Professional Documents
Culture Documents
PP520E-IX - OM Manual
PP520E-IX - OM Manual
PP520E-IX - OM Manual
Page 1
FOREWORD
INTRODUCTION
This manual is prepared for all operators and maintenance personnel. It provides technology
information, which will help you operate and maintain this machine. Unsafe use of this machine may
cause serious injury or death. Operation maintenance personnel must read this manual prior to
operation and maintenance of the machine. This manual shall be placed near or in the machine for
easy and timely reference, and all personnel related with this machine shall periodically refer to the
manual.
Prior to operation and maintenance, operators and maintenance personnel should read this manual
thoroughly for information and guidelines, as many accidents are caused due to non-compliance with
the related basic safety rules for machines operation and maintenance.
As our products are upgraded periodically, we reserve all rights to change any information without prior
notice.
Website: www.powerplus.us
Page 2
FIRST 100 HOUR
POWERPLUS machines have been thoroughly adjusted and tested before shipment. Operating the
machine under severe conditions at the beginning can adversely affect the performance and shorten
the machine life. Please refer to the following:
3. Avoid sudden starts, sudden acceleration, sudden stops and steering except in case of
emergency.
4. For the initial 100 hours, lubricate the pin of the work equipment before using the machine.
Lubrication must be applied to the boom, arm bucket periodically.
Page 3
CONTENTS
A.SAFETY
2. General Precautious............................................................................................................... 10
7. Battery.................................................................................................................................... 19
8. Lifting operations.................................................................................................................... 20
B.OPERATION
Page 4
3. Pre-start Engine Checks........................................................................................................ 61
1. Walk-around check.................................................................................................... 61
4. Starting Engine....................................................................................................................... 63
2. Steering machine....................................................................................................... 66
3. Swinging.................................................................................................................... 67
6. Stopping machine.................................................................................................................. 68
8. Mode of operation.................................................................................................................. 71
C. TRANSPORTATION
Page 5
D.LONG-TERM STORAGE
1. Before storage.......................................................................................................................83
2. During storage.......................................................................................................................83
3. After storage..........................................................................................................................83
E.MAINTENANCE
1. Guides to maintenance......................................................................................................... 84
Page 6
SAFETY
WARNING:
Follow all safety precautions. Failure to do so may result in serious injury or death. Please read and
understand the precautious stated in this Manual and in the safety signs on the machine These
precautious shall be strictly followed during machine operation or maintenance.
Page 7
1. POSITIONS OF SAFETY SIGNS
2. Make sure to fully understand the correct positions and contents of the signs.
3. Make sure to locate the signs in correct positions and always keep them clean, in order that
their contents may be legible. During cleaning of signs, do not use organic solvents or gas,
otherwise the signs will deteriorate / reel off.
4. There are other signs in addition to warning indications and safety signs, and these signs shall
be treated in the same way.
5. The sign shall be replaced with new ones if they are damaged, lost or fail to be legible. Refer to
this Manual or actual signs, and send orders to the Company or dealers, with regards to the
details of part numbers for signs, Some signs may have different positions because of different
excavator types, and may possibly be optional signs. In such case, the physical objects shall
apply.
Safety Signs
1. Precautions for Operation, Examination and Maintenance
22-90-010001
Page 8
2. Precautions prior to Operation 3. Warning for Operation Leaving Seat
22-90-010002 22-90-010003
2. GENERAL PRECAUTIONS
1. Only trained and authorized personnel can operate and maintenance the machine.
Page 9
2. Follow all safety rules, precautions and instructions when operating or performing
maintenance on the machine.
3. Do not operate the machine if you are not feeling well, or if you are taking drowsy medicine .
Operating in such a condition will adversely affect your judgement and may cause an accident.
4. When working with another operator or with a person on worksite traffic duty, ensure that all
personnel understand all hand signals that are to be used.
