mini excavator - kattrak€¦ · foreword this manual contains safety, operation, maintenance, and...

OPERATION MANUAL

35N3

MINI EXCAVATORSERIAL NUMBERS:

WM003001-up

IHI

IHI Construction Machinery Limited

PUB. No.10708 USA

FOREWORD

This manual contains safety, operation, maintenance, and adjustment information.The procedures are designed to provide the best performance of the machine in aneffective and economical way. In order to obtain it, remember the next basic rules.

• This manual should be stored in the operator's compartment in the literatureholder or seat back literature storage area.

• Before inspection, maintenance or operating the machine, read andunderstand this manual completely.

• Since all of the explanations in this manual may not be thoroughly understoodat first, repeat reading it until abilities as an operator are obtained anddeveloped for proper operation.

• Further abilities as an operator outside of descriptions in this manual can beobtained from the experience during normal operations and under propersupervision.

• The illustrations in this manual are used first of all to let you pay attention.They do not show all of illustrations in this manual. Because of continuingimprovement and advancement of product design, the shape of machine inthe illustrations may be partly different from your machine. Please understandit. Whenever a question arises regarding your machine, or this publication,please consult your local Ihl distributor for the latest available information.

0-1

CONTENTS

PageFOREWORD· . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 0 - 1

CONTENTS 0 - 2

SAFETY INFORMATION·································· 0-4

1. SAFETY1 - 1 General' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 - 1

1 - 2 Mounting and Dismounting . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 - 5

1 - 3 Before Starting the Engine .. . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 - 6

1 - 4 Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 - 6

1 - 5 Before starting the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 - 7

1 - 6 Operating the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 - 8

1 - 7 Safe Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 - 22

1 - 8 Towing' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 - 25

1 - 9 Safe Transportation' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 - 26

1 - 10 Parking the Machine' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 - 27

1 - 11 Safe Maintenance' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 - 28

1 - 12 Warning Signs and Labels ... . . . . . . . . . . . . . . . . . . . . . . . . .. 1 - 33

2. OPERATION2 - 1 Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2 - 1

2 - 2 Controls and Instruments' . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2 - 2

2 - 3 Before Starting the Engine 2 - 11

2 - 4 Starting Engine' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2 - 12

2 - 5 Jumper Cable Starting 2 - 13

2 - 6 After Starting the Engine' . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2 - 14

2 - 7 "Break-in" Operation' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2 - 14

2 - 8 Backhoe Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2 - 15

2 - 9 Operating the Special Attachments and Actuators ... . . . . . . .. 2 - 182 - 10 Traveling the Machine' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2 - 20

2 - 11 Towing' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2 - 23

2 - 12 Lifting the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2 - 24

2 - 13 Loading and Unloading the Machine 2 - 25

2 - 14 Precaution on Use of Rubber Track Shoe' . . . . . . . . . . . . . . . .. 2 - 26

2 - 15 Boom Lowering with the Engine Stopped . . . . . . . . . . . . . . . . .. 2 - 272 - 16 Parking the Machine' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2 - 29

2 - 17 Emergency Engine Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2 - 29

0-2

MAINTENANCE3.

3- 1

3- 2

3- 3

3- 4

3- 5

3- 6

3- 7

3- 8

3- 9

3 -10

3 -11

Maintenance Intervals· .

Lubrication Chart Maintenance and Checks .

Recommended Lubrication Table .

When Required Maintenance and Checks .

Daily Maintenance and Checks .

50 hours Maintenance and Checks .




2 years Maintenance and Checks' .

Unusual Operating Conditions .

Long Term Storage .

Page

3- 1

3 2

3- 3

3- 4

3 -10

3 -14

3 -15

3-20

3-25

3-28

3-30

3-33

4. TROUBLE SHOOTING4 - 1 Trouble and Remedy' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4 - 1

5. HYDRAULIC SYSTEM DIAGRAM5 - 1 Hydraulic System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5 - 1

6. ELECTRICAL SYSTEM DIAGRAM6 - 1 Electrical Wiring System Diagram' . . . . . . . . . . . . . . . . . . . . . .. 6 - 1

7. SPECIFICATIONS7 - 1 General Specifications 7 - 1

7 - 2 Overall Dimensions' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7 - 3

7 - 3 Working Renges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7 - 4

0-3

SAFETY INFORMATION

We offer you basic and important rules and precautions for safe operations.

Read, understand, and observe them before starting operation. This is the most essentialway to prevent accidents.Wrong operation, inspection, or maintenance can cause personal injury or death.

Throughout this manual and on the machine, precautions are provided with mmarks

and classified by the words "DANGER", "WARNING", and "CAUTION" according totheir extent of danger.The classification is as follows :

~ indicates an imminently hazardous situation which, if not avoided, willresult in death or serious injury.

~ indicates a potentially hazardous situation which, if not avoided, couldresult in death or serious injury.

1m CAUTION I] indicates a potentially hazardous situation which, if not avoided, couldresult in minor or moderate injury. It may also be used to alert againstpossible damage to the machine and its components.

We have made every effort for you to prevent accidents during operation, however, wecannot be held responsible for predicting every kind of danger in all operating conditions.It is the owner or user of the machine who is responsible for ALWAYS paying attention tooperate the machine; as well as reading and understanding this manual enough to obtainthe essential knowledge and skills fundamental to correct machine operation.

~• BEFORE inspection, operation, or maintenance of the machine, be sure to

read and understand this manual.• Incorrect operation or maintenance of the machine can cause the accident

and serious injury or death.• Keep this manual on hand during operation so that you can immediately

consult it when necessary. If it should be missing or damaged, place an orderfrom IHI distributor for a replacement.

• There are various kinds of federal, state, and local regulations that effectconstruction and industrial machinery. Since the requlations are subject tochange, and differ from one locale to another, it is impossible for us to providesuch information in this manual.It is the responsibility of the owner or user to be familiar with the regulations.

• Specifications and materials of the machine are subject to change withoutany obligation on the part of the manufacturer.

0-4

JUI SAFETY

SAFETY TIPS

I]

This section explains safety tips which youwill find throughout this manual and on themachine.Periodically check labels and platescontaining those tips for damage.If they are damaged, clean or replace them.For replacement, contactyour local lhl dealerwith their Parts Numbers in the PartsCatalogue.

Remember that the safety tips that weprovide cannot cover every kind of dangerthat you may encounter during operation.

11-1 GENERAL I

OBSERVE THE BASICS FOR SAFE ANDEFFECTIVE OPERATION.

The operator's knowledge, skills, andexperience are the most important to utilizethe machine. Therefore, be sure tounderstand operation procedures and to takenecessary training.

OPERATOR SHOULD BE QUALIFIED.

Only qualified operators should be authorizedto operate the machine, and those soauthorized should do so only when physicallyand mentally alert.The operator should be to be familiar with thehazards and necessary safety measuresunique to the operation of hydraulicexcavators.

1 -1

~'" rr__iiQ

JDIREAD AND UNDERSTAND THEINSTRUCTIONS AND WARNINGS.

This manual, plates, and labels on themachine contain necessary instructions andwarnings for safe operation. You aresupposed to read and understand them first.If you should ignore them, injury or death mayoccur. Do not leave what you do notunderstand as it is. Your IHI distributor is gladto answer any question.If the manual, plate, or label is missing ordamaged, contact IHI distributor forreplacement.

OPERATOR SHOULD BE IN GOODHEALTH.

operator should be physically and mentallyalert, which is one of the best insuranceagainst an accident.

NEVER operate the machine under theinfluence of alcohol. medication, orintoxication.

SAFETY II

WEAR PROPER WORKING CLOTHES.

Wear working clothes that closely fitoperators. Avoid loose jackets, shirt sleeves,rings, and other jewelry which may be caughtin moving parts. Avoid also oil stained ordamaged garments. Shoes should be clear ofgrease or mud before operation.Always wear required protective items suchas hard hats, safety glasses. reflectiveclothing. safety shoes, and ear protection asrequired,

1 -2

JUIPERFORM "WALK-AROUND"INSPECTION.

Walk around the machine to check safety

guards, plates. and other related parts are setin place. Do not attempt to operate themachine when any unsafe condition isdetected.

NEVER ASSUME ANYTHINGGUARANTEED.

SAFETY

\'!;\G6-

0'.. \ ."' ....... ~,. ,. .... '.

II

Never assume that everything is all right atthe start of a work day just because it seemedsatisfactory at the end of the previous workday. Before beginning each days operation,thoroughly inspect the entire excavator forsigns of vandalism.

MAKE A WORK PLAN.

Prior to operation, investigate your job sitesufficiently.When any obstruction or hazardsare detected, mark it so that all personnel areaware of it. Avoid any oversight that maycause serious accident.Observe a local weather forecast and discusswell work procedures and let all personnelknow them without exception.

1-3

WATCH FOR UNDERGROUND UTILTIES.

Mark the location of underground utilitiessuch as gas lines, sewers, and power linesbefore any digging operations. If necessary,the utilities should be temporarilydiscontinued.

CHECK THE JOB SITE.

ALWAYS check the job site for grade andstability of the ground, ventilation, depth ofwater and ambient obstructions. Avoidoperating your equipment too close to anoverhang.

Since this machine is not provided with antiexplosion design, NEVER use it inside atunnel or in explosive environment to avoidhazard caused by an explosion.

CLEAR ALL PERSONNEL FROM THEMACHINE AND AREA.

Be sure to barricade the job site to prevententry of the unauthorized. Confirm that thereis no one around the machine before startingthe engine or operating the machine.

SAFETY

.•,. ;.0 I •••• ,.I ~ : 1..:••..····;··' .. '·..·m···:· .. ,·~····· .. ··· ..·m·····' .":OJ ~~~:.~ :-.;:>

11 :

1-4

MAINTAIN GOOD VENTILATION.

Take a countermeasure to Vent the exhaustgas to the outside to start and operate theengine, in a pit, tunnel, or trench. In such aplace, the air trends to stagnate. It is verydangerous to inhale the exhaust gas.Remember, exhaust gas can kill you.

DO NOT MODIFY THE ROPS/TOPS.

Do not modify the ROPS/TOPS unlessinstructed to do so in installation instructions.Modifications such as welding, drilling orcutting can weaken the structure and reducethe protection it provides. A damaged ROPS/TOPS can not be repaired - it must bereplaced.

SAFETY

11-2 MOUNTING AND DISMOUNTING I

CAREFULLY MOUNT AND DISMOUNTTHE MACHINE.

ALWAYS use steps and handholds to mountand dismount the machine.Hold the handholds with both hands and facethe machine keeping a contact with at leastthree points of the steps and handrails.

NEVER hold control levers at mounting anddismounting.

NEVER not try to mount or dismount themoving machine.

NEVER jump off the machine.

Do not try to climb on or off the machine withimplements or supplies in your hand.

1-5

11-3 BEFORE STARTING THE ENGINE

FOLLOW THE NEXT PRECAUTIONS.

• Clear all personnel from the machine andthe area.

• Move all control levers to the NEUTRALposition before starting the engine.

• Inspect the condition of the seat belt andmounting hardware. Replace anydamaged or worn parts.

• Fasten the seat belt (if equipped) securely.

• Adjust the operator's seat to be able todepress the pedal completely.

SAFETY

Fasten the seat belt.

11-4 STARTING THE ENGINE

Adjust theoperator's seat

• ALWAYS start the engine only from theoperator's seat following the startingprocedure in this manual.

• When the start switch or controls aretagged with "DoNotOperate", do not startthe engine or move any of the controls.

• NEVER short across the starter terminalsor across the battery.

1-6

SAFETY

\1-5 BEFORE OPERATING THE MACHINE IFOLLOW THE NEXT PRECAUTIONS RIGHTAFTER STARTING THE ENGINE.

• Clear all personnel from the machine and thearea.

• Make sure the machine horn and all otherwarning device are working properly.

• Be sure all Windows are clean.• Check for proper operation of all controls and

protective devices while moving slowly in an

open area.• When any defect is detected, immediately report

it.

CONDUCT WARM-UP BEFORE OPERATION.

It is ESSENTIAL to conduct warm-up operationafter starting the engine in order to run thehydraulic fluid smoothly.

The pumps may squeak because of the cold andthick hydraulic fluid, which results in the damage tothe pumps.ALWAYS take a time to warm up the fluid withrunning the engine at a low speed to maintain theFREE FLOW OF OIL.

BE SURE TO LOCK DOORS AND OTHERS.

Be sure to lock doors, front windows, and lidsbefore starting operation.Operating with unlocked doors may causepersonal injury,

Crushing of finger or hands.

1-7

JUI SAFETY II11-6 OPERATING THE MACHINE

KEEP EACH OPERATION SECUREDFOR SAFETY.

Conduct every operation with great care forsafety. If you operate the machine roughly, Itmay cause damage to the machine, degradethe machine performance, and result inserious accidents.

OPERATE CONTROL LEVERS IN A WISEWAY.

Do not get angry with the control levers whenyou cannot operate the machine as desired.It may degrade the machine performanceand damage the machine instead ofimproving the situation.ALWAYS consider the machine capacity andtake a time to clear problems in the best way.

OBSERVE THE NEXT PRECAUTIONSFOR SAFE OPERATION.

• Do not read.• Do not drink.• Do not eat.• Do not be distracted. If you have to divert

yourself from the machine operation, stopthe operation first.

ALWAYS OPERATE THE MACHINEONLY FROM THE OPERATOR'S SEAT.

NEVER attempt to operate the excavator

from any position except the operator's seat.If you operate the machine from any otherposition, such as standing by the window ordoor, you may operate the machineinaccurately, which can cause serious injury.Remember that you should not get on or getoff the moving machine to be seated or toleave the machine.

1-8

WATCH FOR OVERHEAD WIRES.

SAFETY

Care must be taken that the boom does notcontact, or even close to, overhead wires.

Know the maximum height and around of themachine. When working near overheadelectrical lines, keep a distance of at least 10feet (3 m) plus an additional 4 inches (100mm) for each 1 , 000 volts over 50.000 volts.Check for local and state codes, which mayrequire a greater distance for safety.Treat alllines as energized.

-DEATH OR INJURY MAY RESULT FROMCONTACTING ELECTRIC LINES.

ALWAYS CONTACT THE ELECTRIC POWERLINE OWNER. THE ELECTRIC POWER SHALLBE DISCONNECTED OR THE POWER LINESMOVED OR INSULATED BEFORE MACHINEOPERATIONS BEGIN.

NEVER OPERATE THIS MACHINE WITHIN10FEET(3m) OF ELECTRIC POWER LINES.

NEVER LEAVE LOAD SUSPENDED INTHE AIR.

NEVER leave the load suspended in mid air,when the machine is out of service, or youhave to leave the machine. ALWAYS putdown the bucket or load onto the ground.Should a malfunction occur, it could fall,striking equipment or personnel.

Should contact occur, stay on the machineuntil the boom is cleared or until the currentis turned off. Keep all personnel off themachine. If you must leave the machine,JUMP, DO NOT STEP OFF.

Electrical shock I erectrocution

1-9

JDINEVER ALLOW ANYONE TO RIDE THEATTACHMENT OR THE LOAD.

NEVER attempt to lift personnel using theattachment since the machine is designed toexcavate and move NOT personnel BUTmaterials. If you lose control of theattachment in such a trial, the personnel willbe dropped down, which is likely to occur.NEVER LIFT, SWING, OR LOWER A LOADOVERANYONEORALLOW AJNYONE TORIDE TEE ATTACEMENT OR THE LOAD.

PROVIDE ADEQUATE TAILSWINGCLEARANCE.

Confirm that there is a sufficient clearancearound the machine for swinging operation.The operator tends to be unconscious of thearea behind the machine. Before tailswing,make sure that there no personnel or objectsin such area.

JI----_

SAFETY II

ALWAYS check for personnel or objectsaround the machine before swinging.

NEVER SWING OVER PERSONNEL

Be sure that no personnel are workingaround the machine before swinging.Pay attention to invisible workers in a trenchor pit in particular. Follow the signal person'sdirection not to swing over such workers.

1 -10

JUICAREFULLY TRUCK LOADING

SAFETY II

Load the truck from the rear wheneverpossible. NEVER swing the load over thetruck cab. "High altitude" dumping into thetruck is a dangerous practice. Use the bucketwrist action for precise dumping.

