hammer head against the working surface to avoid empty striking. Precautions for operating hydraulic hammer Do not extend the hydraulic cylinder to the end of its stroke, and instead, leave a clearance of approximately 5 cm (2 inch). Do not throw the breaking hammer towards the rock or concrete.
  • Page 142 Excavator Operation and Maintenance Manual Do not twist the hammer head when drilling holes on the ground. Do not use the hammer as a hoe. When lifting the machine, do not extend the bucket cylinder to its maximum position.

  • Page 143: Replacement Of Bucket

    Excavator Operation and Maintenance Manual 7 Replacement of bucket △ ! WARNING When knocking the pin shaft with a hammer, metal shavings may fly into the eyes and cause serious injury. Therefore, always wear goggles, safety helmets, gloves, and other PPEs during this operation. When removing the bucket, place the bucket securely.
  • Page 144 Excavator Operation and Maintenance Manual ⚫ Align the stick with the hole (1) and the connecting rod with the hole (2), and then install the lubricated pin shafts (A) and (B). CAUTION! When installing the bucket, the O-ring is easily to be damaged, so the O-ring should be installed on the boss at the end of the stick.

  • Page 145: Gesture Signals

    Excavator Operation and Maintenance Manual 8 Gesture signals Gesture signals suitable machine travel commanding during ground operations (including excavation and leveling) and when obstacles affect the operator's field of vision. If rapid lowering, lifting, or movement is required, the arm movements must be more vivid. ⚫...
  • Page 146 Excavator Operation and Maintenance Manual ⚫ Dipper Arm in As shown in the figure, clench the fists of both hands, and extend the thumbs with fingertips inward. Dipper Arm out ⚫ As shown in the figure, clench the fists of both hands, and extend the thumbs with fingertips outward.
  • Page 147 Excavator Operation and Maintenance Manual ⚫ Steering As shown in the figure, raise one arm and clench the fist to indicate the inner side of steering, and clench the fist of the other hand and draw a circle on the vertical plane to indicate the steering direction of track or wheel.
  • Page 148 Excavator Operation and Maintenance Manual ⚫ Movement As shown in the figure, clench the fists of both hands and raise them, and draw a circle on the vertical plane according to the rotation direction of the track or wheel. ⚫ Moving distance As shown in the figure, raise both hands and move them horizontally with the palms facing inward to indicate the moving...
  • Page 149 Excavator Operation and Maintenance Manual ⚫ Stop As shown in the figure, stretch one of the arms horizontally with the palm facing downwards, and then move the arm back and forth. ⚫ Emergency stop As shown in the figure, stretch both arms horizontally with the palms facing downwards, and then move the arm back and forth.

  • Page 150: Chapter 5 Safety During Maintenance

    Excavator Operation and Maintenance Manual Chapter Safety during maintenance △ ! WARNING If maintenance is required before cooling of the machine, be extremely careful, so as not to get burned by hot liquids and parts. The general safety provisions are covered in this chapter and shall be followed during inspection and maintenance of the machine.
  • Page 151 Excavator Operation and Maintenance Manual ⚫ Lower the dozer blade on the ground. ⚫ Shut down the engine and remove the ignition key. ⚫ Place the control lockout lever in the “locked” position, refer to "3.5 Control lockout lever” in Chapter 2. ⚫...

  • Page 152: Access Or Climbing Of Machine

    Excavator Operation and Maintenance Manual 2 Access or climbing of machine △ ! WARNING Always take care. ⚫ Check the handrails or steps before getting on or off the machine. If there is oil, lubricant or mud, remove it promptly to avoid slipping when you get on or off the machine.

  • Page 153: Safety Regulations

    Excavator Operation and Maintenance Manual 3 Safety regulations 3.1 Prevention of personnel injury It is very dangerous to adopt incorrect maintenance ⚫ methods. Make sure that you have sufficient knowledge, correct information and suitable tools and equipment for maintenance of the machine. ⚫...
  • Page 154 Excavator Operation and Maintenance Manual the machine before opening the engine hood, radiator housing, etc. ⚫ Open all pressure vessels carefully, and release any residual pressure. Residual pressure still accumulated in the system after the engine is shut down. In case of opening before release of the pressure, the fluid will be ejected under a high pressure.
  • Page 155 Excavator Operation and Maintenance Manual If one of the following conditions was satisfied, the modification will be formally permitted: 1. Auxiliary devices, accessories, assemblies, accessories or software are produced, distributed or licensed by Shandong Lingong Construction Machinery Co., Ltd. 2. The modification shall be made with the written permission of SDLG’s technique department.