1. All guards and covers must be in their proper positions. Repair guards and cover if damaged.
2. Use safety features such as safety lock levers 1 and the seat belt properly.
3. Never remove any safety features. Always keep them in good operating conditions.
1. In case of water ingestion into the electrical system, it may cause risk of malfunction or
failure. Do not flush the electrical system (Sensors and connectors) with water or steam.
2. When machine is to be examined and maintained with mud or oil stains danger exists due to a
slippery surface. Always keep the machine clean.
3. Do not bring dangerous articles such as flammable or explosive articles into cab.
1. When leaving the seat, set the safety lock lever to the LOCK position. If the lock lever is not
locked, work equipment movement could result in serious injury or damaged.
2. When leaving the machine, lower the work equipment to the ground, set the safety lock lever
to the Lock position, stop the engine, and use the key to lock all the equipment.
Do not jump on or off the machine. Do not get on or off when the machine is in motion.
When getting on or off the machine, always face the machine and use the handrails and steps. Never
hold any control levers or lock levers.
Page 10
Do not allow anyone to sit the bucket, grab bucket, or any other accessories, as danger may exist with
falling off causing serious injury.
When getting on or off the machine, or moving along the top of track, if you need hold the handrail
inside the door, always open the door and lock it in place, sudden movement may cause you to fall.
Fuel, oil and antifreeze can be ignited by a flame, keep them away from any flame or lighted cigarette.
Do not allow fuel to be spilled on the overhead surface or parts of electrical system. Wipe off spilled oil
after fuel or engine oil is added.
Do not weld or cut the pipelines containing flammable liquids with a cutting torch.
Immediately after operation is stopped, the engine oil and hydraulic oil are at high temperatures and
are still under high pressures. Attempting to remove the cap. Drain the oil or water, or replace the filters
may lead to serious burns. Always wait for the temperature to cool and follow the specified procedures.
To prevent hot water from spurting, stop the engine, wait for the water to cool, and then loosen the cap
slowly to relieve the pressure before removing the cap. (When checking whether the water
temperature has gone down, put your hand near the front face of the radiator and check the air
temperature. Be careful not to touch the radiator.)
To prevent hot oil from spurting, stop the machine, wait for the oil to cool, and then loosen the cap
slowly to relieve the pressure before removing the cap. (When checking whether the oil temperature
has gone down, put your hand near the front face of the hydraulic tank and check the air temperature.
Be careful not to touch the hydraulic tank.)
If there is any danger of falling or flying debris hitting the operator, install protective guards in place to
protect the operator as required for each particular situation.
For breakers, install a front guard on the windshield and a top guard on the windshield. Also, place a
laminate coating sheet over the windshield.
For breakers, in mines, tunnels or other placed where there is a danger of falling or flying objects
debris, install a front guard on the windshield and a top guard on the cab and place a laminate coating
over the windshield.
Close the front window when above mentioned operations performed. Additionally, make sure that
other people are outside the danger zone of falling objects, and kept in a proper safe distance.
Page 11
The above mentioned aims at typical working conditions, and it may possible if required to additionally
fit other protective covers.
On machine equipped with an accumulator, after the engine is stopped, the work equipment will lower
under its own weight when the work equipment control lever is shifted to lower. After the engine is
stopped, set the lock lever to the lock lever to the lock position and lock the attachment pedal with the
lock pin.
The accumulator is filled with high-pressure nitrogen gas, and it is extremely dangerous if it is handled
in the wrong way. Always observe the following precautions.
When carrying out disassembly or maintenance of the accumulator, or when disposing of the
accumulator, it is necessary for this operation, so please contact Powerplus .
If it should become impossible to open the cab door, break the glass with the hammer and use it as an
emergency escape.
When optional parts or accessories are installed, the issue with restriction of safety or law exists. On
this account, please contact the POWERPLUS or the dealers in advance.
POWERPLUS will not accept any liability should the machine be misused, abused or operated outside
the working parameters specified by the manufacturers.