NEVER dump over truck cab. ALWAYS besure truck driver is OUT OF TRUCK CABand clear of the dumping bed when lifting.

ALWAYS OBSERVE THE BUCKET ANDLOAD.

ALWAYS watch the moving bucket or loadcarefully. Moving bucket or load without caremay cause injury to personnel or materials. Ifyou have to look away from it, stop themachine.

<

NEVER CAUSE PHYSICAL SHOCK TOHYDRAULIC CYLINDERS.

Be careful to protect the cylinder from anydamage during operation. The hydrauliccylinder is not immune to physical shock. Ifthe cylinder is collided or bumped, it may bedistorted.

1 -11

JDITAKE SIGNALS FROM ONE SIGNALPERSON EXCLUSIVELY.

use only signals which are predeterminedand common to all personnel. Only one signalperson should exclusively direct and givesignals to personnel

NEVER ALLOW PERSONNEL RIDE ONTHE MACHINE OTHER THANOPERATOR.

Only operator is authorized to be on themachine during operation.Never let unauthorized personnel ride on the

machine.

<>

SAFETY II

CAREFULLY OPERATE THE BUCKET.

Slow down the operation when controlling thebucket or moving the filled bucket close to theoperator's cab in particular. which preventsthe load from being dropped into the cab.

1 -12

PREVENT THE BUCKET FROM HITTINGTHE DITCH.

Be careful that the bucket will not hit the wallsof ditch or the bank during swingingoperation. This is likely to occur whenconducting digging and dumping alternately.Move the bucket slowly.

SAFETY

~I

Ip·••••lIlMlI.PI 3

NEVER SWEEP WITH THE BUCKET.

Avoid sweeping the bucket like a broom inorder to level off ahead of machine. Thiscauses side strains and wear on the boom,arm, and bucket.

DO NOT MOVE THE ATTACHMENTS TOTHE EXTREME ENDS OF THE STROKE.

If the rod is extended to the stroke end of thecylinder, the shock applies a large force to thecylinder, which may cause a damage to theboom or arm.Operate the machine without moving thecylinder to the extreme end of the stroke.

It is recommended to operate theattachments near the stroke end of thecylinder.

USE AN EXCLUSIVE MACHINE TO DIGOR BREAK EXTREMELY HARDMATERIALS.

Do not use the bucket to dig or break veryhard materials like concrete. This will causedamage to the machine.

1 -13

JUIDO NOT OVERLOAD TO CYLINDER.

Do not forcefully conduct digging operationbeyond the capacity, which may overload anycylinder and open its relief valves. Thiscauses damage to the hydraulic system andmachine.

SAFETY II

NEVER CONDUCT DIGGINGOPERATION WITH FALLING FORCE OFMACHINE.

Do not raise off the rear of the machine fromthe ground and drop it down for digging up.This will cause excessive shock and damageto the machine.

MEASURE DEPTH OF WATER ANDCHECK CONDITIONS OF RIVERBEDBEFORE FORDING.

Before fording, measure the depth of waterand check the riverbed for holes. bumps, andany dangerous condition by following the

next:• Measure the depth of water first.• Stop the machine and swing the bucket

under the water to detect any bump orobstacle.

• Lower the bucket to measure the depth ofwater and detect holes occasionally.

OBSERVIE THE ALLOWABLE WATERDEPTH.

Allowable depth of water is limited up to thecenter of the upper rollers.Be sure to lubricate long-soaked parts untilold grease comes out of the bearings.

1 -14

Allowable water depth

JUIDO NOT CRAWL WITH THE BUCKET.

Do not drag the bucket on the ground bycrawling. Level the ground with properequipments in a correct way.

UTILIZE THE BLADE FOR DIGGINGOPERATION.

Use the blade as a stabilizer for digging andfollow the next precautions.

• Keep the entire blade contact with theground. If the blade stays at an angle tothe ground, or touches the ground partially,it may be damaged or loose its balance.To avoid this, level the ground first.

• Do not use the blade to excessively raisethe tracks. Lower the blade only within arange where the tracks behind the bladelift slightly to ground the blade as astabilizer.

MAINTAIN A CORRECT BLADE POSITION.

If you need to conduct the deep digging withthe blade, do not raise the blade so that theblade will not contact with the boom cylinder.Position the blade to rear if it is not necessary.

SAFETY II

1 -15

JDITOPS THAT PROTECTS YOU FROMBEING CRUSHED BY THE TIPPEDOVER MACHINE

The cab-type machine is equipped with aTOPS (Tip over protective structure) as astandard specification.The canopy-type machine is not equippedwith a TOPS as standard, however,when thedanger of turnover is expected while workingon a soft. uneven. or included, werecommend the use of TOPS canopy.Be sure to fasten the seat belt while operatingthe machine

NEVER try to jump out of the cabin when themachine falling down. This may crash anoperator to serious injury or death.TOPS canopy is avoidable as option.Consult your local IHI dealer.

THE FRONT GUARD PROTECTS ANOPERATOR FROM FLYING OBJECTSTHE FRONT.

When braking materials with the machineand objects are likely to fly from the front, thefront guard shall be equipped. If it is notequipped, flying objects may cause injury ordeath.

The front guard is avoidable as option.Consult your local IHI dealer.

SAFETY

Never try to jump out

~'r\ T/"'r::':..rr.(J

Stay in cabin

" .... " . ,.. ..:~ .......... ,.#;", ..

II

FOPS (TOP GUARD) PROTECTS ANOPERATOR FROM FLYING OBJECTS.

When working underneath cliff or destroyinga building with the machine, the top guardshall be equipped.Use the top guard to protect the operator andwatch falling object. Otherwise falling objectsmay cause injury or death.The top guard is avoidable as option. Consultyour local IHI dealer.FOPS: Falling-object protective structure.

1 -16

JD'SECURE FOOTING FOR SAFEOPERATION.

Check, that the machine footing is level andfirm to avoid the skid or overturn. If you needto operate the machine on the shoulder of aroad or a grade. check the ground forlevelness and stability prior to operation.

BE CAREFUL TO PREVENT TURNOVER.

The operating radius should be as small aspossible when using the heavy bucket, andswing the boom slowly to prevent a turnover.Also, watch for buried objects during diggingoperation to prevent a turnover.

SAFETY II

AVOID UNDERCUTTING THE MACHINE.

Do not try to dig close to the machine. If youundercut the machine, the footing may easilycollapses. Recede from the digging siteenough to keep a distance.

EMERGENCY ESCAPE

If the machine tips over and the cab door willnot open, break the window with the hammerfor emergency escape located at the rear ofthe operator cab and escape away from the

machine.

1 -17

Rightwindow

OBSERVE FOOTING AT SWINGING.

To avoid tipping of the machine in swingingmotion, check the machine footing whether itis level enough or not.

OBSERVE PRECAUTIONS ONOPERATION ACROSS TRACKS.

Pay attention to avoid turnover of themachine when lowering and swinging theboom from the blade side to either side of themachine at the same time. Since the width ofeach track is shorter than its length, stabilityis poorer over side than on the blade side.On a grade, operate the machine slowly withthe retracted arm in a reduced workingradius.

SAFETY

OBSERVE PRECAUTIONS WHENOPERATING WITH LONG ARM.

Observe the following precautions to use thelong arm.

Q) Do not use any combination of arm andbucket that we do not specify.

ell Do not use the breaker attachment.

@ Do not lower and swing the boom at thesame time on a soft ground or grade. ((Operate the machine slowly with theretracted arm in a reduced working radius.

1 -18

JDIREMEMBER OPERATING LIMITS.

1. Ground conditionsThe, ground should be level and firm for

safe operation.If you have to operate the machine on agrade. the machine should be parallelwitha grade. Do not have it cross a grade.If you have to operate the machine on asoft or unlevel ground, carefully operatethe machine to avoid serious accidentslike a turnover.

SAFETY II

__ -_r-):::· __-....- -ON SOFT GROUND

2. Use of attachment

CD When using the longer arm, great careshould be taken. If tends to reduce themachine stability and limits the bucketsize. Slowly operate the machine withthe longer arm and watch the groundcondition.

@ When using the larger bucket, greatcare should be taken. It tends toreduce the machine stability. Slowlyoperate the machine with the largerbucket and watch the groundcondition.

® ALWAYS use a bucket whose capacitymeets the specification.

ON UNEVEN GROUND

1 -19

JUILIFT COORDINATOR

One person should assume responsibility forcoordinating all facets of the lift. He must takeinto consideration the operator, the machine,other personnel. bystanders and thesurrounding area. He must be totally alert tothe hazards involved, have in-depthknowledge of proper procedures andexercise good common sense all time.

DO NOT OVERLOAD LIFTING.

SAFETY II

Prominent among the safety measuresunique to hydraulic excavators is the solereliance upon the manufacturer's load ratingchart as a guide to lifting capacity. Relyingupon signs of tipping to warn of overload canresult is machine damage or personal injury.Lifting capacity in excavators is usuallydetermined by hydraulic and structuralfitness, not tipping load. Before making a list,ALWAYS consult the load rating chart in theoperator's cab.

Stay within the lifting limits when laying pipes.Remember, you may be able to lift the pipeclose in at ground level, but as you reach outand down, the lifting capacity decrease. If themachine is not on level ground. an instabilitywill result, which could cause tipping. alwaysuse short slings to prevent excessive loadswing.

TION

There may be some local governmentregulationsregarding the use of excavatorsto lift heavy objects. Please observe thoseregulations where they apply.

CHECK THESLING CABLE ANDDEVICES.

ALWAYS be certain that slings, ties andhooks are properly placed, secure, ofadequate capacity and good condition beforelifting materials

1 - 20

JUILIFT THE UNDERCARRIAGE IN APROPERWAY.

Do not lift up the machine excessively or inincorrect direction, which may cause aturnover.

In particular, avoid lifting up the machine withthe extended arm at an angle with themachine.

When you have to lift up the machine.position the tracks either parallel with or atright angle with the machine.

POSITION THE ARM VERTICALLY.

Do not try to lift up the front end of the trackswith the arm cylinder or bucket cylinder fullyextended.Position the arm vertically against the ground

for lifting.

NEVER USE THE BLADE TO EXTRACTPILES.

Do not use the blade to lift up the machine toextract a pile. The great force of the bladecylinder overloads the machine, theattachment. cylinders, and other parts, which

may cause serious accidents.

SAFETY II

1 - 21

JDI SAFETY

1-7 SAFE TRAVEL I

I!

ALWAYS CHECK THE TRAVELDIRECTION.

ALWAYS check in which direction thesuperstructure faces before controlling thetravel levers. The machine is likely to travel inthe opposite direction to your expectationwhen the superstructure directly faces to therear.

MAINTAIN OVERHEAD CLEARANCES.

ALWAYS be on the alert for overheadobstacles and be sure there is adequate sideclearance when traveling. Get the assistanceof the man on the ground when clearancescannot be ascertained from the operator'sposition.

CAREFULLY TRAVEL THE MACHINE INA NARROW AREA AND LOWCLEARANCE.

NEVER travel in an area where persons arecoming and going or there are many objects.ALWAYS keep a safety distance around themachine. In a narrow area. place a signalperson to guide the operator.Before traveling, keep away persons from thetraveling range.

1-22

JDICAREFULLY GO DOWNHILL.

SAFETY II

Keep the bucket 200 mm to 300 mm@abovethe ground while traveling on a grade.When the machine skids or loses its balance,immediately put down the bucket onto theground and stop travel.Do not travel down in backward direction.When traveling over any object, keepattachment close to the ground and slowlytravel.

• When traveling uphill, or on a slope, keepthe boom on the uphill side of the machine.

NEVER STEER ON A GRADE.

NEVER steer on a grade or unstable ground,which causes a turnover.NEVER travel across a grade.When traveling on a grade, travel up anddown in parallel with the grade. Be careful totravel on the frozen ground since the machinetends to skid or fall down.

CHECK BRIDGES ARE SAFE.

Check the capacity of any bridge to becrossed to determain whether it will supportthe machine's weight.

1-23

JDI SAFETY IISLOWLY TRAVEL THE MACHINE INSPECIAL CONDITIONS.

Travel slowly when the ground is rough orcovered with chunks of rock. Control thetravel speed with the engine throttle lever.NEVER cause shocks to the tracks and themachine.

POSITION THE DRVIE SPROCKET TOTHE RIGHT POSITION.

ALWAYS travel with the drive sprocket torear. Keep the drive sprocket to rear in longtravel in particular. If you position tt to front,wear at the lower structure will be enhanced.

UTILIZE MATS AT A SPECIAL JOB SITE.

Use mats made of lumbers to support themachine on the soft ground or in a marsh.Use the clean and level mats for safeoperation. Remember that the mats cannotsupport the machine in every condition.Carefully check the job site first and confirmthat safety can be secured by the mats.

~\G6-o\6.ef-==-~--'--===I »)"

Sprocket

1-24

JDIALWAYS MAKE SLOW TURNS.

ALWAYS try to make slow turns as much aspossible other than emergency. Sharp turnsor standing pivot turns will shorten themachine useful life.

Slowly change the travel direction on theunlevel or rough ground. Sharp turns tends tooverstress the crawler.

SAFETY I]

1-8 TOWING

CAREFULLY TOW THE MACHINE.

If the machine sinks down on a soft groundand cannot crawl up by itself, a wire ropeshould be attached to the rear axle and themachine should be towed by a towingmachine.

NEVER attach the wire rope to the towinghook at the rear axle, which causes damageto the axle and the hook, and personal injurymay occur.

USE THE TOWING HOOK PROPERLY.

The towing hook is used to tow for lightweightmaterial. The maximum allowable towedweight is 500kg.

NEVER tow the machine with the towinghook, which may damage the towing hookand cause a personal injury.

Keep the to line angle to a minimum. Do notexceed a 30° angle from the straight aheadposition.

1-25

SAFETY

11-9 SAFE TRANSPORTATION

CAREFULLY LOAD AND UNLOAD THEMACHINE.

ALWAYS load and unload the machine onthe level ground.Use a ramp that has sufficient strength, width,length, and thickness.Remove ice, snow, or slippery material fromthe ramp and truck deck before loading.NEVER make a turn on a ramp.

Do not raise the boom excessively at loadingand unloading.

NEVER LOAD AND UNLOAD THEMACHINE WITHOUT RAMPS TOPREVENT TURNOVER.

NEVER lift up the machine using the boom toload and unload the machine on and out ofthe truck. This is very dangerous.

ALWAYS ensure that a ramp has sufficientstrength and length to accommodate the sizeand weight of the machine.

OBSERVE PRECAUTIONS ONTRANSPORTATION.

Block tracks and secure the machine to thetruck before transporting.Prior to transportation, check the travel routefor clearances around the truck and themachine.

1-26

JDI SAFETY

11-10 PARKING THE MACHINE I

II

BANKS AND SLOPES

NEVER leave the machine on or near anybank which may case. or on the edge of anexcavation which might give way. Back themachine away from such areas which it is tobe left idle or unattended for more than a briefperiod. Whenever possible, park on levelground.

DO NOT PARK THE MACHINE ON AGRADE.

If you have to park the machine on a grade,ALWAYS lower the bucket and the blade ontothe ground and block the machine.

OBSERVE PRECAUTIONS WHENPARKING THE MACHINE ON THEROAD.

If you have to park the machine on the road,use appropriate flags, barriers. flares, andwarning signals.

OPERATOR LEAVING MACHINE

ALWAYS lower attachments to rest onground and stop engine before leaving themachine unattended.Engage all locks, turn off the start switch, and

remove the start key. Lock the windows anddoors.

1 - 27

11-11 SAFE MAINTENANCE IKEEP ROUTNE MAINTENANCE

JDI

Maintenance work can be hazardous if notdone in a careful manner. All personnelshould realize the hazards and strictly followsafe practices. before performing anymaintenance or repair work. consult theinstruction manual.Before maintenance, stop the engine and donot conduct any operations.

SAFETY

...

I]

PERFORM MAINTENANCE WORKCORRECTLY.

While maintenance work is being done, thatstarting controls should be TAGGED. the tagshould be removed only by someone who isaware of the circumstances, and who canassure that it is safe to do so.

ALWAYS CLEAN THE MACHINE.