  • Page 156: Prevention Of Machine Damage

    Excavator Operation and Maintenance Manual 3.2 Prevention of machine damage ⚫ It is very dangerous to adopt incorrect maintenance methods. Make sure that you have sufficient knowledge, correct information and suitable tools and equipment for maintenance of the machine. ⚫ Hoist or support the machine or its parts using the equipment with a sufficient lifting or supporting capacity.

  • Page 157: Preventing Environmental Pollution

    Excavator Operation and Maintenance Manual case that the fluid cannot be drained into the container directly, use a pump or connect a hose to drain fluid safely. Oil spilled onto the ground will pollute the environment and cause a fire. Any used oil and other fluids shall always be disposed of by an authorized waste disposal agency.
  • Page 158 Excavator Operation and Maintenance Manual hand them over to a waste disposal agency. ⚫ Do not discard the used battery, because it contains substances harmful to the environment and health. Hand it over to a waste disposal agency. ⚫ Do not discard the rags, gloves and bottles stained with oil directly, otherwise the environment will be polluted.

  • Page 159: Fire Prevention

    Excavator Operation and Maintenance Manual 4 Fire prevention 4.1 Fire prevention measures △ ! WARNING If the machine is used in an environment prone to fire, e.g. in an explosive environment, special equipment shall be provided. Be careful when cleaning the machine using a high- pressure nozzle, because electrical components and wires may be damaged even at very low water pressure and temperature.
  • Page 160 Excavator Operation and Maintenance Manual inhaling these solvent vapors. ⚫ Most solvents are flammable and should be stored properly to avoid a fire hazard. ⚫ Keep the maintenance site clean. Cleanliness is essential to the normal operation of all systems in the machine.
  • Page 161 Excavator Operation and Maintenance Manual connected with fuses, and confirm that they are not and will not be damaged due to friction. ⚫ After disconnecting the wires that are not connected with fuses, check them, and confirm that they are connected and clamped in such a way that they aren’t affected by friction.

  • Page 162: Measures In The Event Of A Fire

    Excavator Operation and Maintenance Manual 4.2 Measures in the event of a fire Take the following measures immediately after a sign of fire is found: ⚫ Drive the machine to a safe place to prevent the fire from spreading. ⚫ Lower the working device to the ground.

  • Page 163: Disposal Of Hazardous Materials

    Excavator Operation and Maintenance Manual 5 Disposal of hazardous materials 5.1 Heated paint △ ! WARNING The paint will be decomposed and produce irritating compounds when heated. Working in this environment for a long time is very harmful to health. Heated paint will emit toxic gas.

  • Page 164: Heated Fluorocarbon Rubber

    Excavator Operation and Maintenance Manual subjected to thermal insulation in advance. ⚫ Do not burn polymer materials when removing them. ⚫ Be careful when handling the machine that has been burnt or exposed to high heat. ⚫ Always gloves, goggles respiratory protective equipment.

  • Page 165: A/C Refrigerant

    Excavator Operation and Maintenance Manual redness or tingling after contact with heated fluorocarbon rubber. CAUTION: It may take several hours for any symptom to appear. ⚫ As hydrofluoric acid cannot be washed away from the skin, treat it with medicine, and seek medical care. 5.4 A/C refrigerant CAUTION! The workshop disposing of refrigerants must have been qualified r approved, and its responsible personnel...

  • Page 166: Battery

    Excavator Operation and Maintenance Manual the hazardous area to a place with fresh air. If symptoms persist, please seek medical attention. ⚫ Liquid refrigerant may cause frostbite. If this occurs, warm the affected area with warm water or warm clothing. If the symptom persists, please seek medical treatment.
  • Page 167 Excavator Operation and Maintenance Manual ⚫ Disconnect the ground wire first when removing the battery and connect it last when installing the battery, so as to reduce the risk of sparks. ⚫ The battery contains substances that are harmful to health and pollute the environment.