Read the specification manuals and general descriptions about related accessories in this manual,
when option accessories are installed and used.
Any refit without approval of POWERPLUS may cause danger, and we will not be liable for any injury,
accident, or product failure arising from refit.
Do not jump on or off the machine. Do not get on or off when the machine is in motion.
Examine thoroughly for any anomalous dangerous situation exists in the working area, prior to start of
operation, and necessary measures, to prevent entry of any unauthorised people into the working
area.
Page 12
Check the terrain and condition of the ground at the worksite, check (include under lines,
electrical) and determined the best method of operation.
Check for leakage of fuel, lubricant and hydraulic system. If any abnormality is found, check for
loose bolts of the track and damaged to other parts. Do not operate the machine under this
situation.
Check the fuel level, and lubricant level and coolant level. Do not smoke when refuelling.
Check and tighten radiator and all fuel and oil caps securely.
Wipe any oil, grease or mud on the handrails, grounds and control levers. Never jump on or off
the machine.
Do not put tools and other things in the cabin, so as not to influence operation and cause
accident.
Adjust operator’s to a position where it is easy to carry out operations. Do not operate the
machine in other position.
Before starting the engine, check that all the control levers are at the NEUTRAL position.
Adjust the rear view mirror, so that the rear part of the machine may be clearly in sight from the
driver’s seat.
Examine the running alarm device (if fitted) is working normally. Fasten the seat safety belt, prior
to operation.
Make sure that all the gauges and alarm gauges are in normal situation.
Check the clearance and the stroke of all the control levers.
Before operating the travel and swing lever, check the direction of the track frame. When the
track frame is at the back, the operation of the travel and swing lever are reversed.
Before operating the machine, sound the horn to warn people in the area.
Operate the machine slowly and check for any abnormality in the sound of the engine and
gearbox.
Move the machine to a safe place and swing, check that travel and swing works properly.
Examine the sound, vibration, hearing, and smell of the machine or whether any abnormality
exists with instruments and check whether there is a leak with engine oil or fuel.
The indication of adjusting weight display (kg) for the seat suspension is consistent to the weight
of operator. The adjustable range is 50 – 130 kg (slight difference with different models of seats).
Page 13
5.PRECAUTIONS WHEN OPERATING
Before travelling and swing, look around to see if t there are any people or rough grounds.
Set the bucket to a height of 40 ~ 50cm, in case of emergency, quickly lower the bucket to the ground
to help the machine to stop.
Avoid making the machine tilt. (Even when static, the angle of inclination must not exceed 35 degree)
Page 14
1. Operating on slopes could result in the machine tipping over or slipping sideways.
2. Operating the machine in normal speed. Never: 1 drive too fast 2 starts suddenly, turn sharply
3 zigzag.
3. If you find any abnormality in the machine during operation, incorrect gauges, noise, vibration,
air leakage and control lever, move the machine to a safe place. It is important to check for oil
leakages, and oil leakage can cause fire.
5. Keeping the working ground smooth as possible, this can improve working efficiency and
stability.
6. While working at river embankments or other places like pile driving, should take at
precautious that the machine may be prone to sinking.
7. When working on snow or icy grounds, even a slight slope may cause the machine to slip to
the side.
8. Always operate carefully to avoid getting stuck in the mud. If the machine does get stuck in
mud, use the following procedure to get the machine out.
When only one side is stuck in mud, use the bucket to raise the track, then lay board or logs and drive
the machine out. If necessary, put a board under the bucket.
Page 15
When the tracks on both sides are stuck in mud, lay boards as explained above, and dig the
bucket into the ground in front. Then pull in the arm as in normal digging operations and the travel
levers in the FORWARD position to hit the machine out.
9. When passing over bridges, check first that the structure is strong enough to support the mass
of the machine, Check the depth and flow of water and the ground condition before working in
water and mud or crossing a river or mud. Do not immerse the machine in water by more than
the bottom section of the swing frame. When working on muddy ground, lay boards to avoid
the machine from tipping over.