Maintain the machine clean for safeoperation.Remove dirt, grease, maintenance tool fromthe operator's cab for secured control.Clean the window to obtain good sight.Do not place anything flammable around themachine.

SET HYDRAULIC PRESSURECORRECTLY.

Only qualified person is allowed to gauge andadjust the hydraulic pressure following thespecified procedure and using the correctgauge if necessary.If there is no qualified person, consult yourlocal IHI distributor.

1-28

~..lV~

JDIPREVENT CRUSHING OR CUTTING.

Before ANY kind of adjustment or service ofthe machine, stop the engine and do notoperate the machine.

NEVER fuel or lubricate when the engine isrunning.

NEVER LEAN OUT OF THE WINDOW.

Keep your body inside the operator's cab.

The boom may fall down onto you if the boomcontrol lever is accidentally pressed.If the window is missing or broken, replaceimmediately.

SUPPORT THE UNDERCARRIAGEWHEN WORKING UNDER TRACKS.

NEVER allow anyone to work undercarriagethat is lifted and not properly blocked.Check that the machine is supportedsufficiently by the blocks and will not falldown. Do not keep the machine lifted up onlyby the boom and arm. Attach a warning tag towarn, "DO NOT OPERATE".

SAFETY II

1-29

JUIPREVENT FIRE OR EXPLOSIONS.

Keep away fuel, lubricant. and coolant fromany fire or heat. Most of them are veryflammable.NEVER place flammable materials or objectsclose to fire or heat.

NEVER SMOKE WHILE REFUELLING.

NEVER smoke while refuelling or in a placeclose to flammable objects.

SAFETY I]

DO NOT TOUCH BATTERYELECTROLYTE.

Battery post, terminals and relatedaccessories contain lead and leadcompounds. Wash hands after handling.

Battery acid will burn skin, eat holes inclothing, and cause blindness if splashedinto eyes. If you spill acid on yourself flushskin immediately with lots of water. Applybaking soda to help neutralize the acid.If acid gets in your eyes, flush immediatelywith large amount of water and seek propermedical treatment immediately.

When servicing battery remember that alead-acid storage battery generates (whencharging or discharging) hydrogen andoxygen - a very explosive mixture.A spark orflame could ignite these gases.

Always wear safety grasses and groveswhen working with battery.

1 - 30

Eye protection required

JUIALWAYS RELEASE PRESSUREBEFORE DISASSEMBLING HYDRAULICLINES.

Before disconnecting hydraulic fluid lineson a hydraulic machine, be sure you.

• Place boom on the ground or have itsupported.

• Shut off engine.• Always release any pressurized air on

hydraulic tank.• Move control levers and pedals repeatedly

through their operating positions to relievepressures.

PRESSURIZED HYDRAULIC FLUID CANPENETRTE THE SKIN AND. CAUSESERIOUS INJURY OR DEATH.

Therefore, be sure all connection are tightand that lines, pipes, and hoses are in goodcondition before starting the engine.

SAFETY II

Fluid escaping from a small hole can bealmost invisible. Use a piece of cardboard orwood, instead of your hands, to search forsuspected leaks.

If you are struck by escaping hydraulic fluidunder pressure, serious reactions can occurif proper medical treatment is notadministered immediately..

NEVER WATCH THE RELIEF VALVEWHEN ADJUSTING TRACKS.

NEVER watch the relief valve When servicingthe tracks. Position yourself not to besplashed with grease. Grease used to adjustthe tracks is highly pressurized and cancause serious injury or death.Carefully read and understand themaintenance procedure for track adjustment.

1 - 31

JDIBE CAREFUL TO ROTATING ANDMOVING PARTS.

SAFETY II

Do not come close to all rotating or movingparts such as a fan belt.Do not allow any object to come near movingparts.It will be repelled and thrown out, which maycause personal injury.

BE CAREFUL TO HOT ENGINE AFTERTHE MACHINE STOPS.

NEVER touch the engine or muffler right afterthe machine is stopped. It is very hot andcauses burns.

CAREFULLY HANDLE THE ENGINECOOLANT.

NEVER try to open the coolant filler cap whilethe engine is running or right after the engineis stopped. If the cap is open. the very hotsteam will blowout. which causes seriousburns. Wait until the coolant temperature

goes down.

Slowly open the filler cap to release thepressure.

Do not touch the engine coolant directly. Itmay cause injury to your skin. Wear gloves oruse a cloth to handle it. NEVER drink it. orNEVER let it come in contact with your eyes.

Before draining the engine coolant. cooldown the radiating systems.

If you drink antifreeze. IMMEDIATELY haveit thrown out and call for emergency medical

cure.

Do not leave any tool on the machine aftermaintenance and place it in place beforere-starting operation.

1 -32

JUI SAFETY

11-12 WARNING SIGNS AND LABELS

II

There are several specific safty signs on your machine. Their exact location anddescription of the hazard are reviewed in this section.Please take the time to familiarize yourself with these safety signs.

Wake sure that you can read all safety signs. Clean or replace these if you cannotread the words or see the pictures. When cleaning the labels use a cloth, water andsoap. Do not use solvent, gasolin, etc.

You must replace a label if it is damaged, missing or cannot be read. If a label ison a part that is replaced, make sure a new label is installed on the replaced part.See your IHI dealer new labels.

Located warning lavels

Cabin specifications

1- 33

JUIIllustratedsymbol

Recommendedexpantion

SAFETY

Illustratedsymbol

Recommendedexpantion

II

wCD Warning!

Read manual beforeoperation, maintenance,disassembly, assemblyand transportaion.• Part No.: 040535900

@ Sign indicates a hazard of

being crushed or run overby unexpected moving ofstopped machine.Lower working device tolocke position and removeengine key with you beforeleaving machine.

• Part No.: 040550800

r;:::=;;;;;;;;;;=;=;;;;;;-] a> Sign indicates an

electroction hazard ifmachine is broutht toonear electric power lines.Keep a safe distancefrom electric power lines .

• Part No.: 0405 506 00

@ Sign indicates a crush hazard byrotation of upper structure of themachine.Keep away from swing area ofmachine .

• Part No.: 040602200

~ Sign indicates a hazard

of being hit by theworking device of themachine.Keep away from machineduring operation .

• Part No.: 0405511 00

@ Sign indicates a hazard of

rotating parts, such as belt.Turn off before inspectionand maintenance.

• Part No.: 0405 366 00

1 -34

JUi SAFETY IIIllustrated Recommended Illustrated Recommendedsymbol expantion symbol expantion

s; (j) Sign indicates a hazard of ® Sign indicates an

rotating parts, such as fan.

~electrical hazard from

Turn off before inspection handling the cable.

and maintenance. Read manual for safe and

• Part No.: 0405 509 00proper handling .

i?~• Part No.: 040536300

~ 0 ~ W~;;'l~'iJ@[Fl

® Sign indicates a burn hazard fromspurting hot water or oil if radiatoror hydraulic tank is uncappedwhile hot.Allow radiator or hydraulic tank tocool before removing cap.

• Part No.: 0405 503 00

® Sign indicates a hazard from fallingwindow.After raising window, be sure to lock itin place with lock pins.• Part No.: 040551000

(@ Sign indicates a hazard of flying plug fromtrack adjuster that could cause injury.Read manual before adjusting track for safeand proper handling.

• Part No.: 040550500

@ DANGER!Attach a 00 NOT OPERATE warning tag to start switch or controlsbefore servicining or repeairing the machine.Do not start the engine or move any of the controls if their isDO NOT OPERATE or similar warning tag attached to the start switchor controls.Keep in the tool box do not use warning tag.• Part No.: 040532300

1 - 35

J~I

6

OPERATION

I 2-1 NOMENCLATURE I

Right

~10

Front

II

17 Rear

18V

4

Left

1 Bucket

2 Bucket Link

3 Arm Link

4 Tooth

5 Bucket Cylinder

6 Arm

7 Track Shoe

8 Arm Cylinder

9 Boom

10 Boom Cylinder

11 Fuel Tank

12 Hydraulic Tank

13 Battery

14 Return Filter

15 Radiator

16 ROPS Canopy

17 Air Cleaner

18 Engine

19 Muffler

20 Hydraulic Pump

21 Rotary Joint

22 Travel Drive (with motor)

2-1

23 Control Valve

24 Upper Roller

25 Track Roller

26 Swing Drive (with motor)

27 Track Adjuster

28 Front Idler

29 Swing Bearing

30 Boom Swing Cylinder

31 Blade Cylinder

32 Blade

J61 OPERATION

I 2-2 CONTROLS AND INSTRUMENTS

II

1 Engine Oil Pressure 8 Light Switch 15 Left Operating Lever

Warning Lamp 9 Heater Switch (option) 16 Right Operating Lever

2 Charge Warning Lamp 10 Engine Start Switch 17 Engine Throttle Lever

3 Heat Indicate Lamp 11 Horn Switch 18 Travel Lever

4 Fuel Level Gauge 12 High Speed Travel 19 Blade Lever

5 Water Temp. Gauge Switch 20 Boom Swing Pedal

6 Service Hour Meter 13 Special Attachment 21 Operator's Seat

7 Travel speed changeover Switch 22 Seat Belt

switch 14 Control Shut-Off Lever 23 Socket

2-2

J~I1. MONITOR LAMPS

OPERATION II

Q) Engine Oil Pressure Warning LampWhen warning lamp comes on and the actionalarm sounds with the engine running, stop theengine. This indicates insufficient oil pressure.Check the engine oil level and have anynecessary repairs made before starting theengine.

@ Charge Warning LampThis indicates a malfunction in the electricalcharging system.If the light comes on while the engine is running,check the electrical system.

a> Heat Indicate LampHold the engine start switch in the HEAT positionfor approximately 15 seconds. The air heater isactivated and the indicator comes on.

2-3

Jfll2. GAUGES and METER

OPERATION II

® Fuel Level GaugeIt indicates the amount of in the fuel tank. Addfuel immediately when the gauge indicates thelevel is in the E range.F : The fuel tank is full.E : Fuel level is too low.

FFUEL E9

~ Water Temperature GaugeThis indicates the engine coolant temperature.Upon start-up, the lowest "White" rangeindicates. While running the engine, with out loadand low idling warming up.The "Green" range is the normal operatingtemperature.The "Red" range indicates overheating.If the gauge indicate red range, reduce machineoperating speed and keep the engine at low idleuntil the engine is cooled down. Stop the engine.Check the coolant. Check the fan drive belt. Haveany necessary repair made.

@ Service Hour MeterIndicates the total operating hours of the machine.It should be used to determine service hourmaintenance intervals.

2-4

WATER TEMP

Red H $

[I]~1Aol!I

HOURS

OPERATION II3. SWITCHES

(f) Travel speed changeover switch

High-speed travel if .., mark is pressed.

Low-speed travel if .... mark is pressed.

® Light SwitchPush down on the [ //2l marked of the switch toturn the light on.Push down on the blank half of switch to turn theworking light off.

® Heater Switch (If equipped)It starts the room heater fan in 2 stage changeover.Depress the [9rl mark turns the fan in low blow.

Depress the~ mark turns the fan in high blow.

To stop the fan, depress the center of the switchplate.

@ Engine Start Switch

LIGHT

HEATER

Engine Start Switch

If the engine does not start after 10 seconds,return the key to OFF and wait for two minutesbefore returning it to START.

OFF: The engine must be in the OFF position toinsert or remove the key.Turn the key switch to theOFF position before trying to restart the engine.Turn the key switch to the OFF position to stop theengine.

ON : Turn the key clockwise to active the electricalSystem. The key will return to the ON positionwhen released from the START position.

START: Turn the key to the START position tocrank the engine. Release the key as soon as theengine starts.

HEAT: If the engine is hard to start in coldweather, hold the switch in the HEAT position topreheat the engine intake air.After approximately15 seconds the heater indicator on the monitor willturn off.

2-5

Preheat(HEAT)

Stop Operation(OFF) (ON) Start

(START)

JfJl OPERATION II® Horn switch

Push down on the top of the right operating leverto activate the horn.

@ High Speed Travel Switch

Never high speed travel on a grade or loadingand unloading the machine.

If the travel speed changeover switch is set to thelow speed (shown at right), pressing this switchchange the travel speed from low-speed to highspeed. If the travel switch changeover switch setto the high speed, the speed is not changed.

@ Special Attachment SwitchSee 2-9.

4. MACHINE CONTROLS

@ Control Shut-off Lever(for all hydraulic activation contorols)

r-------I~lmCAUTION '111- - - - -----

To mounting and dismounting the machine, besure to put the shut-off lever in the LOCKEDposition.If the lever is in the UNLOCKED position,upperstructure can swing and can result personalinjury.

Locked : Move the lever back to the lockedposition. This makes all hydraulic activationcontorols inoperable.

Unlocked : Move the lever forward to theunlocked position. This makes all hydraulicactivation controls operable.

2-6

Horn switch

Travel speedchangeover switch

JfJl@ Left Operating Lever

OPERATION II

Arm and swing controls1. Arm Out:

Move the lever forward to move the arm out.

2. Arm In:Move the lever back to move the arm in.

3. Swing Right:Move the lever right to swing the upper structureto the right.

4. Swing Left :Move the lever left to swing the upper structure tothe left.

5. Hold:When the lever released from any position, thelever will return to hold (center position). Arm orswing movement will stop.

Two Functions may be performed at the sametime by moving the lever diagonally.

@ Right Operating Lever

1.Arm Out

~

r:::f>4. Swing

Left

5. Hold

Boom and bucket controls1. Boom Lower:

Move the lever forward to lower the boom.

2. Boom Raise:Move the lever rear to raise the boom.

3. Bucket Dump:Move the lever right to dump the bucket.

4. Bucket Dig. :Move the lever left to close the bucket.

5. Hold:When the lever released from any position, thelever will return to hold(center position) . Boom orbucket movement will stop.

Two Functions may be performed at the sametime by moving the lever diagonally.

2-7

5. Hold

1. Boom LLower. 3. Bucket~ ~Dump

/.,.,.4. Bucket

Dig.

OPERATION II® Engine Throttle Lever

Slow ( .... ) : Move the lever to forward todecrease the engine speed.

Fast ( it' ):Move the lever to the rear toincrease the engine speed.

@ Travel Lever

IV' ! ,. CAUTION III

* Normal traveling is when the drive sprocketare under the rear of the machine. Blade areunder the front of the cab. Reverse travelingis when the cab is over the sprockets. Boththe directional and traveling functions will bereversed.

* Always travel with sprockets under the rear ofthe machine.

Forward Direction Travel:Move the both travel levers forward to move themachine forward direction.

Stop:Release the travel levers to stop the machine andapply the brakes.

Reverse Direction Travel:Move the both travel levers rear to move themachine reverse direction.

Refer to Traveling the Machine section of thismanual.

2-8

Slow

ReverseTravel

J61 OPERATION II@) Blade Lever

N

The bladefalls with its self-weight if pushing thislever to forward when the engine stops. Becareful.

Blade raise : Move the lever back to raise theblade.Blade lower: Move the lever forward to lower theblade.

@ Boom Swing Pedal--------Jiim~!ijiiiiCiiiiAiiiiUiiiiTiiiiIOiiiiNiiiilII -r-v

ALWAYS locked pedal when is not in use.

Boom swing right:Push down right on the pedal to swing the boomto the right.Boom swing left:Push down left on the pedal to swing the boom tothe left.

@ Operator's Seat

* Seat adjustment should be checked at thebeginning of each shift or when changingoperator.

* Lower the bucket on the ground, stop theengine and then make adjustment.

Seat AdjustmentSeat position can be adjusted forward orbackward and seat back tilt. Select the desiredposition to allow full pedal and lever travel.

1. To Adjust the Seat Suspension (if equipped).Turning nob CD until the indicator read theapproximate weight of operator within of 40 to110kg. Turning nob CD clockwise increases thereading and turning it counterclockwisedecreases the reading.

2. To Adjust the Seat Forward or Backward withRight and Left Control Levers.Pull up and hold lever ~ and move the seat andcontrol levers to the desired position from thetravel levers and pedals. Release the lever to holdthe seat in the selected position.

3. To Adjust the Seat Forward or Backward.Pull up and hold lever @ and move the seat tothe desired position. Release the lever to holdthe seat in the selected position.