  • Page 168: Chapter Vi Repair And Maintenance

    Excavator Operation and Maintenance Manual Chapter VI Repair and maintenance 1 Clean the machine The machine shall be cleaned regularly. Important! Avoid using corrosive cleanser chemicals at the time of cleaning, so as to avoid damage to paint of the machine. Attention! Clean the parts with accumulation of inflammables such as wood chips, leaves and paper on the machine every day, clean up fuel, lubricating oil, etc.
  • Page 169 Excavator Operation and Maintenance Manual △ Warning The engine cannot be run when the cab is cleaned, because damage will be caused by the rotating spare parts. ⚫ It would be best to carry out cleaning after finishing work schedules and before parking the machine. ⚫...

  • Page 170: Engine

    Excavator Operation and Maintenance Manual 4 Engine 1 Oil filler 2 Oil dipstick 3 Oil drain screw plug 4 Oil filter element 5 Filter element of fuel fine filter...

  • Page 171: Check The Engine Oil Level

    Excavator Operation and Maintenance Manual 4.1 Check the engine oil level Check the engine oil level daily. ⚫ Place the machine in the maintenance position. Refer to "1 Maintenance position" of Chapter V. ⚫ Open the engine hood. ⚫ Pull out oil dipstick A, wipe it clean, insert it, and pull it out again (at least twice).

  • Page 172: Replacing The Engine Oil And Oil Filter Element

    Excavator Operation and Maintenance Manual 4.2 Replacing the engine oil and oil filter element Change the oil and replace the oil filter element every 500 hours. If the machine is working in an acidic or dusty environment, the replacement period shall be shortened. The oil filter is a disposable appliance that cannot be cleaned and must be replaced.
  • Page 173 Excavator Operation and Maintenance Manual ⚫ Turn the oil filter counterclockwise with a wrench. ⚫ Clean the mounting surface of the oil filter. ⚫ Fill the filter element with oil, place the new gasket on the new filter, and apply a proper amount of oil to the surface of the gasket.

  • Page 174: Adjusting The Clearance Of Intake/Exhaust Valves

    Excavator Operation and Maintenance Manual 4.3 Adjusting the clearance of intake/exhaust valves Check and adjust the valve clearance every 1000 working hours. To ensure the accuracy of valve opening and closing time, its clearance must be adjusted correctly. Otherwise, the engine will be noisy during operation, which will affect the engine performance and cause damage to the machine.
  • Page 175 Excavator Operation and Maintenance Manual Similar to the EGR valve, the pilot valve also needs to be inspected every 500 hours and cleaned regularly every 3000 hours, as the exhaust gas needs to circulate through the pilot valve for a long time, and carbon accumulates on its inner surface, which will damage the EGR performance.

  • Page 176: Fuel System

    Excavator Operation and Maintenance Manual 5 Fuel system IMPORTANT!! Clean fuel is essential to avoid engine running failure. IMPORTANT!! Before removing the fuel filler cap, carefully clean its surrounding parts, and avoid fuel splashing during refueling. In cold seasons, keep the fuel tank full to prevent condensation in the fuel tank.

  • Page 177: Replacing The Fuel Fine Filter

    Excavator Operation and Maintenance Manual 5.3 Replacing the fuel fine filter △ Warning Just after operating the machine, the fuel is hot, so wait for the fuel to cool down. Avoid open flames. It shall be replaced every 500 hours, and the replacement period shall be shortened when inferior fuel is used.

  • Page 178: Drainage Of Oil-Water Separator

    Excavator Operation and Maintenance Manual 5.4 Drainage of oil-water separator ⚫ Prepare a container and place it under the oil-water separator. ⚫ Close the fuel cock of the oil-water separator (set to the "OFF" position). ⚫ Drain water according to the instructions on the oil-water separator.

  • Page 179: Bleeding Of Fuel System

    Excavator Operation and Maintenance Manual Fill the filter with fuel. Use a new filter sealing ring and lubricate it. Notice! The sealing ring must be positioned and placed properly! Tighten the filter on the bracket by 1/4 turn. Notice! If the filter is tightened too much, the O-ring may be damaged, resulting in fuel leakage;...

  • Page 180: Air Filter

    Excavator Operation and Maintenance Manual 6 Air filter The air filter may prevent dust and other impurities from entering the engine. The wear of the engine depends largely on the cleanliness of the inhaled air. Therefore, the air filter shall be checked regularly and maintained properly. IMPORTANT!! In no case shall the engine without a filter or with a damaged filter be started.
  • Page 181 Excavator Operation and Maintenance Manual cleaned, just replaced. Clean the main filter element ⚫ Loosen the snap ring. ⚫ Remove the air filter cover, and gently rotate the main filter element B back and forth to slowly take it out. ⚫...
  • Page 182 Excavator Operation and Maintenance Manual ⚫ After confirming that the elasticity of the rubber ring on the new filter element is good, install the new filter element into the housing. Replace the safety filter element If the main filter element is damaged, the safety filter element acts as a protective filter.