10. Do not carry out the operations in fog, mist or other conditions. Wait for the weather to clear so
that visibility is sufficient to carry out work.
12. When working near electric cables, do not let machine contact overhead electric cables. Wear
rubber shoes and gloves. Use a signalman to give warning. Always maintain the safe distance
given below between the machine and the electric cable.
Page 16
13. Do not dig work face under an overhang. Do not carry out deep digging under the front of the
machine. This may cause accident.
Page 17
14. When travelling close to the edge of cliffs, road shoulders or travelling on slopes, if it is
necessary to operate the work equipment, stop all travelling motion and operate the machine.
15. Never pass the bucket / load over the head of any worker or over the operator’s cab on a dump
truck.
It is strictly prohibited to carry out breaking operation with impact force of the rig, as this may
cause danger of personal injury or damaged of rig by the falling debris of broken material.
Lock up the cab door or the excavator window on the position (opened or closed) during operation,
to be firmed fixed and locked up in place, to avoid damage of door. Ensure the door and the
window is tightly closed on the working site where danger exists with entry of falling into cab.
Park the machine on firm and flat ground, and completely drop the rig onto the ground.
When stopping the machine, set it on level ground where there is no danger of falling rocks or
landslides.
If it is necessary to park the machine on a slope, set blocks under the tracks to prevent the machine
from moving, then dig the work equipment into the ground.
After stopping the machine, operate the right work equipment control lever several times to the RAISE
and LOWER position to release the remaining pressure in the hydraulic lines.
When leaving the machine, do as follows. Set the safety lock lever to the lock position. Lower the
bucket to the ground. Set the work equipment control lever in NEUTRAL position and lock it. Always
close the door of the operator’s compartment.
Page 18
7.BATTERY
Battery electrolyte contains sulphuric acid, and batteries generate hydrogen gas, so mishandling can
lead to serious injury or fire. For this reason, always observe the following precautions.
1. When working with batteries, wear safety glasses and rubber gloves.
2. If you spill acid on your clothes or skin, immediately flush the area with large amounts of water.
3. Battery acid could cause blindness if splashed into the eyes. If acid gets into your eyes, flush
them immediately with large quantities of water and see a doctor at once.
4. Before working with batteries stop the engine and turn the starting switch to the OFF position.
5. Avoid short-circuiting the battery terminals through accidental contact with metal objects, such
as tools.
6. When removing or installing, check which is the positive terminal and negative terminal and
tighten the nuts securely. If the battery electrolyte is near the LOWER LEVEL, add distilled
water. Do not add distilled water above the UPPER LEVEL.
7. When cleaning the top surface of the battery, wipe it with a damp cloth. Never use gasoline,
thinner, or any other organic solvent or cleaning agent.
8. If the battery electrolyte is frozen, do not charge the battery or start the engine with a different
power source. There is danger that this will ignite the battery.
9. Always remove the battery from the chassis before charging it.
10. Set the voltage on the charge to match the voltage on the battery to be charged. If the voltage
setting is wrong, it will cause the charger to overheat and catch fire, and this may lead to an
explosion. Connect the positive charging clip of the charge to the positive terminal of the
battery, then connect the negative – charging clip to the negative – terminal of the battery.
Tighten both terminals securely.
11. If the battery charge is less than 1/10 of rated charge, and a high speed charging is carried out,
set to a value below the rated capacity of the battery. If there is an excessive flow of charging
current, it may cause leakage or evaporation of the electrolyte, which may catch fire and
explode.
It is required to disconnect the negative pole or disconnect the switch of negative pole of the battery, if
machine is to be parked for a long time (longer than 10 days). Activate the excavator for about 2 hours
periodically within one month, apply necessary electric charge to the battery, and have the engine and
respective connection parts of the complete vehicle fully lubricated and maintained.