4. To Adjust the Seat Back Tilt.Pull up and hold lever @ and tilt the seat back tothe desired position. Release the lever to hold theseat in the selected position.

2-9

Blade lever

Pedal Lock

4

J~I@ SEAT BELT

OPERATION

"'CAUTION

II

ALWAYS fasten the seat belt while operating the machine.Before operating the machine, be sure to inspect the seat belt and mounting forexcessive wear and damaged. Replace if damaged.

1. Confirm that the seat belt (1) is not twistedand put it into the buckle (2) securely.

2. Adjust the seat belt length according to yourbody size.Slightly pull the belt and confirm the belt (1)is locked.

3. Press the button (3) of the buckle (2) andunfasten seat belt.

@ SOCKET• Usable for the light, etc. for maintenance.• Use at DC12V, 60W (max).• If it is used for many hours with the engine

stopped, the battery runs out.(Usable with key switch ACC.)

• If it is not in use, close the lid.

2 -10

Jf:J1 OPERATION

I 2-3 BEFORE STARTING THE ENGINE

The following items should be checked each day before startup or the start operations.

II

II Walk-Around InspectionInspect the loose bolts, trash build up, oil orcoolant leaks, broken or worn parts. Inspect thecondition of the attachments and the hydrauliccomponents.

Inspect the operator's compartment forcleanliness. Keep it clean.

Inspect any cracks in boom and arm pivot areaand cylinder mounting brackets.Repair if damaged.

Refer to Walk-Around Inspection in theMaintenance Section.

III LubricationPerform the daily lubrication as required by theLubrication Chart.

III Pre-start ChecksCheck all of oil, coolant and fuel levels.

Refer to the Daily in the Maintenance Section formore detailed information.

II1II Seat and Seat Belt ChecksAdjust the seat to allow full travel of the levers andpedals when the operator is seated against theseat back.

Inspect the belt mounting hardware. Replace anydamaged or worn hardware. Keep the mountingbolt tight.

Fasten the seat belt before starting the engine.

2 -11

J~I OPERATION III 2-4 STARTING ENGINE I

Once the pre-start inspection has been completed, the enginemay be started.

Starting at Normal Temperature

Fast

Operation Start(ON) (START)

/'III_~~

Start switch

(It\

Engine throttle lever

Slow

Stop(OFF)

Preheat(HEAT)

Starting In Cold Weathr

,-----------.1:m CAUTION 111- - - - ---..

If the engine does not start after 15 seconds,return the key to OFF and wait for 15 secondsbefore returning it to START.

This engine has an inlet manifold heaterfor coldweather starting. Do not use other types ofstarting aids such as ether. Such use couldresult in an explosion and personal injury.

1. Move Control shut-off lever to the LOCKEDposition.

2. Move all Controls to the HOLD position.3. Move the engine throttle lever above the low to

medium position (advance aboutone-third toone-half).4. Insert key into the switch and turn the switch to

the ON position.5. Turn the switch to the START position.

Do not crank the engine for more than 15seconds.Allow the starter to cool for seconds beforecranking again.

6. Release the switch key after the engine starts.7. Move the engine throttle lever to position LOW to

allow the engine to warm.

1. Repeat steps 1 through 4 in Stating At NormalTemperature.

2. Hold the switch in the HEAT position to preheatthe engine intake air. After approximately 15seconds the heater indicator on the monitor willturn off.This indicates that the engine is ready to start.

3. Repeat steps 5 through 7 in Stating At NormalTemperature.

Heater indicator

2 -12

Jf11 OPERATION

I 2·5 JUMPER CABLE STARTING I

II

Battery gives off flammable fumes that canexplode.

When starting from another machine,make sure the machines do not touch.This will prevent damage to enginebearings and electrical circuits.

Always connect the battery POSITIVE (+)to battery POSITIVE (+) and and thebattery NEGATIVE (-) to batteryNEGATWE (-).

Jump only with a battery source and withthe same voltage as the stalled machine.This machine has a 12 volt startingsystem.Use only equal voltage for lump starting.Use higher voltage will damage theelectrical system.

Be sure the start switch is in the OFFposition BEFORE attaching the jumpercables to the machine to be started.

Use of Jumper Cables

1. Move boost start machine near enoughto stalled machine for the jumper cablesto reach. But, do not allow machines totouch.

2. Lower the bucket to the ground.Move all controls to HOLD. Stop theengine on boost machine.

3. On stalled machine, turn the start switchkey to OFF. Turn of all accessories.

4. Connect POSITIVE (+) jumper cable(red) POSITIVE (+) cable terminal ofdischarged battery.Do not allow positive (+) cable clamp totouch any metal other than batteryterminals.

5. Connect POSITIVE (+) jumper cable(red) POSITIVE (+) cable terminal ofboost battery.

6. Connect one end of NEGATIVE (-)jumper cable (black) to theNEGATIVE (-) boost battery terminal.

7. Make final connection of NEGATIVE (-)cable to frame of the stapled machine(not NEGATIVE (-) post) away frombattery or fuel line.

8. Start the engine on the boost machine.

9. Wait a minimum of two minutes for thebatteries in the stalled machine topartially charge.

10. Attempt to start the stalled engine.Refer to section on Engine Starting.

11. Immediately after starting the engine,disconnect the jumper cables in reverseorder.

12. Conclude failure analysis on starting/charging system of stalled machine asrequired now that engine is running andcharging system is in operation.

2 -13

JfJl OPERATION

I 2-6 AFTER STARTING THE ENGINE

II

I" . 'lIII CAUTION II"

Keep engine speed low until the engine oilpressure warning lamp goes out. If doesnot go out within 10 seconds, stop theengine and investigate the cause beforestarting the engine. Failure to do so, cancause engine damage.

With any piece of hydraulically operatedequipment, it is EXTREMELY IMPORTANTthat the hydraulic fluid be thoroughly warmedfluid-up BEFOREany work is begun.A warmup period is time well spent in preventivemaintenance.

Practice the following warm-up procedurebefore attempting full load operations.

1. Allow the engine to warm up at LOW IDLEfor at least five minutes.Engage and disengage attachmentcontrol levers to help speed warm-up ofhydraulic components.

2. To warm up the hydraulic oil, move theengine throttle lever to medium engine

speed. Run the engine for about fiveminutes while intermittently holding thebucket control lever in the bucket dumpposition.Operate the bucket control lever for 10 to15 seconds and then return the controllever HOLD position to ten seconds.

3. Move the engine throttle lever tomaximum engine speed. Run the enginefor an additional five minutes whileintermittently holding the bucket dumpposition.This will allow the oil to reach reliefpressure, which causes it to warm morerapidly.Cycle all controls to allow warm oil tocirculate through all cylinders and lines.

4. Observe the OK warning monitorfrequently during the operation.Be sure to perform the pro-operationwarm-up procedure whenever thehydraulic oil temperature is lower than20°C at start-up.

I 2-7 "BREAK-IN" OPERATION

In case of the new machine, as the severeoperation from the beginning will have a badinfluence upon the machine life, perform theenough break-in operation as described theright table.

Hour meter Load

Up to 10 hours About 60% load

Up to 50 hours About 80% load

After 50 hours Full load

2 -14

J~I OPERATION III 2-8 BACKHOE OPERATION

Shown lever pattern ISO type operations.

OPERATIONS

BOOM

BUCKET

ARM

SWING

DIRECTION OF LEVER

Operating lever (R.H.)


DIRECTION OF MACHINE

When leaving the operator's seat, stop the engine, lower the bucket and theblade on the ground.

2 -15

JfJl

OPERATIONS

BOOM

BUCKET

ARM

SWING

OPERATION

Shown lever pattern F,Standard Backhoe Loader System.

DIRECTION OF LEVER DIRECTION OF MACHINE



When leaving the operator's seat, stop the engine, lower the bucket and theblade on the ground.

2 -16

J61 OPERATION II

OPERATIONS DIRECTION OF LEVER DIRECTION OF MACHINE

A AI';"'ays locked pedal.. when is not in use.

BOOMSWING

BLADE

Blade lever@Lower~,

CD Raise

2 -17

JfJl OPERATION II12-9 OPERATING THE SPECIAL ATTACHMENTS AND ACTUATORS I

* Select a hydraulic breaker. a wrecking fork and special actuators, etc., witch areapplicable to the machine body.Consult your local IHI dealer to select a special attachment and an actuator.

Precautions on use of special attachment and actuator.* Before using a special attachment and an actuator, read and understand their

instruction manuals issued by a manufacturer to obtain correct operation andmaintenance.

* When a special attachment and an actuator are mounted, the machine specificationssuch as stability, working radius, transport height, etc., should be altered. Beforestarting operation, confirm each specification to ensure safety of workers and themachine.

When operating special actuators such as the hydraylic breaker and wrecking fork, setthe foot pedal as explained below.Meanwhile, before setting the pedal, position the changeover valve direction properlyas shown below.

1. SINGLE ACTION OPERATION

USED: ROR BREAKER AND OTHERS1) Push on switch CD right. (Nothing occurs if the

pedal is stepped on left.2) Set the (-) mark on selection valve @ to the

vertical position ( I ).3) Push on switch CD to activate the breaker.4) If the breaker is not to be activated, move

switch CD to the neutral position.

r---------J:m CAUTION ~II--------..

If the (-) mark of the valve is set in horizontalposition, the pressure of returned oil becomeshigher and the breaker does not functionefficiently. ALWAYS set the (-) mark in varticalposition.

~ Changeover Valve

2 -18

J~I OPERATION II2. DOUBLE ACTION OPERATION

USED: WRECKING FORK AND OTHERS1) Push on switch CD right and left.2) Set the (-) mark on selection valve C?> to the

horizontal position (-).3) If you push on the switch right, pressurized oil

is supplied from the piping to the left of thepiping. If you push on the switch left,pressurized oil is supplied from the piping tothe right of the attachment.

4) If the disassembly fork is not to be used, moveswitch CD to the neutral position.

r-------l11ti] CAUTION 1:1- - - - - -

Make sure the (-) mark of the changeovervalveis set in horizontal position before works.IIf it is set at vartical position, the B port of thedouble action will not function.

NOTE:Hoe to Remove Residual Pressure forReplacement of Breaker, etc.

1. Stop the engine.2. Set the starter key to ACC. (Do not start the

engine.)3. Press the switch for reserved piping (for both

right and left).4. Set the starter key to OFF.

2 -19

LeftR~ Switch

•

@ Changeover Valve

J~I OPERATION II

I 2·10 TRAVELING THE MACHINE

STRAIGHT TRAVEL

* Be sure no one is working on or near the machine to prevent injury.Keep the machine under control at all times to prevent injury.

* Before control levers, confirm which direction the track frame faces.* Always travel with sprockets under the rear of the machine.

SPROCKET

ReverseTravel

2 Control Shut-off Lever

Travellever(R.H.)

StopSlowly move both the travel levers (J) to the stopposition to stop the machine and apply the brakes.

Reverse Direction TravelMove the both travel levers (J) rear to move themachine reverse.The machine will always travel toward theSPROCKETS.

Forward Direction TravelMove the both travel levers (J) forward to move themachine forward.The machine will always travel toward theBLADE.

1. Move engine throttle lever CD to the operatingrange.

2. Move the control shut-off lever ~ to the unlockedposition.

3. Raise the boom and the blade enough to providesufficient ground clearance.

4. Control right and left travel levers (J) as follows.

BLADE

40-50 em

2-20

J~I OPERATION IISTEERING CONTRTROL

* Be sure no one is working on or near the machine to prevent injury.Keep the machine under control at all times to prevent injury.

* Before control levers, confirm which direction the track frame faces.* Always travel with sprockets under the rear of the machine.

PIVOT LEFT TURN

PIVOT RIGHT TURN

Forwar~Steering " Reverse

Steering

CD

Pivot Right TurnMove the left lever (£) forward to travel forward andright, and move it rear to travel reverse and right,pivoting on the right track.

Pivot Left TurnMove the right lever CD forward to travel forwardand left, and move it rear to travel reverse and left,pivoting on the left track.

SPOT TURNSpot Left TurnMove the left travel lever (£) rear and move theright lever CD forward at the same time. This allowsa quick left turn.

STEERINGTo make turns, control the travel levers.Control the two travel levers as follows.

1. Move engine throttle lever to the operating range.2. Raise the boom and the blade enough to provide

sufficient ground clearance.

Spot Right TurnMove the right travel lever CD rear and move theleft lever (£) forward at the same time, allowing aquick right turn.

SPOT LEFT TURN

2 - 21

Jf11 OPERATION IIHIGH SPEED TRAVEL

r-------irm CAUTION 1111- - - - ------.

Do not change travel speed ranges while goingdownhill.NEVER high speed travel on a grade or loadingand unloading the machine.

There are two ways for starting high speed travel:

1. Press the 'it' mark on the travel speedchangeover switch (shown at right).

• In the state shown at right, high-speed travel isalways performed.

2. Press the high-speed travel switch.• High-speed travel is only performed while this

switch is being pressed.• Releasing the switch changes from the high

speed to the low speed.

CAUTION ON TRAVEL ON A GRADE

!'t CAUTION

* Reduce engine speed when maneuvering intight quarters or when breaking over a rise.

* Do not change travel speed ranges whilegoing downhill.

* Work up and down slopes rather thensideways, whenever possible. Do not travelacross a grade by all means.

* Avoid changing the direction of travel on aslope, which could result in tipping or sideslipping of the machine.

* Keep the arm in and carry the boom in a lowposition.

* When starting up a steep grade or breakingover a rise, keep the boom lowered as closeto the ground as possible.

1. When traveling up on a grade inclining bygreater than 15°, keep the position in the rightillustration and travel with a low engine speed.

2. When traveling down on a grade inclining bygreater than 15°, travel with the position in theright illustration.

2-22

Travel speed changeover switch

Pressing the switchstart high speed travel..

20-30cm

J61 OPERATION

2-11 TOWING

II

* Personal injury or death could result when towing a disabled machine incorrectry.* Follow the recommendations below, to properly perform the towing procedure.* Never use the towing hook at the rear axle to tow the machine.* During towing operation, NEVER allow anyone between the towing machine and the

towed machine.* Quick machine movement could overload the tow line or bar and cause it to break.

Gradual and smooth machine movement will work better.* Keep the tow line angle to a minimum. Do not exceed a 30° angle from the straight

ahead position.

1. If the machine sinks down on a soft ground andcannot crawl up by itself" a wire rope should beattached to the rear axle and the machine shouldbe towed by a towing machine.To prevent the damage of the wire rope, be sureto place a protector at the corner of the axle.Use the towing wire rope with sufficient strength totow the machine.

2. Use of the towing hookThe towing hook is used to tow for lightweightmaterial. The maximum allowable towed weightis 500 kg.NEVER tow the machine with the towing hook,which may damage the towing hook and cause apersonal injury.

2-23

Rear axle

Towing hook

J61 OPERATION II12-12 LIFTING THE MACHINE

Improper lifting or tie downs can allow load to shift and cause injury or damage.* Use proper rated cables and slings for lifting.* Position crane for level machine lift.* NEVER lift the machine loaded with any personnel.* Use guide or tag lines to prevent the machine from swinging or turning.* Make sure the lifting cables and other lifting devices are strong enough to support

the machine.* Use a crane whose lifting capacity meets the weight of the machine.

Lifting Procedures1. Start the engine and swing the machine to position

the blade to front.

2. Position the machine on the level ground with theboom, arm and bucket cylinders fully extended.

Selection of the lifting cables:Be sure to use are wire ropeswith breaking force of greaterthan 10.0 tons.

6. Install the cables to the crane hook.

8. Once the machine is lifted off the ground, checkthat the machine is well balanced.

7. Confirm that no obstacles nor personal are aroundthe machine and have the operator leave themachine.

Lifting eyeon the blade

/

Lifting cable:Two cables with alength of 3.3 m x 2

100 -150

Lifting eyeon the boom

~

Lifting cable:One cable with alength of 2m

5. Install the cable to the lifting eyes on the bladewith shackles.Install the cable to the lifting eye on the boom ofthe center with shackle.