  • Page 183: Cooling System

    Excavator Operation and Maintenance Manual 7 Cooling system If the coolant level is normal and the engine temperature becomes high, the radiator must be cleaned. IMPORTANT!! Be careful not to damage the radiator chip. 7.1 Checking the coolant level Check the coolant level daily. ⚫...

  • Page 184: Replacing The Coolant

    Excavator Operation and Maintenance Manual 7.2 Replacing the coolant The coolant shall be changed every 2000 hours or 1 year, whichever comes first. △ Warning Antifreeze is flammable, so keep it away from open flame. △ Warning The coolant will be very hot just after the engine stops running.
  • Page 185 Excavator Operation and Maintenance Manual drain valve to drain the coolant. ⚫ Open the drain screw plug on the engine cylinder block, drain the coolant and collect it with a container. ⚫ After draining the coolant, close the drain valve and drain screw plug, and refill the radiator with clean soft water.

  • Page 186: Cleaning Radiators, Hydraulic Oil And Fuel Coolers And Condenser Fins

    Excavator Operation and Maintenance Manual the radiator filler cap at this time.) ⚫ Shut down the engine, wait for about 3 minutes, add the coolant to a proper level, and then tighten the radiator filler cap. ⚫ Install the radiator bottom cover and check the cooling system for leakage.
  • Page 187 Excavator Operation and Maintenance Manual of whether it is time for regular maintenance.

  • Page 188: Hydraulic System

    Excavator Operation and Maintenance Manual 8 Hydraulic system IMPORTANT!! For all operations performed on the hydraulic system, very high cleanliness must be guaranteed. Even very small particles may cause damage or blockage of the system. 8.1 Checking the hydraulic oil level Check the hydraulic oil level daily.
  • Page 189 Excavator Operation and Maintenance Manual working conditions, the replacement cycle of the hydraulic oil shall be shortened, and the hydraulic oil shall be replaced according to the use frequency of the hydraulic hammer. △ Warning Be careful when changing oil; hot oil may burn unprotected skin..

  • Page 190: Replacing The Filter Element Of The Hydraulic Oil Return Filter

    Excavator Operation and Maintenance Manual ⚫ Remove the drain plug, install the drain valve, drain the hydraulic oil, and collect it with a container. ⚫ Unscrew the filler cap to speed up the oil draining process. Remove the O-ring and oil suction filter. ⚫...

  • Page 191: Replacing The Filter Element Of The Hydraulic Oil Suction Filter

    Excavator Operation and Maintenance Manual ⚫ Stop the engine. 8.4 Replacing the filter element of the hydraulic oil suction filter Replace it every 2000 hours of operation. ⚫ Unscrew the screw plug, remove the cover and pull out the filter element. ⚫...

  • Page 192: Releasing The Pressure In The Hydraulic Oil Tank And Hydraulic Circuit

    Excavator Operation and Maintenance Manual 8.7 Releasing the pressure in the hydraulic oil tank and hydraulic circuit IMPORTANT!! In the hydraulic circuit, there is always internal pressure. Before releasing the pressure, do not fill oil or drain oil, and do not maintain or inspect the machine. When unscrewing the hydraulic oil tank cap and hose connector, stand aside and slowly loosen it.

  • Page 193: Traveling Drive Mechanism

    Excavator Operation and Maintenance Manual 10 Traveling drive mechanism 10.1 Checking the gear oil level of traveling drive mechanism Check the oil level every 250 hours at the working temperature. IMPORTANT!! Before checking the oil level of traveling drive mechanism, be sure to clean around the oil port. If there are impurities in the oil, the traveling drive mechanism will be damaged.

  • Page 194: Replacing The Gear Oil

    Excavator Operation and Maintenance Manual ⚫ If the oil level is too low, add the specified gear oil through the filler plug C. For the selection of gear oil, refer to "18 Selection of oil products" of this Chapter, the same below. 10.2 Replacing the gear oil Replace it every 2000 hours.