8. LIFTING OPERATIONS
Page 19
Use special hanger during lifting operation and examine for any damage prior to hoisting operation.
Descend the working mode of engine, and use L or F mode for hoisting operation. Pay attention to the
correct angle of rig, to prevent hook disengagement.
Be cautious during operation as rigs such as bucket and rod may be touched during hoisting operation.
Prohibited methods:
1. Do not weld a lifting hook on the bucket without permission, used for lifting things.
2. Do not set a steel wire rope on the bucket tooth for lifting things.
3. Do not wrap steel wire rope on the moving arm or bucket rod for lifting things.
If maintenance must be carried out with the engine running, carry out the operation without
load.
If it is necessary to lift the machine, the angle of boom and arm must be 90 degree ~ 110
degree. Always block the track shoes securely.
Page 20
Never work under the machine if machine is supported by boom.
Use non-flammable materials as the flushing oil for cleaning parts. Do not use diesel or
gasoline. As it may catch fire.
When repairing the electrical system or when carrying out welding, removing the negative (-)
terminal.
Precautions when using high-pressure grease to adjust track tension of the battery.
Grease is pumped into the track tension adjustment system under high pressure. If the
specified procedure for maintenance is not followed when making adjustment, valve 1 may
dislodge and cause damage or personal injury.
When loosening grease, draining valve 1, never loosen it more than one turn.
Never put your face, hand, feet, or any other part of your body directly in front of any grease
drain valve.
In relation to the safety rules for HP oil, pressure is always present inside the hydraulic system.
Examine to ensure that the pressure inside the hydraulic oil pipeline has been released during
examination or replacement of pipeline or hose. If pressure is still present in oil pipeline, it may cause
grievous injury or damage.
1. Do not make examination or replacement, when there is still pressure inside the hydraulic
system.
2. The surrounding area is wet if any leak exists at pipeline or hose, and on this account,
examine if a crack exists at pipeline or hose, as well as whether or not the hose is expanded.
Wear goggles and leather gloves when examination is carried out.
Page 21
3. The HP oil leaked from micropores may penetrate into skin, and may cause blindness if it
comes into direct contact with eyes. Flush with clean water and immediately contact physician
for treatment, if skin or eyes are affected by HP oil.
Page 22
B. OPERATION
Page 23
2.GENERAL VIEW OF CONTROLS AND GAUGES
Note: Those serial numbers in **in front may have different fittings because of different machine types
or spare parts.
Page 24
2.1.FUNCTION OF ELECTRONIC MONITOR (For WJK-7C type)
1. Mute switch. 2. Auto idle switch 3. High and low speed switch 4. Work model select switch 5.
Work model select switch 6. Water temperature gauge 7. Fuel gauge 8. Water level monitor
(option) 9. Hydraulic temperature monitor 10. Water temperature monitor 11. Air cleaner
monitor (option) 12. Fuel level monitor 13. Engine oil pressure monitor 14. Hydraulic oil level
monitor (option) 15. Preheating monitor 16. Charge monitor 17. Battery low voltage monitor
(option) 18. Engine speed monitor 19. Service meter
Page 25
FUNCTION OF GAUGE
This displays the engine cooling water temperature (Fig 2.1) During the normal
operation, the lamp should light up in the green range. If the lamp in the red range
lights up during operation, this displays the water temperature is high (Fig 2.1.1),
then engine temperature monitor flashes. Stop the machine or run idling and
check the water level.
2. Fuel Lever:
This displays the engine cooling water temperature (Fig 2.1) During the normal
operation, the lamp should light up in the green range. If the lamp in the red
range lights up during operation, this displays the water temperature is high
(Fig 2.2.1), so check or ad fuel.
3. Air cleaner strainer monitor:
This displays the air cleaner. (Fig 2.3) During the normal operation, the signal does not flash. If the
air cleaner is stuffed, the monitor lamp flashes.