3. Position the boom at the center of the machinewith the boom swing pedal.

4. Stop the engine.

Total Shoe type RaPS Canopy Cabin

operation Rubber 3250 3385weight (kg) Steel 3365 3500

2-24

J~I OPERATION

I 2-13 LOADING AND UNLOADING THE MACHINE

II

* Choose as flat ground as possible for loading the machine.* When using loading ramps, be sure there is adequate length, width, firmness and

slope.* To prevent the machine from slipping while loading or Shifting transit, remove ice,

snow or other slippery material from the loading ramps and the truck bed beforeloading.

* NEVER operate the high speed travel switch when loading the machine on a traileror loading lamps.

* Perform warm-up the machine before loading and unloading under cold weather.* Do not raise the boom excessively at loading and unloading.* NEVER make a turn on a ramp. To make a turn, get off the machine from the ramp

first.

MACHINE LOADING ONTO A TRUCK.

1. Block the truck wheels before loading.2. Install the loading ramps to the truck

securely. Maintain the slope of loadingramps within 15 degrees.

3. Position the machine so that it can be runstraight on the loading ramps. Neveroperate control levers other than the travellever while machine is on the ladingramps.

4. Maintain the machine balance point whiletraveling over the loading ramp jointareas.

5. Lower the attachment to the bed of truck.6. Be sure to chock both tracks.

Block ~

Max. 15 degrees ":: Width oframps

SECURING THE MACHINE

Upper structure movement can causepersonal injury or death.

1. Align the upper structure with the truck.2. Move the control shut-off lever to the

LOCKED position.3. Turn the engine start switch of OFF to stop

the engine and remove the key.4. Block the tracks and secure the machine

with tie-downs. Install and fasten properrated wire rope cables located on the carbody and arm point.

Wire ropes

2-25

J~I OPERATION III 2·14 PRECAUTION ON USE OF RUBBER TRACK SHOE

r------------I'm CAUTION ~II--------------.

The rubber track shoe may be damaged or worn faster depending on workingconditions. Perform working operation properly according to working site conditionsand machine operation.

III Structure of Rubber track ShoeThe right illustrates the structure of rubbertrack shoe. It consists of steel cord tosustain tension, iron core to support it, andcovering rubber to them.

~---....jim CAUTION 1:1- - - - -..

If a crack reaches the steel cord, of maybe rusted and cut off by moisture.When any crack is detected, repair itimmediately with vulcanizer.

Coveringrubber

\

Brokensteel cord

I11III Precaution on Use1. Adjust the track often enough to keep

a proper tension.• Insufficient tension slips off the rubber

track shoe and wears out the sprocket

and iron core extremely.• Excessive tension increases travel

resistance, which prevents propertravel force and speed. it also causesdamages and extreme wear atundercarriage as well asoverextension of the rubber trackshoe.

2. To prevent damages of the rubbertrack shoe, avoid the following in travelas much as possible.

• Pointed rocks or quarry• Craggy place such as riverbed or path

2-26

through woods• Steel rods or scraps• Steel board or cornered objects of

concrete• Heat source such as acre• Travel in contact with concrete path or

wall3. Immediately wipe off spilt fuel,

hydraulic oil, or grease on the rubbertrack shoe with a cloth.

4. Avoid sudden spot turns or pivot turns.Make slow turns several times at a lowspeed.

5. Do not use for long (3 months or more).Store it to avoid direct sunlight or rain.

6. Use the rubber track shoe at atemperature between -25°C and+55°C (-13°F and 131°F) because ofa rubber's characteristic.

J~I OPERATION II

This machine is equipped with an accumulator as standard.Within 1 minute after the engine stops (fails) with the lever unlocked, the boom can be lowereddown to the ground as described below.

Engine Start Switch

Stop Operation(OFF) (ON) Start

(START)

Be sure no one is under or the frontimplements before manually loweringthe boom.Keep all personnel away from theboom area when lowering the boom

with engine stopped.

II Method of Boom Lowering WhenEngine Daamaged. (Within 1 minuteafter stop)

Use the following procedure when it isnecessary to lower the boom while engine isshut down or the hydraulic system disabled.

1. Move the lever forward to the unlockedposition.

2. Turn the switch to the "ON" position.

3. Boom can be lowered by operating boomlowering lever.

Note: For further information, contact yourIHI dealer. Boom

Lower

~[>,

2-27

J~I OPERATION IIiii If Boom Cannot be Lowered

According to the Above Method

..Be sure no one is under or the frontimplements before manually loweringthe boom.Keep all personnel away from theboom area when lowering the boomwith engine stopped.

Use the following procedure when it isnecessary to lower the boom while engine isshut down or the hydraulic system disabled.

1. Open the cover.

2. Remove the lock nut~ of the boom raiserelief valve <D located inside the controlvalve.

3. Slowly loosen adjusting screw Q) untilboom start lower. The boom will start tolower slowly.

4. After making sure that the front implementhas lowered completely on to the ground,install the lock nut ~.

5. Make any necessary repairs placing theexcavator back into service.

NOTE: For further information, contact yourIHI dealer.

2-28

Control valve

Boom raise relief valve

JfJl OPERATION

I 2-16 PARKING THE MACHINE

II

At the end of a day's work, following steps should beobserved as the established machine shut-downprocedure:

Machine StoppingPark on a level surface, if necessary to park on agrade, block the tracks securely.1. Move engine throttle lever forward to reduce the

engine speed.2. Release the travel lever to stop the machine.3. Lower the bucket to the ground and apply slight

down pressure.4. Move the control shut-off lever to the LOCKED

position.Wood planks

Freezing ConditionsIf freezing temperature are expected, each crawlerframe should be cleaned of mud and dirt and themachine parked on wood planks. Stop

(OFF)Operation

(ON)

Engine Stopping1. Operate the engine at LOW IDLE for five minutes.

This gives the engine a chance to cool offgradually before they are stopped.

2. Turn the start switch key to OFF.Remove the key.

Leaving the Machine1. Use the steps and handhold, use both handles

and face the machine, when dismounting.2. Inspect the entire machine for leaks, loose

connections, signs of wear, crack etc. Report anysigns of trouble discovered during this inspection.

Engine start switch

I 2-17 EMARGENCY ENGINE STOP I

To stop the engine in emergency, turn the start switch key to "OFF" position.

2 -29

J~I MAINTENANCE

I MAINTENANCE INTERVALS I

II

Check Point Item PageWhen Required

.......!~?.~~~ 5;?~~~~ ..?!:!9..~9.j~~~.I~.~~.!~.~ ~.:::- ::l: .Track Check Rubber Shoes 3 - 5........ __ - -.__ .

.......~.~~.~.~ ~.~J?!9.~.~ ~.:::- ? .

.....x.~~.!~.1.~..!::!~.~ ~.~J?!9.~.~ }.:::- ~ .

.......~.~~!~ry g.l.~.~!:! ..~~~.g~.~~~ ..~!~~~~.~!y.!~ ..~~~.~! ~.:::- .!....

.......~.~.~~.~~ g.~9.~g.~ ..!?~~.~~.! ?.-::- ?. .

.......~.~.?~.~~ ~.~~.~~!..~.~.~.~!.i.~~..~!~~~~.~~.~.~~).~.~!.~.~.~! ~..~ ~ .Bucket Bucket Tooth Replacement 3 - 9

Daily Check (8 Service hours)

Engine Oil Check Oil Level 3 - 10.........................................................__ _- __ .

Engine Coolant Check Coolant Level 3 - 10.........................................................................................................................................................................................................

Hydraulic Tank Check Hydraulic Oil Level 3 - 11.........................................................................................................................................................................................................

Fuel Tank Check Fuel Level 3 - 11.........................................................................................................................................................................................................

Air Cleaner Check Dust Indicator 3 - 11.........................................................................................................................................................................................................

Water Sedimenter Check Level and Drain Water 3 - 12Every 50 Service Hours (First perform previous service hour items)Fuel Tank Drain Water and Sediment 3 -14.........................................................................................................................................................................................................

......~!~.~~~.~.~.~~.~!.~~ ~~.~~~~.~~~.y~!~~~.~ ..~.i.~~..~~~.~~~ ?.~ ?. .

.......~.~!.~~ ..~.~.~~~~.~ ~~.~~~~.~~~ ..~~!~~~.~ ..~.i.~~.g~~.?~.~ ?.-::- ?. .

.......~.~.~!.~~ ..Q!.I g~~~~.~.g~~.~~~ ..~!!~~.~..~ ~..~..1.~ .Hydraulic System Change Return Element * 3 - 22Every 250 Service Hours (First perform previous service hour items)

Engine Oil Change Oil and Filter 3 - 15.........................................................................................................................................................................................................

......~~~.g.I.~.~~~.~ gl.~.~~.9.~.~~.~.~~~ ..~!!~~E..~!~~~~.~~ ~.::-:..1.? .

.......~~~ ..~.~!.~ !~~P~~.~.~~.~ ..~9J.~.~~ ~.::-:..1.~ .Engine Coolant Change Coolant (When not used L. L. C) 3 - 28Every 500 Service Hours (First perform previous service hour items)

......I!~~!~~ ..~.~.I.~~ ~.~~~~.~~~.~!.~~ ..~.~.I.~ ~.::-:..~g .

.......~~!~~~..~~~!.~~ g.~~~~.~..~.~~~~~.Y..i.I.~~~ ~.::-:.?! .

......Y..~~~ ..~.i.I.!~~ g.~~~g.~..~~!~.~~ ..~~.~~.i.~~~ ~.::-:..~.? .

......~~~.g.I.~.~~~.~ g.~~~~.~.y~!~.~~ ..~I.~.~.~.~~~ ~.::-:..?.~ .Travel Drive Check Gear Case Oil Level 3 - 24.........................................................................................................................................................................................................

Swing Bearing Swing Ring Gear Grease Check/refill 3 - 24

Every 1000 Service Hours (First perform previous service hour items)

......I~~.Y.~! ..~~~~~ g~~~.g.~.g.~.~~.~~.~~ ..Q!! ~.::-:..~.~ .Hydraulic Tank Change Hydraulic Oil and Clean Strainer 3 - 26

Every 2 years Service HoursEngine Coolant Change Coolant (When used L.L.C) 3 - 28* Interval given applies only to initial period of use (Break-In).

3-1

J~I MAINTENANCEIi

I 3-1 LUBRICATION CHART MAINTENANCE AND CHECKS I

The interval of lubrication, maintenance and check is the maximum interval indicatedby the hour meter. It should be shortened in service operating conditions.

Interval

Component Servicing item FirstDaily 50Hr. 250Hr. 500Hr. 1000Hr.

50Hr.

CD Attachment pin Pin lubricate G@ Fuel tank Water sediment drain 0

Hydraulic Hydraulic oil H H*@

oil tank Water sediment drain 0Suction strainer cleaning 0

@ Return filter Cartridge 0* 0*Engine oil E* E E*

@ Fuel filter 0*Engine

Oil filter 0* 0*Radiator W

@ Swing Bearing lubricate Gbearing Rino cear lube G

(J) Traction Gear lubricate L L I L*@ Blade Pin lubricate G

* means replacement. Otherwise, check/refill is required.

Symbol G L H E W 0Kind of Grease Gaeroil Hydraulic oil (VG-46) Engine oil

Inspection andlubricant EP-2 Lithium API' GL-4, Anti-wear API-CD Water maintenanceand grade grease GL-5, SAE90 hydraulic oil SAE10W30

3-2

J~I MAINTENANCE

I 3·2 RECOMMENDED LUBRICANT TABLE

II

REFILLCHANGE LUBRICANTLOCATIONS CAPACITIES USE

(APPROXIMATE) INTERVALS VISCOSITIES

Cold RegionsAPI, Class CD

Max. 250 Hrs. SAE206.7 liter

API, Class CDDiesel Engine Initial oil General

Min. change SAE30

3.9 liter 50 hours Tropical API, Class CDRegions SAE40

Total 1000 Hrs. Ambient Wear Proof

Amount Temperature Hydraulic Fuluid

Hydraulic 60 liter (500 Hrs. -5 DC ISO-VG 46

Oil when Ambient Wear ProofTank Capacity breaker Temperature Hydraulic Fuluid

35 liter used) Below- 5 DC ISO -VG 32

Track Rollers0.08 liter Upon API, GL-4(Each) occasion -

ISO-VG 320

Front Idlers0.08 liter Upon (SAE 90)

(Each) occasion - Gear Oil

Upper Rollers0.06 liter Upon(Each) occasion -

API, Class CD

0.6 liter SAE30Travel Drives

(Each)1000 Hrs. -

Grease in4.0 liter 1000 Hrs.

swing gear EP2 Lithium-Lubricate Swing Bearing, Greasethe Fitting Attachment pins, etc.

Note:1. Oils in the hydraulic fluid columns marked with *should be use above 0 DC.2. If the oil becomes dirty or deterioration of the oil's properties are excessive, replace more

frequently than described above.3. Disassemble the track roller and upper roller when replacing the oil in them.

3-3

J~I MAINTENANCE WHEN REQUIRED II

3-3 WHEN REQUIRED MAINTENANCE AND CHECKS

TRACKS CHECK I ADJUST

..* Grease is under high pressure.* NEVER remove the grease fitting.* Grease coming out of the check valve under

pressure can penetrate the body causinginjury or death.

* DO NOT watch the check valve to see ifgrease is escaping. Watch the track or trackadjustment cylinder to see if the track is beingloosened.

* Loosen the check valve one turn only.

III Measuring Track Tension1. Position bucket to the sprocket side. Use boom

and blade down pressure to lift the track onboth side off the ground.

2. Measure the maximum amount of the tracksag from the shoe upper face to the roller face.Properly adjusted track will haveapproximately 10 to 20 mm slack with rubbershoes. In case of steel shoes, approximately30 to 50 mm.

III Track Tightening1. Add grease through check valve fitting CD until

the correct track tension is reached.2. Move the tracks forward and reverse to

equalize the pressure.3. Check the amount of track sag again and

adjust as necessary.

II Track Loosening1. Remove soil deposited on front idler bearing.2. Loosen the check valve ~ carefully (one turn

maximum) until the track begins to loosen.3. Tighten the check valve ~ to 59 to 69 N· m (6

to 7 kgf· m) when the desired track tension isreached. NEVER over tighten the check valve.

4. Move the tracks forward and reverse.5. Check the amount of track sag again and

adjust as necessary.

If the correct adjustment cannot be obtained, consultyour IHI dealer.

3-4

Jack up until theshoe leaves theground surface

Lower roller

\Shoe _elL.';\ ....~~{;;!;! Track sag

Rubber shoes: 10 to 20mmSteel shoes : 30 to 50 mm

(6) Check valve(Width across flat: 24 mm)


RUBBER TRACK SHOE MAINTENANCE

,------:m CAUTION 1:1- - - - ------..

* Rubber track shoe should be repaired orreplaced under the next conditions.

* If is necessary to repair or replace it,consult your IHI dealer.

1. Height of lugsThe rubber track shoe can be used even if it isworn, however, if it is excessively worn, therubber track shoe is likely to be slippery andmore travel force is required. If the remaininglug is less than 5 mm high, replace it withbrand-new one.

2. Exposure of Steel CordsIf steel cord is exposed because of wearyrubber or damage, replace it with brand-newone.

3. Break of Steel CordsWhen break of steel cord is detected, replaceit immediately. If you leave it as it is, the rubbertrack shoe can be break without expectation,which causes a serious accident.

4. Crack of Covering RubberIf a crack is 30 mm or more long and 8 mm ormore deep, repair the cover immediately. IfSteel cord appears even if a crack is small,repair it immediately.Otherwise, water may come into a crack, whichrusts steel cords and break the rubber trackshoe.

3-5

Repair is necessarywhen a crack is30 mm length, orover 8 mm depth.


FUSESThe fuse box is located on the front of theinstrument panel.Fuses will protect the electrical system fromdamage caused by overloaded circuits.

Replace fuses with the same type and size only.Otherwise, electrical damage can result.Change a fuse, have the circuit checked andrepaired.

III Replace1. Pull the latch and remove the cover for fuse

access.

2. Change the damaged fuse to new one.

The following circuit protected by each fuseincludes the fuse amperage.

Q) Fuel pump, Lever lock, Auxliary, socket and 2way speed - 20 amps

~ Horn, Lighter and Room lamp - 20 amps

® Light - 20 amps

® Monitor, Radio, Heater and Wiper - 20 amps

® Engine stop - 30 amps

FUSIBLE LINKThe fusible link is provided between the positiveterminal of the battery and the starter switch toprevent electrical circuit wires from being burnedbecause of short circuit. When the power is turnedoff by short circuit, check the fusible link.When it is blown out, replace it with new one afterrepairing the wires.