  • Page 195: Electrical System

    Excavator Operation and Maintenance Manual 11 Electrical system 11.1 Battery charging △ Warning When charging the battery quickly, remove the battery cover first. When the battery is charged, explosive hydrogen-oxygen mixture generated, and short circuit and nearby open flame may cause strong explosion. ⚫...
  • Page 196 Excavator Operation and Maintenance Manual ⚫ When charging the battery, the positive pole of the charger shall be connected to the positive pole of the battery, and the negative pole of the charger shall be connected to the negative pole of the battery. Charging with reverse connection is strictly prohibited.

  • Page 197: Precautions During Welding

    Excavator Operation and Maintenance Manual ⚫ During the charging process, if a large amount of acid is sprayed from the battery vent, the charging shall be stopped immediately and the cause shall be found out. ⚫ During the battery charging, check the indicator status every hour.
  • Page 198 Excavator Operation and Maintenance Manual battery from exploding. ⚫ Remove the paint from the place to be welded (in the area at least 10 cm (3.9 inch) around the welding spot) to prevent the generation of harmful gases. ⚫ If electric welding is carried out on or very close to hydraulic equipment or pipelines, flammable steam and sparks will be generated, and there is a risk of fire or explosion.

  • Page 199: Distribution Box (Epd)

    Excavator Operation and Maintenance Manual 11.3 Distribution box (EPD) The distribution box is located in the cover plate under the seat. After opening the distribution box cover, the relay and fuse may be seen. Relay and fast fuse When the high-capacity current flows, the fast fuse protects the component, the circuit is disconnected, the distribution box sends the fault information of the fuse to the display through the CAN network, and the display displays the relevant fault...

  • Page 200: Sprinkling Can

    Excavator Operation and Maintenance Manual 11.4 Sprinkling can Check the windshield washer fluid level daily. Notice When the temperature is lower than the condensation point, antifreeze shall be added to the windshield washer fluid.

  • Page 201: Lubrication System

    Excavator Operation and Maintenance Manual 12 Lubrication system 12.1 Greasing the work equipment For the linkage lubrication points 1-12 of the work equipment, lubricate and maintain them every 10 working hours or every day. For lubrication points 13-15, lubrication maintenance should be carried out every 50 working hours.

  • Page 202: Greasing The Swing Bearing

    Excavator Operation and Maintenance Manual 1 Boom cylinder mounting pin 2 Boom mounting pin 3 Pin shaft at the end of the boom cylinder piston rod 4 Arm cylinder mounting pin 5 Boom and arm connecting pin 6 Arm cylinder mounting pin 7 Bucket cylinder mounting pin 8 Arm and bucket connecting pin 9 Connecting pin shaft of arm and connecting rod 10 Connecting pin shaft of piston rod and connecting rod 11 Pin shaft at the end of the bucket cylinder piston rod 12 Connecting pin shaft of bucket and piston rod 13 Dozer blade mounting pin...
  • Page 203 Excavator Operation and Maintenance Manual bucket to the ground. Turn the Start key to the "O" stop position. Move up the control lockout lever to lock this system. Refer to "Control lockout lever" of Chapter II. Clean the grease filler nozzle and fill the grease manually.

  • Page 204: Replacing The Bucket Teeth

    Excavator Operation and Maintenance Manual 13 Replacing the bucket teeth △ Warning It is very dangerous to move the work equipment due to mis-operation when replacing the bucket teeth. Keep the work equipment in a stable state, then shut down the engine and lock all control levers securely. If the dowel pin is knocked out with excessive force, there will be a danger of the dowel pin flying out.
  • Page 205 Excavator Operation and Maintenance Manual teeth A into the teeth seat, push in the pin assembly partially by hand, then knock the pin assembly in with a hammer, and install the bucket teeth on the bucket.

  • Page 206: Cmaintenance

    Excavator Operation and Maintenance Manual 14 A/C maintenance Clean the filter every 500 hours. Replace them every 1000 hours. If the A/C filter is blocked, the air flow, cooling and heating capacity will be reduced. Therefore, it should be cleaned regularly.
  • Page 207 Excavator Operation and Maintenance Manual ⚫ Check the surface of the heat exchanger of the condenser for foreign matter. ⚫ It is required that the inside of the radiator fins shall be clean, and there shall be no blockage between the fins.