3-6

Fuse box

~...Ratch ,~---,,,,Cover-!,

n

10\I ...."

(i)

~

®@@,\31

Fuse amperage

Fusible link (65A)

Replaceable fuse

MAINTENANCE WHEN REQUIREDIBATTERY MAINTENANCE

* Battery give off flammable fumes thatcan explode.

* Do not smoke when observing thebattery electrolyte levels.

* Electrolyte is an acid and can causepersonal injury if it contacts skin oreyes.

* If the electrolyte comes in contactwith eyes, wash it away with waterand call for emergency medical cure.

* Always wear protectiveglasses whenworking with battery.

* Battery post, terminals and relatedaccessories contain lead and leadcompounds, chemicals known tocause cancer and reproductive harm.WASH HAND AFTER HANDLING.

Cap Indicator

Sight level line

• Electrolyte shortage (White) ®

Display of indicatorShows the standard of charge andelectrolyte level.

3. InspectionInspect the electrolyte level look at theindicator or sight level line on the battery.

4. Topping UpMaintain the level to the upper level of thesight level line with distilled water whenrequired. If any electrolyte is spilled,replace it with fresh sulfuric acid of samespecific gravity as that of remaining in cell.Level of electrolyte must never fall belowtops of plates.

®®

(Blue)

• Charge is necessary (Red)

• Good

The battery should be given a smallrecharge, sufficient to bring it back to fullycharged state about everyone or twomonths.

Trickle charging is not recommend andduring charging as before, care must betaken that temperature of electrolyte doesnot rise above 40°C for temperateclimates and 52 °C for battery using lower

gravity acids specified for tropical use.

2. Battery RechargeBattery should not be allowed to stand ina fully discharged condition, but should berecharged as soon as possible. If batteryis out of use for a long time, it must not beallowed to run down completely.

1. CleanlinessClean the battery surface. Keep theterminals clean and coated with goodquality grease.Install the post cover after coating.

3-7

Jr!ll MAINTENANCE WHEN REQUIRED II

CHANGE THE BUCKET

Ir r1l CAUTION

* Bucket pins, when struck with force, can fly out and injure nearly persons.Make sure the area is clear of people when driving bucket pins.

* Wear protective glasses when striking a bucket pin to avoid injury to your eyes.* Chips or other debris can fly off objects when struck. Make sure no one can be injured

by flying debris before striking any object.

Bolt IWasher

Bucket boss

Movement of a-ring

Bucketlink

Thickness ofshim: 0.8 mm

Bucket boss Arm boss Flange

_.._.._.L .._.

f~-~-~,'--=No gap 1

a-ringTotal clearance:0.1 to 0.8 mm

III Bucket Clearance (If Equipped with a BucketCapable of Shim Adjustment)If the bucket installed clearance becomesexcessive, adjust clearance to 0.1 to 0.8 mm byremove appropriate number of shims.1. Stop the engine.2. To remove shims, remove bolts, washers and

flange.3. After correct number of shim have been

removed, install flange washers and bolt.Tighten bolts.

4. After installation, make sure that clearance isstill correct.

I11III Install the Bucket1. Clean the removed pins and pin holes and

apply coat the grease to them surface.2. Place a new bucket in a stable position as

illustrated.3. Connect the arm into the hole A, and the link

into the hole B with pins.4. Install a stopper bolt to each pin securely.5. Adjust the bucket clearance.6. Move the O-rings for sealing into the regular

position.7. Lubricate each pins with grease.8. After install the bucket, start the engine and low

speed rotate the bucket to the stroke end.Check if anything interrupts the bucket rotation.

III!I Remove the Bucket1. Place the bucket in a stable position.2. Move the O-rings from the regular position to

the bucket boss.3. Remove the pins of section A and B, then

remove the arm and the bucket.

3-8

JIiII MAINTENANCE WHEN REQUIREDII

NutI Washer\b/el,,€t Side cutter (R.H.)o " I

III Replacement of Side Cutters1. Remove the mounting bolts and

remove the side cutters.2. Clean the mounting surfaces. Install the

new side cutters.

* Personal injury or death can resultfrom bucket falling Change Over use

* Block the bucket before changingbucket tooth or side cutter. Adoptor

Rubber pin lock

11III Replacement Period of Tooth Tooth

Replace the bucket tooth when a wearhole appears.

II Replacement of Tooth1. Drive the lock pin from the worn tooth.

Remove the tooth.2. Clean the adaptor and pin hole. X Wrong

Hole

3. Install the new rubber pin into the tooth. Rubber

4. Install the new tooth over the adaptor.5. Drive the lock pin through the tooth,

until the pin is flush with the tooth X Wrongsurface. Tooth pin Length

short-end

NOTICE: Tooth pin

After driving the lock pin, make sure thelock pin fits snugly into the hole of thetooth.

REPLACE THE TEETH AND SIDECUTTERS

Block3-9

J~I MAINTENANCE DAILY II

I 3-4 DAILY MAINTENANCE AND CHECKS

I!IIII Check the Engine Oil Level

IF ,. CAUTION

* Check the oil level with the engine stopped.DO NOT check the oil level with enginerunning.

* DO NOT overfill the crankcase to avoidengine damaged. Engine damage can result.

* NEVER operate the engine when oil level isabove MAX or MIN marks.

Drain plug

Reserve tank level

Lowerlimit

Upperlimit

1 Coolantfill cap

1 Oil levelgauge

MAX---'i~MIN-----~

1. Open the access door on the rear of themachine.

2. Always check the coolant level in the reservetank. Maintain the coolant level between theMAX and MIN marks on the reserve tank.

3. Remove the coolant fill cap CD and add thecoolant if necessary.

4. If the reserve tank is empty, check the radiatorlevel with the engine stopped. Add coolant tothe radiator and the reserve tank.

5. Close the access door.

* Steam generated by hot fluid under pressurein radiator can cause personal injury.

* Remove filler cap only when cool enough totouch with bare hand.

1. Place the machine on level ground. Stop the

engine.2. Remove the oil level gauge CD and wipe it

clean. Insert oil level gauge CD, then remove itagain to read actual oil level. Install oil levelgauge CD.

3. Maintain the oil level to the MAX mark on theoil level gaugeCD. Add oil if necessary.

4. Remove the oil fill plug (£) and add oil.Clean and install the oil fill plug (£).

5. Close the access door.

II Check the Coolant Level

3 -10

J~I11IIII Hydraulic Oil Level

MAINTENANCE DAILyl1

r'l CAUTION

* Always clean around fill plug before removing.* DO NOT OVER FILL.* DO NOT OPERATE the machine when oil

level is above FULL or ADD marks.

1. Place the machine on level ground and lowerthe bucket to the ground, with the arm andbucket cylinders fully retracted, as shown.

2. Maintain the oil level between the FULL andADD marks on the level gauge CD.

3. Slowly loosen the fill plug @ to relieve any andremove it to add oil if necessary.

4. Clean and install the fill plug @. To pressurizethe hydraulic tank, refer to "Change HydraulicOil" section.

11II Fill Fuel TankFuel can be added to the tank by removing the fillcap on top of the fuel tank. Do not remove strainerin the fill port when fill fuel tank.After completion of refueling, be sure to c1se andlock the enjne cover to protect against vandalism.

11III Dust IndicatorCheck the air filter dust indicator. If the indicator isin the red zone, clean or replace the element.See Service the Filter Elements.

After servicing, reset the dust indicator pushing inthe reset button.

3 -11

Bucket position at the time ofchecking the hydraulic oil level.

H CD Oil levelgauge

Red signal Reliese

J~1 MAINTENANCEDAILY II

II Water Sedimenter

Maintenance intervals:• Check Level: Daily• Drain the Water and Sediment: When the float

floated up to the bottom of the filter in thesedimenter.

Fuel leaked or spilled onto hot surfacescancause a fire.

Water sedimentor

The water sedimenter is located on the rear oftheengine.

1. Stop the engine.2. Turn the fuel stop lever to the "closed"

position.3. Loosen the ring nut CD and remove the bowl~ and the filter ®.

4. Drain water and sediment into suitablecontainer.

NOTE: Always dispose of drained fluids asestablished by local regulations.

5. Clean the inside surfaces of the body andbowl <%l.

6. Clean the filter Q).7. Inspect the 0 ring ® on bowl Replace them

if they are worn or damaged.8. Installa filter ® to the body. Install a spring~

and float ® into the bowl. Install the bowl tothe body. Tighten ring nut CD.

9. Turn the fuel stop lever to the "opened"position.

10. Priming the system. There should be enoughfuel in the system to allow the engine to start.Keep the engine start switch key at ON for aperiod of 20 seconds. which operates the fuelpump and priming automatically.

NOTE: Do not start the engine until all fuel systemservice is completed.

3 -12

Body

3 Filter

5 Spring

6 Float

4 D-ring

1 Ring nut

J~I MAINTENANCE DAILY I]

III Walk-Around InspectionInspect the operator's compartment forcleanliness. Keep it clean.

Inspect the loose bolts, Tighten any loose bolts.Repair if necessary.

Inspect any cracks in boom and arm pivot areaand cylinder mounting brackets.Repair if damaged.

Inspect attachment cylinders, linkage and bucketfor damage or excessive wear. Repair if damaged.

Inspect and remove any trash build up in theengine compartment.

Inspect the cooling system for leaks, faulty hoseand trash built up. Correct any leaks and removeany trash from the radiator.

Inspect the hydraulic system for leaks. Inspect thetank, cylinder rod seals. tubes, plugs, joints andfittings. Correct any leaks.

Inspect and repair travel drive leaks. Check oillevel if leakage is noticed.

III Daily LubricationPerform the daily lubrication as required by theLubrication Chart.

3-13

J~I

FUEL TANK

MAINTENANCE

3-5 50 HOURS MAINTENANCE AND CHECKS

First perform previous service hour items

50HOURS II

II Drain the Water and Sediment

NOTE: Before draining the water and sediment,be sure to fill the tank with fuel.The drain valve located under the fuel tank.

1. Stop the engine.

2. Open the drain valve CD.

3. Drain water and sediment into suitablecontainer.

NOTE: Always dispose of drained fluids asestablished by local regulations.

4. Close the drain valve.

II LubricationPerform the 50 hours lubrication as required bythe Lubrication Chart. Be sure to lubricate allcylinder mounting bushings and pins.

IMPORTANT: Use Extreme Pressure Grease(EP) No.2.

*: The following maintenance and checks should bemade in 50 hours for the initial time only.Interval given applies only to period of use(break-in.)

• Return filter replacement.• Engine oil replacement.• Engine oil filter replacement.

3-14

J~I MAINTENANCE 250HOURSII


First perform previous service hour items

ENGINE OIL AND FILTER

Filter wrench

® Oil levelgauge

/

MAX---,,<,MIN---...."<:l

CD Drain plug

* Hot oil and components can cause personalinjury. Do not allow hot oil or components tocontact skin.

* DO NOT overfill the crankcase to avoidengine damaged. Engine damage can result.

* NEVER operate the engine when oil level isabove MAX or MIN marks.

NOTE: Always dispose of used oil and filters asestablished by local regulations.

1. Stop the engine.2. Remove the crankcase oil drain plug CD. Allow

the oil to drain into a container. Install thecrankcase drain plug CD.

3. Open the engine cover on the rear of machine.4. Remove the used filter ~ by the filter wrench.

Use a filter wrench with the type shown at right.Clean the filter housing base.

5. Apply a light coat of engine oil to the gasket ofthe new filter.

6. Install the new filter by hand. When the sealcontacts the base, tighten the filter 3/4 turn moreby filter wrench. Do not overtighten.

7. Remove the oil fill plug G). Fill the crankcasewith oil. Refer to "Recommended lubricant table."Clean and install the oil fill plug ®.

8. Before starting the engine, make sure the oil levelis between the two notches on oil level gauge®.

9. Start and run the engine at low idle for twominutes. Inspect for oil leaks. Stop the engine.

10. Wait 10 minutes to allow the oil to drain backinto to the crankcase. Check the oil level Maintainthe oil level to the FULL mark on dipstick@).

11. Close and latch the engine hood.

11IIII Change the Oil and Filter

3-15

JIClIIII Service the Filter Elements

MAINTENANCE 250HOURS II

,---------------1lm CAUTION 1111----------~

* Service the air cleaner only with the engine stopped to prevent engine damage.* Do not clean the filter elements by bumping or tapping them.

Do not use filter element with the damaged pleats, gaskets or seals.Engine damage could result.

* When using pressure air for cleaning, wear a protective face shield or protective

grasses.

4 Dust indicator

@ Element

1. Stop the engine.2. Release the two latches and remove the service

cover CD.3. Remove the element ~ from the air cleaner

housing @.

NOTE: Remove the seal unit of element gently. Theelement is radially sealed by the element seal unitand seal tube. To loose the seal unit, move the outerof element gently up and down or right and left or

turn the element to remove it.

Take out the element not to scatter dust.

4. Clean the inside of the cleaner housing @ andservice cover CD.

NOTE: Clean the seal tube in the cleaner housing.Dust on the seal tube causes dust leak.

3 -16

J~I MAINTENANCE 250HOURSI!

5. Element Q) can be cleaned with compressed air200 kPa (2 kgf/cm2

) maximum.Direct air along pleats inside of filter element.

6. Inspect the filter element after cleaning. Do notuse a filter element with damaged pleats, gasketor seats.

NOTE: The used element may be useful to find aforeign substance on the seal surface of the filterelement, which can cause leak. If the striped dustis seen on the seal surface, it is a symptom of dustleak. If such dust seen, inspect if there are foreignsubstances, on the inside and outside of thehousing seal tube.

7. Install a clean element 0. Install and secure theservice cover CD.

NOTE: Insert a new element correctly. When theelement seal unit is inserted into the seal tube, itsseal surface is extended uniformly to seal theelement. To seal the element more accurately, pushsecurely not the center but the outer of the elementend surface.

8. Reset the dust indicator ® by pushing in the resetbutton.

9. If the dust indicator indicated the red signal afterstarting the engine, change to new element.

NOTE: Normally a filter can be cleaned up to fivetimes. Replace after five cleanings maximum.

3 -17

Cleaning Element

Inspect Element

L

Install Element

@) Indicator

I Reset button

~

J~IChange the Secondary Element

MAINTENANCE 250HOURS II

Ir. AUTION

* Always replace the secondary filter element.NEVER attempt to reuse it by cleaning.

* The secondary filter element should bereplaced at the time the primary element isserviced for five time.

Replacement: When replaced the primaryelement with the secondary element.

1. Remove the service cover CD and the primaryelement ~ from the air cleaner housing ®.

2. Remove the secondary element @ from the aircleaner housing ®. Cover the engine intakeopening.

3. Clean the inside of the air cleaner housing ®and service cover CD. Remove the coveringfrom the intake opening.

NOTE: Clean the seal tube in the cleaner housing.Dust on the seal tube causes dust leak.