  • Page 208: Parts That Should Be Checked At Any Time When A/C Is Running

    Excavator Operation and Maintenance Manual Insufficient refrigerant: There are bubbles emerging continuously. ⚫ Check the connection status of nuts and screws around the compressor. ⚫ Check whether there is refrigerant leakage at the connection of the refrigerant pipe and the connection inside the unit.

  • Page 209: Troubleshooting Of Common A/C Faults

    Excavator Operation and Maintenance Manual season, start the A/C at least once a month (for about 5 minutes) to prevent the drying of the gasket, O-ring or bearing inside the compressor, so as to increase the durability of the compressor and the system and minimize the leakage of the refrigerant.
  • Page 210 Excavator Operation and Maintenance Manual d. Air leakage; Check for air leakage between the evaporator and the air duct. Poor compressor start a. The fuse in the fuse box is disconnected; Check and replace the fuse. b. Poor pressure switch or abnormal pressure; Check the connection of pressure and high-voltage switch harness or replace the high-voltage switch.
  • Page 211 Excavator Operation and Maintenance Manual a. Poor condensation of the condenser; Check the surface of the condensing heat exchanger for foreign matters and clean it. b. Excessive refrigerant: The temperature of the low- pressure pipe is too low or the pressure is too high; Inject an appropriate amount of refrigerant after discharging the refrigerant or re-vacuumizing.

  • Page 212: Operation Of Accumulator

    Excavator Operation and Maintenance Manual 15 Operation of accumulator Warning The accumulator is filled with high-pressure nitrogen. Handle with care. Otherwise, it will cause serious accidents or injuries. - Do not knock, drill, or weld the accumulator. - Keep it away from open flame or other high heat sources. - If you operate the control lever downward just after the engine stops, the accumulator may make the accessory move by its own weight.
  • Page 213 Excavator Operation and Maintenance Manual 4 Move the lock control lever downward to unlock the system. 5 Move the control lever and pedal forward/backward and leftward/rightward to their end positions respectively so as to release the pressure in this control circuit. 6 Turn the ignition key to the "O"...

  • Page 214: Track Tension

    Excavator Operation and Maintenance Manual 16 Track tension 16.1 Check the track tension Check the track tension every 50 hours. △ Warning Check the track tension, in which case the track must be lifted off the ground. When taking measurements, great care should be taken to avoid the track falling or moving.

  • Page 215: Adjusting The Track Tension

    Excavator Operation and Maintenance Manual 16.2 Adjusting the track tension △ Warning Valve A may be ejected by the high-pressure compressed grease in the oil cylinder. Do not loosen more than one turn when loosening valve A. Do not loosen other components except valve A. In addition, keep away from the valve installation position.

  • Page 216: Lubrication

    Excavator Operation and Maintenance Manual 17 Lubrication Lubrication is an important part of maintenance. If the machine is lubricated correctly, the service life of the gasket, bearings, and bearing pins may be greatly extended. Lubrication diagrams may make lubrication easier and avoid the missing of lubrication points.

  • Page 217: Regular Maintenance

    Excavator Operation and Maintenance Manual 18 Regular maintenance Regular servicing is divided into servicing every 10 hours, every 50 hours, every 250 hours, every 500 hours, every 1000 hours, and every 2000 hours. 18.1 Maintenance every 10 hours Check the engine oil level. Refer to "4.1 Checking the ⚫...

  • Page 218: Maintenance Every 250 Hours

    Excavator Operation and Maintenance Manual Refer to "12.1 Filling grease into work equipment" of this Chapter. (It shall be filled daily within the first 100 working hours of a new machine.) ⚫ Check the oil-water separator for water or sediment and drain it (if any).

  • Page 219: Maintenance Every 1000 Hours

    Excavator Operation and Maintenance Manual every 250 hours shall be carried out at the same time. ⚫ Replace the engine oil and filter element. Refer to "4.2 Replacing the engine oil and oil filter element" of this Chapter. ⚫ Replace the fuel fine filter element. ⚫...

  • Page 220: Maintenance Every 3000 Hours

    Excavator Operation and Maintenance Manual 1000 hours shall be carried out at the same time. ⚫ Replace the filter element of the ventilation filter of the hydraulic oil tank (or replace it if necessary). Refer to "8.6 Replacing filter element of ventilation filter" of this Chapter. ⚫...