4. Install the new secondary element @.

5. Install the primary element ~ secure the servicecover CD.

6. Reset the dust indicator ® by pushing in the resetbutton.

3-18

!Secondary element

~~~\~ cleLer housing

jw 2 Primary element

~ Valve1 Service Cover

CleanSeal Cover

~ Indicator

~button

J~I MAINTENANCE 250HOURsii

11IIII Change the CoolantCoolant should be drained and changed every250 service hours or six months. However, whenadding "Long-Life-Coolant", the drain period canbe extended to 2 years.

Drain the coolant earlier whenever the coolant isdirty or foaming is observed.

See 3-9. 2 years Maintenance section.

III Fan and Alternator Belt

* Hot components can cause personal injury.* Stop the engine and remove the start switch

key.

InspectStop the engine. Inspect the belt for wear andcracking. To check the belt tension, Push the beltinward by hand apply 98N (10kgf) force midwaybetween the pulleys. Correctly adjusted belt willdeflect 10mm.

Adjust1. To adjust the belt, loosen mounting bolt <D and

adjust plate bolt ~.

2. Move the alternator in or out as required to obtainthe correct adjustment by turn adjusting screwG).

3. Tighten mounting bolts <D, adjust plate bolt ~and reinspect the adjustment.

4. Check the belt adjustment again after 5 minutesof engine operation at rated speed.

3-19

2 Adjust plate bolt AC generator

1 Mounting bolt

JBJI MAINTENANCE


First perform previous service hour hems

500HOURS II

III Check the Fixed BoltTorqueWhen loosened bolt or nut is found at daily check,tighten it with torque specifications table.

1. Special torque specificationsSpecial tighten is applied for main bolts asillustrated below.When replacing bolts, apply molybdenum greaseto bolts, nuts, and bearing surface of nuts.Then, tighten them with specibied torque.

Items Tighten pointWrench size Thread size Tighten torque

(mm) metrie Nom

Q) Travel drive 19 M12

(l) Sprocket 17 M12

® Lower roller 24 M16

® Swing bearing 19 M12

~ Swing motor 24 M16

Newrton meter (N 0 m) is approximately the same as 0.1 kg 0 m

2. General torque specificationsOther than above-mentioned, refer the next tablefor torques.

108

108

245

108

256

Thread WrenchTighten torque

size size Metric Metric fine

metric (mm) coarse H.T. H.T. boltNom Nom

M8 13 23 25

M10 17 47 50

M12 19 83 91

M14 22 134 135

M16 24 206 220

M20 30 412 450

M24 36 715 813

3-20

High pressure-hoseunion nut

Hose size Tighten torque

(inch) Nom

1/4" 25

3/8" 49

1/2" 59

3/4" 118

1" 137

1-1/4" 167

J~I MAINTENANCE 500HOURSI]

Fill plug

@ Cartridge

fill Change the Return Filter

~-----J~m CAUTION 1111- - - - - ---

* Hot oil and components can cause personalinjury. Do not allow hot oil or components tocontact the skin.

* At operating temperature, the hydraulic tankis hot and can be under pressure.

* To relieve the pressure from the hydraulictank, loosen the oil fill plug Q)on the hydraulictank.

* Remove the return filter (l) only after theengine has been stopped and the return filteris cool enough to touch with your bare hand.

1. Lower the bucket on the ground and stop theengine.

2. Relieve the internal pressure from the hydraulictank by loosening oil fill plug Q).

3. Clean the area to keep dirt out of the filter base®.

4. Remove the used filter (l) by filter wrench. Cleanthe filter base ®.

NOTE: This is a cartridge type element. It cannot bereused.

5. Coat the gasket ® of new filter with cleanhydraulic oil.

6. Install the new filter a> by hand. When the sealcontacts the base, tighten an additional 3/4 turn

by filter wrench.7. Start and run the engine to fill the filter. Stop the

engine. Maintain the oil level between marks onthe level gauge. Add oil if necessary.

8. Pressurize the hydraulic tank. After fully extendingall the cylinders and loosen oil fill plug Q) to supplyair to the hydraulic tank, tighten the plug again.

9. Start and operate the engine. Inspect for leakson the oil filter (l).

"* When operation breaker works, replace the returnfilter every 100 hours operation."* Replace this filter in 50 hours for the initial time

only.

3-21

Return filter

Oil levelgauge

J~I MAINTENANCE 500HOURS II

11III Change the Fuel Filter

-------Im CAUTION ,1111- - - - ----.

* Perform replacement after each part of theengine is cooled.

* Do not put fire closely.* Since the spilt light oil may cause fire

disasters, wipe it off carefully.

IMPORTANT:Do not tighten Filter Cartridge CD too much. Overtightening may damage the element.

1. Lower the working machine to the ground andstop the engine.

2. With a filter wrench, turn Filter Cartridge CDcounterclockwise and remove it.

3. Before attaching, thinly coat engine oil on thegasket of Filter Cartridge. After Gasket ~contacts the seal surface, tighten by 3/4 to 1turn.

4. After installation, perform air purge.

3-22

Bucket position at the time ofsealing off hydraulic tank.

Fuel filter

Body

J~I MAINTENANCE 500HOURSI!

11IIII Change the Air Cleaner Element

The air cleaner is equipped with a"Service-Signal" indicator located on theoutlet side of the air cleaner. With theengine running, check indicator each day.

If red signal is in the service level, cleanfilter element or replace if necessary.Inspect filter gaskets for damage andreplace if necessary.

Element holder

Dust pan

Clener housing

Filter element

Dust indicator

1. Stop the engine. 6. Install a new filter element. Install andsecure the dust pan with arrow point

2. Release the two latches and remove upward.

the dust pan.7. Reset the dust indicator by pushing in

3. Remove the filter element from the air the reset button.cleaner housing.

1m CAUTION II4. Clean the inside of the air cleaner

housing. • Service the air cleaner only with theengine stopped. Engine damage

5. Remove the element holder from the could result.

dust pan and clean the element holder.

3-23


II Check the Travel Drives Oil Level

When the quantity of oil is found to haveincreased abnormally, it is necessary to checkthe oil seal of the travel motor.If the seal is leaking, contact a IHI dealer.

1. Position one travel drive with oil drain plug CDat the bottom.

2. Remove the oil level plug ~. Oil should be tothe bottom of the level plug ~ opening.

3. Add oil through the opening of oil fill plug Q), if

nececcary.4. Clean the plugs <l) and Q).

Install the plugs ~ and Q).5. Perform procedure on the other travel drive.

iii Check and Refill of Swing Ring Gear Grease

1. Remove Cover CD on the upper swing body. Makesure that grease is SUfficiently provided for the

swing gear.If grease on the gear surface is insufficient, addgrease (approximately 0.5 kg).

2. If grease is whitened with water, mud, etc., replace

the full volume with new grease.Remove Cover ~ on the lower raveling body.Remove old grease. Attach Cover <l) and supply

new grease.

Specified Extreme Pressure Grease No.2

grease (Lithium Grease EP2)

Volume 3.7 kg (full volume)

3-24

@ Oil level @Oil fillplug plug

-?-~

~DralnPlug

J~I MAINTENANCE

I 3-8 1000 HOURS MAINTENANCE AND CHECKS

1000HOURSII

III Change the Travel drive Oil

1. Position one travel drive with drain plug CD atthe bottom.

2. Remove drain plug CD, oil level plug C?> and fillplug ®. Allow the oil to drain into a container.

NOTE: Dispose drained material according to localregulation.

3. Clean the plug CD and install drain plug CD.

4. Fill the travel drive to bottom of level plugopening.

Recomended oil Refill capacities

Engine oilAPI , Class CD 0.6 Liter

SAE30

5. Clean the oil plugs ~ and ®. Install the plugs

~ and ®.

6. Perform procedure on the other travel reduction.

7. Start the engine and allow the travel drive to turnthrough several cylcles.

8. Stop the engine, check the oil level.

9. Check the drained oil for metal chips or particles.If there are any, consult your IHI dealer.

3-25

J~I MAINTENANCE 1000HOURS IIII1II Change Hydraulic Oil and Clean the Strainer

~----[mCAUTION )111- - - - ---

* Hot oil and components can cause personalinjury. Do not allow hot oil or components tocontact the skin.

* At operating temperature. the hydraulic tankis hot and can be under pressure.

* To relieve the pressure from the hydraulictank, loosen the oil fill plug @ on the hydraulic

tank.* Relieve the tank pressure with engine off by

removing fill plug slowly to prevent burnsfrom hot oil.

1. Place the machine on level ground, with the armand bucket cylinder fully retracted andattachments lowered, as shown. Stop the engine.

2. Relieve the internal pressure from the hydraulictank by loosening the fill plug @.

3. Clean area thoroughly to keep dirt out of strainercover unit ® and fill plug @.

4. Remove the oil drain plug CD. Drain oil into acontainer. Drain oil in all parts of the hydraulicsystem thereafter.

NOTE: Always dispose of used oil as established bylocal regulation.

5. Remove the joint ®. Remove the bolts ~ andthe strainer cover unit ® /strainer (j) from the

hydraulic tank.

6. Inspect the 0 ring @ and replace it if damaged.

7. Clean the inside of the tank with the clean oil.

8. Clean and install the strainer cover unit @strainer (j) and the joint ®.

9. Clean and install the drain plug CD.

3-26

Bucket position at the time ofdrain the hydraulic oil.

7 Strainer

8 0 ring

6 Strainer cover


10. Fill the hydraulic tank with oil. SeeRecommended Lubricant Table.

11. Loosen the air purge valve (@ on the pumphousing. When oil flow of air bubbles, tighten thepurge valve (@.

12. Start and operate the engine at idling speed forfive minuets.

13. Operate the control levers to allow the hydraulicoil to circulate through all hydraulic circuits.

Fill plug

H ® Oil levelgauge

Bucket position at the time ofchecking the hydraulic oil level.

!'WCAUTION

Hydraulic Oil Change Intervals for BreakerWorks.Hydraulic oil should be changed in every 500service hours.

18. Lower the bucket on the ground and stop theengine.

17. Remove the fill plug ~ and then install fill plugagain.

16. Pressurize the hydraulic tank.Raise the boom with the arm, boom and bucketcylinder fully extended.

14. Lower the bucket to the ground with the arm andbucketcylinder fully retractedand stop the engine.

15. Maintain the oil level between FULL and ADDmarks on the level gauge ®.

Bucket position at the time ofsealing off hydraulic tank.

3-27

J~I MAINTENANCE

I 3-9 2 YEARS MAINTENANCE AND CHECKS

2YEARS II

COOLING SYSTEM COOLANT

* At operating temperature, the engine coolant

is hot and under pressure.* Steam can cause personal injury.* Change the coolant only after the engine has

been stopped and radiator cap is coolenough to touch with your bare hand.

* Remove the radiator cap slowly to relievepressure.

III Change the CoolantCoolant should be drained and replaced every250 service hours or six months. However, whenadding "Long-Life-Coolant", the drain period canbe extended to 2 years.Drain the coolant earlier whenever the coolant isdirty or foaming is observed.

1. Place the machine on the firm and level ground.2. Loosen the radiator cap CD slowly to relieve

pressure, and remove the cap.3. Open the radiator drain pulg a> and allow the

coolant to drain into a container.4. Remove the radiator drain plug ® allow the

coolant to drain into a container. Drain plug islocated under the injection pump on the front sideof cylinder body.

5. Close the radiatordrain plug a> and drain plug ®.Fillthesystemwithcleanwaterandcleaning solution.

6. Start and operate the engine for 1/2 hour. Stopthe engine and drain the cleaning solution.

7. Flush the system with water, with the enginestopped, until the draining water becomes clear.

8. Close the drain valve a> and drain plug ®. Fillthe system with clean water and operate theengine for five minutes. Stop the engine and drainthe water.

9. Repeat step 7 several times, if necessary, untilthe drained water becomes clear.

10. Add the coolant solution. See next page.11. Operate the engine for five minutes with the

radiator cap CD off.

3-28

2 Drain cock

4 Reservetank

J~I MAINTENANCE 2YEARS II

12. Maintain the coolant level to the fill port neck.13. Replace the cap gasket if the gasket is damaged.

Install the radiator cap a>.14. Maintain the coolant level between the MAX and

MIN marks on the reserve tank@).

III Clean the Outside of the Radiator CoreWhen the radiator core is clogged, the cooling airflow is interrupted lowering the cooling efficiency.Remove dust or debris from the radiator fins.Clean the radiator with a pressurized air, highpressure water or steam at 500 hours interval.Whenever the radiator is found to be closed, cleanit at any time.

III Selection of coolantLong-Life-Coolant (LLC) is supplied to thismachine before shipment.This is a coolant provided with proper ties ofantifreeze, corrosion-proof and foullnq-proof.Its long lasting .effects will maintain the machinefree from coolant exchange for 2 years throughsummer and winter seasons.The Long -Life-Coolant is thereforerecommended for use with this machine whenexchanging its coolant.

III Mixing Rate of Long-Life-CoolantThe mixing ratio of Long-Life-Coolant with waterdetermines the freezing point.Select the mixing ratio for a freezing point lower by5° than the expected lowest atmospherictemperature.Normally, the Long-Life-Coolant is used under amixing ratio of 30 to 50%.If the mixing ratio is less than 30%, occurrence ofrust is feared and when it is over 50%, overheatingis feared and sealing components may bedeteriorated quicker than usual.Meanwhile, use city water to mix with Long-LifeCoolant.

3-29

Freezing point-15 -25 -35(0C)

Mixing ration30 40 50

(%)

Quantity of1.4 1.9 2.3

LLC (L)

Quantity of3.3 2.8 2.4

water (L)

Coolant Total Engine proper: 2.0 Lamount: 4.7L Radiator and

other proper : 2.2 L

Reserve tank: 0.5 L

J~I MAINTENANCE

3-10 UNUSUAL OPERATING CONDITIONS I

UNUSUAL II

Special problems in maintenance andoperation are caused by unusual conditionssuch as extremes in heat, cold and humidity,high altitude, salt water, and dusty or sandywork sites. When operating under suchconditions, special precautions must betaken to prevent machine damage, minimizewear, and avoid component deterioration.

II Extreme ColdIn periods of extreme cold, the problems offreeze damage, inadequate lubrication andbattery failure may become particularlytrouble - some. With the onset of very coldweather, it is advisable to "winterize" themachine by servicing the cooling system andswitching to the lubricants recommended forcold weather usage.Follow the recommendations below when themachine must be operated in very coldconditions.

1. To prevent freeze damage to the coolingsystem and cracking of the engine blockor head, drain and flush the coolingsystem. Clean the radiator exterior,making certain the air passages throughthe core and the cooling fins are free offoreign matter.

Refill the cooling system, adding anantifreeze solution recommended by theengine manufacturer in an amount andstrength appropriate to the anticipatedtemperatures. A corrosion inhibitor isrecommended.

Never use a chromatic base corrosioninhibitor when the coolant contains ethylline glycol. Use only non-chromatic baseinhibitors.

Inspect the thermostat, clamps, radiatorhoses and radiator core for propercondition. Replace or repair any coolingsystem component found to be defective.

2. Condensation in the fuel tankcontaminates the fuel supply with water,

which can freeze in the fuel lines andblock the fuel flow to the engine. Tominimize this possibility, keep the tank asfull as is practical during cold weather.This may entail refilling the tank morefrequently than usual, but theinconvenience is small compared toclearing a blocked fuel line.If water should be noticed in the fuelsupply, drain the tank and refill it withuncontaminated fuel.

3. Lubricate the machine with the lubricantsrecommended for cold weather operationin the Lubrication Section. If necessary,change the engine oil and other lubricantsin order to conform to the recommendations.

4. The battery is more likely to sustain freezedamage if not kept fully charged becauseits electrolyte will freeze at a highertemperature than that in a fully chargedbattery. Be certain the battery is chargingwhen the engine is running and use anexternal charger to restore full chargewhen the machine is not being operated.The battery can discharge if snow or iceshort circuits the terminals. Keep thebattery posts and cable connectors cleanand dry. Remove any corrosion with asolution of soda and water.During extremely cold weather, it isadvisable to remove and store the batteryin a heated area when the machine is toremain idle overnight or for any extendedperiod.

I"." CAUTION

Water added to the battery can freezebefore it mixes with the electrolyte.During very cold weather, add water tothe battery just prior to, or duringoperation of the machine.If the machine is not to be run. watermay be added if an external charger isconnected to the battery.

3-30

Jf!l1 MAINTENANCE UNUSUAL II

5. Special attention must be given to thehydraulic oil during very cold weather.

BEFORE attempting any workingoperations, warm up the hydraulic oil asdescribed in "After Starting the Engine"on Sheet No.2-6.

6. At the end of the work period, or wheneverthe machine is to be left idle for extendedperiods, prevent it from being frozen tothe ground by parking it on wood,concrete, asphalt or mat surface.

II Extreme Heat.Like extreme cold, extreme heat requires thatprecautions be taken with respect to thecooling system, the battery and lubrication.Protect the machine by performing thefollowing recommended procedures:

1. High temperatures necessitate the use oflubricants which are both more viscousand which resist deterioration at higheroperating temperatures. Refer to theLubrication Section and lubricate themachine using the lubricantsrecommended for the expectedtemperatures.Crankcase oil is particularly importantbecause it helps dissipate heat. Check theoil level frequently and add oil as requiredto maintain required level. Too little oil willhinder heat dissipation.

2. To ensure proper coolant circulation, drainand flush the cooling system, clean anyforeign matter from the radiator coolingfins and through-core air passages,replace defective hoses, tighten hoseclamps, tension the water pump drive beltproperly. eliminate any leaks detected andfill the system with a 50% solution ofethylene glycol.A corrosion inhibitor is recommended.Engine overheating due to loss of coolantwill most often be corrected by SLOWLYadding coolant while the engine is runningat FAST IDLE. Should this fail to correct

the problem, drain and flush the systemand refill with fresh coolant (50% solutionof ethylene glycol) and a corrosioninhibitor.

Allow the engine to cool before drainingand flushing the cooling system.Water containing more than smallconcentrations of salt or minerals shouldnot be used in the cooling system. Saltfacilitates corrosion and minerals depositon the coolant passage walls.Both processes inhibit proper cooling.

3. Increased evaporation rates will cause thebattery electrolyte level to fall more rapidlyduring very hot weather. Check the levelfrequently and add distilled water asrequired to maintain the proper level.

4. Air circulation around the engine andbattery must not be restricted. Keep airintake and exhaust openings clear ofleaves, paper or other foreign matterwhich may restrict air flow.

5. Keep the engine clean of dirt. grease andother substance s which inhibit heatdissipation.

6. Operate engine at full throttle whendigging or tracking machine.Run the engine only when engaged inwork operations or when traveling themachine. Avoid prolonged periods at idleand shut the engine down if operationsare interrupted.

l1li Sandy or Dusty Work SitesThe presence of large amounts of sand ordust at the work site can contribute toaccelerated component weather. Eithersubstance win act as an abrasive whendeposited on moving parts of the machine.This problem can be alleviated by increasingthe schedule of lubrication and by servicingbreathers and fillers at more frequentintervals. Follow the recommendations belowwhen operating in sand or dust on a regularbases.

3 - 31

J~I MAINTENANCE UNUSUAL II1. Keep sand and dust out of the hydraulic

system by keeping the reservoir filler captight and servicing the hydraulic systemfilters frequently.

2. The fuel system should be kept free ofsand and dust by keeping the tank fillercap tight and servicing the fuel filtersfrequently.

3. The engine breathers and air cleanershould also be serviced frequently toprevent sand and dust from entering theengine. The engine oil and oil filter shouldbe changed at shorter than normalintervals to ensure a clean oil supply tothe engine's moving parts.

4. When lubricating the machine, thoroughlyclean each grease fitting before attachingthe grease gun. Pump generous amountsof grease into all lubrication points, usingthe fresh grease to pump out old.

5. Adequate ground bearing support may berequired for the tracks when operating insoft sand. Be alert for signs of trackdigging into sand during operations. Itmay be necessary to back off and fill inarea where tracks dig in.The increased frequency of lubricationand service discussed above should bedetermined by observations made at thework site. Inspection will determine howlong it takes for lubricants, breathers andfilters to accumulate unacceptableamounts of sand or dust. The frequencyof lubrication and service should beadjusted accordingly.

I11III High Humidity or SaltwaterIn some locations, such as coastal areas, themachine may be exposed to the deterioratingeffects of salt, moisture, or both. To protectexposed metallic surfaces, wiring, paint andother items, keep them dry and welllubricated where salt or high humidity areencountered. Follow the recommendationsbelow when operating in these conditions.

1. Make frequent inspections for rust andcorrosions and remove them as soon asthey are detected. Dry and paint exposedsurfaces after rust and corrosion havebeen removed.

2. Where paint may not be applied, such ason polished or machined surfaces. coatthe area with grease or lubricant to repelwater.

3. Keep bearings and their surroundingsurfaces well lubricated to prevent theentry of water.

4. Never use saltwater in the coolingsystem.Internal corrosion will occur and all partswill have to be replaced.

5. Hose down the machine periodicallywhenworking in saltwater. If necessary, use anoil soaked cloth to clean moving parts.

6. If the machine is submerged, be sure it isnever SUbmerged in water deeper thanupper crawler belt.If the machine exceeds this limit,disassemble, clean and lubricate thelower.

I11III High AltitudesVariations in altitude alter the fuel-air mixtureburned in the engine and affect the engine'sperformance. At high altitudes. atmosphericpressures are lower and less oxygen isavailable for combustion of the fuel. Above1500 meter, the engine fuel setting may haveto be changed to ensure proper performance.Consult engine manufacturer should thisproblem answer.Keeping the air cleaner clean and free ofobstructions will help alleviate high altitudeproblems.At high altitudes, closely monitor the enginetemperature for overheating.

3-32

J~I MAINTENANCE

I 3-11 LONG TERM STORAGE I

I]

II Before StorageTo protect the cylinder rods, set the machineposition in the right illustration.(To prevent the cylinder rods from being rusted)

To store the machine from long term, follow thenext procedures.

• Clean parts of the machine and store indoors.If you have to place the machine outdoors,choose a flat place and cover the machine.

• Be sure to perform fill the fuel, lubrication, andoil change.

• Apply grease on the exposed part of thehydraulic cylinder piston rods.

• Store the battery after move the negativeterminal and covering it or dismounting thebattery from the machine.

• Lock the control levers and pedals with the locklever and pedal lock.

III During Storage

If you have to operate the machine indoors toprevent rust, keep good ventilation and gaspoisoning by window or entrance.

During storage, operate the machine once amonth to maintain films of oil at the lubricationsection and charge the battery at the same time.

III After StorageAfter long term storage, follow the nextprocedures before operating the machine.

• Wipe away grease on the hydraulic cylinderrods.

• Be sure to perform fill the fuel and lubrication.

3-33

Bucket position at the time oflong term storage.

JI9I TROUBLE SHOOTING

4-1 TROUBLE AND REMEDY I

II

Detect the occurrence of anything unusual in its early stages by well getting hold of the normalperformance and condition of the machine while at daily operation.When detecting anything unusual, investigate the cause, and make the repair.When keeping the operation continue by neglecting anything unusual, it is in danger of relatingwith further big trouble.

SYMPTOM PROBABLE CAUSE REMEDYOperating lever o Lack of lubricating lever working part. • Lubricateis felt hard or o Poor control valve • Request repair to distributor for servicedoes not returm and repair.automatically.

All movements o Lack of hydraulic oil o Fill to regular level.are impossible o Hydraulic oil is not yet warm. o Perform arm-up operation.or lack vigour o Decreasing of engine output horse • Clean air cleaner and inspect fuel system.

powero Poor pump or coupling • Request repair to distributor for service and

repair.o Hydraulic oil is not proper o Replace with recommended hydraulic oil.o Lowering of pressure setting of relief o Request repair to distributor for service and

valve repair.o Poor control valve o As above

Travel of left, o Clogging foreign material such as stone o Exclude foreign material.

right, or both o Poor control valve o Request repair to distributor for service andsides are repair.impossible. o Malfunction of traction motor or • As above

reduction unito Poor brake valve o As above

Unable to travel o Clogging foreign material • Exclude foreign material.straight o Poor adjustment of shoes belt tension • Adjust to regular dimension on both sides.

o Poor pump • Request repair to distributor for service andrepair.

o Poor motor or brake valve • As aboveo Poor control valve • As above

Swing is o Lack of lubrlcatinq swing bearing • Lubricateimpossible or o Poor cushion valve • Request repair to distributor for service and

smooth swing repair.

is impossible. o Poor brake valve • As aboveo Poor motor • As above

Lack of digging o Lack of hydraulic oil o Fill to regular level.

force o Hydraulic oil is not yet warm o Perform warm-up operationo Hydraulic oil is not proper • Replace with recommended hydraulic oil.o Decreasing of engine output horse • Clean air cleaner and inspect fuel system

power.o Poor pump • Request repair to distributor for service and

repair.o Lowering of pressure setting of relief • As above

valveo Poor hydraulic cylinder • As aboveo Poor control valve • As above

4-1

J(;)] HYDRAULIC SYSTEM DIAGRAM II

Swing

15-1 HYDRAULIC SYSTEM DIAGRAM IBoomswing Travel Right Blade Travel Left Arm Boom Bucket

HydraulictankSuctionstrainer

EngineYANMAR3TNV88

,.....................

Re~otf Main pump~~~~o (variable plunger + gear)

Relief valve set pressure

Brakevalve

Code NamePressure

MPa kgf/cm2

MR1 Main relief valve P1 Pump 20.6 210



TRB1 Travel pressurization relief valve (P1 Pump) 24.5 250

TRB2 Travel pressurization relief valve (P2 Pump) 24.5 250

OR1 Overload relief valve (Boom) 22.6 230

OR2 Overload relief valve (Arm) 22.6 230

OR3 Overload relief valve (Bucket) 26.5 270

OR4 Overload relief valve (Blade) 22.6 230

SWR Swing relief valve 17.6 180

RER Remote control relief valve 2.9 30

Tank level capacity35 liters

Total system volume60 liters

Pump flow rate:P1 ; 40.3 liter/minP2 ; 40.3 liter/minP3 ; 24.6 liter/min

The service ports usethe flow shared by theP2 pumps.

5-1

ELECTRICAL SYSTEM DIAGRAM

6-1 ELECTRICAL WIRING SYSTEM DIAGRAM

t OPT Travelalarm-- - - -- --II

Llmlt swltch for buzzer

W COM E I

I :: ~Rightl

;I~DRW ~C:~ ~C 1