  • Page 221: Regular Replacement Of Main Components

    Excavator Operation and Maintenance Manual 19 Regular replacement of main components When operating or driving the machine, the user must check and maintain the machine regularly to ensure safety. In addition, to further improve safety, users should also regularly replace the parts specified in the list of parts subjected to periodic replacement.
  • Page 222 Excavator Operation and Maintenance Manual Regular replacement of Replacement Quantity safety-critical parts cycle Fuel hose (fuel tank - fuel injection pump) Fuel hose (fuel filter element - fuel injection Fuel return hose (nozzle - Every 2 years pump) fuel tank) Hose (main pump oil or 4000 outlet)

  • Page 223: Recommended Lubrication

    Excavator Operation and Maintenance Manual 20 Recommended lubrication Recommended viscosity at different ambient temperatures —30 —20 —10 ℃ —22 —4 +104 +122 System Oil quality grade ℉ SAE 5W—30 SAE 10W—30 Engine oil Engine *SAE 15W—40 API CK-4 SAE 30 SAE 40 Traveling *SAE 90...
  • Page 224 Excavator Operation and Maintenance Manual Engine oil Use engine oil that meets or exceeds the following standards or grades: ➢ API Servicing Classification CJ-4 ➢ ACEA Servicing Classification E6 ➢ JASO Servicing classification DH-2 Notice Use the specified engine oil only. Using other engine oil will affect the warranty, thereby causing seizure of internal components of the engine and/or shortening the service life of the engine.
  • Page 225 Excavator Operation and Maintenance Manual - Reduce engine efficiency and durability - Increase corrosion - Increase sediments - Reduce fuel economy - Shorten the time interval between oil replacement period - Increase overall operating costs Biodiesel Biodiesel is a renewable oxygen fuel made from agricultural and renewable resources such as soybeans or rapeseeds, and biofuel is a fuel composed of methyl or ethyl ester-based oxygenators using long-chain fatty acids, which are obtained in the form of transesterification from vegetable oils, animal fats, and edible oils.
  • Page 226 Excavator Operation and Maintenance Manual Warranty does not cover damage caused by mixing with biodiesel higher than 7% Coolant For filling and replacing the coolant, it is recommended to use SDLG coolant LCS. Do not mix different coolants or corrosion protectants as this may cause damage to the engine. If concentrated coolant LCS and purified water are used, the mixture shall contain 40-60% of concentrated coolant and 60-40% of purified water.
  • Page 227 Excavator Operation and Maintenance Manual ➢ Long-life coolants of different models and/or different colors shall not be mixed. Hydraulic oil Only the SDLG hydraulic oil certified by us may be used. Do not mix different brands of hydraulic oil as this may cause damage to the hydraulic system.

  • Page 228: Capacity

    Excavator Operation and Maintenance Manual 21 Capacity Capacity Engine oil 11.5L (338.9 fl oz) Coolant 11.5L (338.9 fl oz) Hydraulic oil (hydraulic oil tank) 45L (1521.9 fl oz) Hydraulic oil (hydraulic system, total) 96L (3246.7 fl oz) Gear oil (swing motor gearbox) Gear oil [traveling motor gearbox (each)] 1.3L (44.0 fl oz) Fuel...

  • Page 229: Units And Conversions

    Excavator Operation and Maintenance Manual 22 Units and Conversions Common units and conversions in the Manual Unit prefix 前缀 符号 系数 百万 × 1000000 千 × 1000 厘 × 0.01 毫 × 0.001 微 µ × 0.0000001 Length unit mile ×1.6090 = km ×0.3050...
  • Page 230 Excavator Operation and Maintenance Manual Mass unit ×0.45360 = kg ×28.35000 ×2.20500 = lb ×0.03527 = oz Force unit ×4.4480 ×0.4536 = kgf ×0.2248 = lbf ×0.1020 = kgf ×2.2050 = lbf ×9.8070 Torque unit ft-lb ×1.3558 = N·m ft-lb ×0.1383 = kgf·m in.-lb...
  • Page 231 Excavator Operation and Maintenance Manual Pressure unit ×0.0689 = bar ×6.8950 = kPa ×0.0703 = kg/cm² ×14.5030 = psi ×100.0000 = kPa ×29.5300 = in.Hg(60°F) ×0.1450 = psi ×0.0100 = bar ×0.0102 = kg/cm² kg/cm² ×98.0700 = psi kg/cm² ×0.9807 = bar kg/cm²...

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