~~~~Leftl

: LB (B",;,,,,,, iL "K_I

I,II,,

3RB

WB

'BR

i.25R

3BRGY

GY

WR

I--

RL

Reservedpiping(Choose1 or 2)

~

____________________ Jr----------------~

I ~.ON.OFFS~I;,S--- - - -- - - -- - -llI

Remotecontrollerlever IIf----:-,-ON-QFFSW .::..~----, :

:I~ : L ~ HO;.~It'h _! I

OFF 0

r------------------------···-------·----------,

KEY SWITCH CONTACTSB BR ACC R1 R2 C

Pre-heat

>- Water temperature sensor I

to<lJlJ1@::Jt::l I

I

RWRL

ColorRedYellow

. .t:f\~ Engine 011-r-r-cu~ Pressureswitch

White YBlack RColor Symbol

COLOR SIMBOL TABLE

Bw

Symbol

1-~ ---------

• MB"'-.." B--+- StarterMotor ........

1-------' rF""""'----iI ~5BRPFLW2L 1 I Fuellevelsonsor W'( :

I ~ Fuse pull link I I ~ JI

BATTERY 'SA I I ~12Y I L- _

}--- - ~;

--

3G

~~) ~L ~I;i1-==--3WB--t++-'

Alternator

r<1L3W

i i-------h ---- -------, B

--0 I I - 3G SAFERYRELAY I, n- ~~ II I L ~ a 1 11m,"'SEC 14 ~:;r'3;--+--'''''----''

': ~ JD=~'·~~I~ ":.~lD i L ~_~r,~-L"'=- -~--~- ~ , ~B~'" r'~"~,~~~~,~MO~"::-~'~~wl(;- i JrlY

I ~ ~ e j'TI' 'TI,''IT".,TI, ~' , co 'W L I L LR~ WG ,y1

come:(~ I C@: I ~ ® '---= .!!,~ =--.J "rk '~Diode ~D~~~ C RG 1 GRJ21~R Hourmeter = 1 B~_§:

J ,-=,~.~, I i "'; --,\,.1'~ 1 , , i~

Glow plug

Always-oN type

For Engine stop solenoid

-Englne-------II

I

II

L _

~~=~hn I Pump1----"~--~II i :: Travel2..t;peed Lever lock SOlcnOldjl

II ~:.'~ctlon solenoid (lever unlockedIf ON)

I R RW CI ~h~~~ _

, ,L __~'- t-r--...., - -Foo,p,mpl

: ~~?~:l ~

Fuse

l~:Sparepowersupply

GoSbv

Green LOranoe BrSkyblue GrViolet P

BlueBrownGrayPink

ON 10--0--0

L ~ta_rt J

Notes:1. AVS=O.85 is applied for a thickness of wire without remarks.2. All figures of copierare illustrated from the connected side.

6-1

J61 SPECIFICATIONS III 7-1 GENERAL SPECIFICATIONS

II BASE MACHINE PERFORMENCE

Swing speed rnirr' (rpm) 10 (10)

Travel speed km I h 2.8 I 4.8

Gradability % (deg.) 58 (30)

II ENGINE

Engine model - YANMAR 3TNV88

4cycle, water cooled,Engine type over-head, valve,

direct injection

No. of cyl.- bore x storoke mm 3 - 88 x 90

Total piston displecement L 1.642

Rated output kW I rnirr' (psI rpm)20.1 12300 (27.3 I 2300)

[DIN6271 19.9 I 2300]

Max. torpue Nom I mirr" (kqf-rn I rpm) 106.4 11380 (10.7 11380)

III WEIGHT

ROPSCabinCanopy

Rubber shoe 3250 3385Total operation weight

Steel shoekg

3365 3500

Average ground bearing Rubber shoe 31 (0.32) 32 (0.33)

pressure Steel shoekPa (kgf I ern")

32 (0.33) 33 (0.34)

III REFILL CAPACITIES - (APPROXIMATE)

Fuel L 49

Hydraulic Oil level L 35

fluid Total amount L 60

Engine oil Max. level L 6.7

Min. level L 3.9

Coolant Engine proper L 2.0

Total amount L 4.7

7-1

JDI11III BUCKET

SPECIFICATIONS II

@: Std. applicableo :ApplicableX : Not applicable

Bucket capacity Side Number Combinations

ISO(m3)cutter

ofWeight

Remarks Remarkswidth (kg) Std. LongHeaped Struck (mm) teeth arm arm

0.11 0.078 600 4 100 @ X Standard. General digging

0.11 0.078 600 4 105 0 X OPT. Reinforced

0.055 0.047 400 3 80 0 0 OPT. Ditch digging

0.08 0.062 500 3 90 0 @ OPT.Long armDitch digging

0.12 0.088 660 4 110 0 X OPT. Ditch digging

Slope bucket (1000) - 85 0 X OPT. Slope finishing

7-2

J61 SPECIFICATIONS

I 7-2 OVERALL DIMENSIONS I

II

~--D----.

Unit" mmCodes Description Rubber shoe Steel shoe

A Crawler shoe width 300 300B Overall length of crawler 2060 2070C Overall width of crawler 1550 1550

D Cab widthROPS Canopy 1560 1560Steel cab 1560 1560

E Cab heightROPS Canopy 2350 2350Steel cab 2420 2420

F Rear end swing radius 1390 1390G Rear end ground clearance 585 585H Mini. ground clearance 305 305I Overall length of undercarriage 2590 2590J Blade height 365 365K Blade width 1550 1550

Overall lengthBlade in front 4835 4835

LBlade in rear 5040 5040

7-3

J61 SPECIFICATIONS II7-3 WORKING RENGES I

11II OFFSET DIGGING WORKING RANGE

1725

925 800

625 500

600

50

Minimum frontturning radius

(at right swing)

150I

I~~I

7-4

25

Minimum frontturning radius(at left swing)

J61 SPECIFICATIONS II11II WORKING RANGE (BACK HOE)

w

LN

BA

Unit: mm

Key Description Std. arm Long arm

Std. of bucket capacity (rn"), ISO Heaped 0.11 0.08A Max. digging radius 5080 5390B Max. bucket outreach at ground level 4960 5280C Max. digging depth(Not used blade) 3150 3450D Radius of max. digging depth 2070 2070E Max. digging height 4830 5120F Radius of max. digging height 2860 2950G Max. dumping height 3350 3620H Radius of max. digging height 2580 2740I Min. dumping height 1250 960J Radius of min. dumping height 1720 1850K Max. vertical digging depth 2450 2900L Radius of max. vertical digging depth 3370 3250M Radius of min. digging ground level 1540 1470N Max. clean-up radius at floor level 3780 4090

7-5

MANUFACTURER

IHI Construction Machinery Limited

3174 Showa-machi, Kanazawa-ku,Kanagawa-prefecture

JAPAN

35N3

MINI EXCAVATOR

PUBLISHED, AUGUST 2007

IHI CONSTRUCTION MACHINERY LIMITED

JAPAN

mini excavator - kattrak€¦ · foreword this manual contains safety, operation, maintenance, and...

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