During cold weather engine start, set the key to the HEAT position, then the preheating
monitor lights up. (Option)
This monitor indicates the charging system. While the charging system is
normal, the signal will remain lighted. While the charging system is not
functioning, the signal will flash and check the condition of the charging system.
Page 26
1.10 Charge Level:
This monitor indicates the charge level (Fig 2.10).
If the monitor lamp flashes, check the V-belt tension.
Page 27
2.2.FUNCTION OF ELECTRIC MONITOR (For WZ-2 type)
Shown as fig.1 this diagram is outward diagram of keyboard, among it, on upper
throttle, upper part on these both keys is indicating lamp of throttle, this lamp indicates
Pressing descent key of throttle, then throttle of engine will descend; Pressing ascent key of throttle,
then the throttle of engine will ascend. Key is rain shield wiper key, pressing this
Page 28
when pressing this key again, the rain wiper lies in continuous work state, when
pressing this key again, the rain wiper will stop operation. Key is the
sprinkling key of rain wiper, when pressing this key, sprinkling of rain wiper will
begin work, when departing this key, the sprinkling of rain wiper, sprinkling will stop.
Main Menu
When unlocking the key, enter into the main menu firstly, Block 1 displays calendar, Block II is the
warning block, Block III is erroneous-display code block, block IV s the time-display block, block V is
Page 29
the working time display block IV is the time-display block, block V is the working time display, block VI
is work timing destination, block VII is oil level and water temperature display block.
1. Calendar display block: It can display specific numerical values of year, month, day and week.
2. Warning block: it can display figures of each warning quantity, when charging frame flickers
and buzzer sounds warning simultaneously, showing that generator of this excavator does not
generate electricity. When machine oil pressure frame flickers, and buzzer sounds warning
simultaneously, showing that the machine oil pressure of engine of this excavator is abnormal, it
is necessary to stop operation of the engine for immediate checking. When preheating indicating
frame emerges, showing that the engine is lying in preheating state. When low water level frame
flickers and buzzer sounds warning simultaneously, showing water level of cooling water is low, it is
necessary to stop operation of engine for immediate checking. When air filter blockage frame
flickers and buzzer sounds warning simultaneously, showing that air filter is dirty, stop operation
of air filter at once to eliminate dirt. When high oil temperature frame flickers, and buzzer sounds
warning at same time, showing that temperature of hydraulic oil is high, stop operation of excavator
at once to check hydraulic oil temperature.
E04 Showing the revolution signal of engine has not been measured out and
checked up
Notice: The E03 or E12 error codes may appear when external ambient temperature is too low or when
engine temperature is fairly low, and this error code shall disappear when engine temperature or
temperature of hydraulic oil rises to about 30 degree C. E01 error code may also possibly appear when
oil level is too low, and this code shall disappear when fuel is added.
4. Time display block: Display specific time numerical value in this block, its accuracy is 25 degree C
+/- 5 minutes / month.
5. Working time display block: It can display total working time of excavator.
6. Working time-reckoning mark: When engine begins to operate, this mark start flicking: when this
mark stops flickering, indicating that work time-reckoning action stops.
7. Water temperature and oil level display block: this block displays high and low water temperature
and oil level. When water temperature warns, both characters “water temperature” flicker, and buzzer
sounds at same time; both characters “oil level” flicker, and buzzer will sound simultaneously when oil
level warns.
Page 30
8. Small working time-reckoning place, time-reckoning operation in this place can be eliminated,
pressing and hold carriage return key, working time-reckoning operation will clear
When pressing menu key code, table shown as fig. 3 will appear.
When pressing ascent key of menu or descent key of menu, the black frame in figure will move up and
down correspondently to select right and correspondent menu, if “systematic disposition is selected
satisfactorily in fig 3, at this time pressing the menu once again, the table shown in fig 4 will appear.
Excavator Pattern:
Production date:
Excavator serial number, production date of the excavator and electro control edition are shown in fig 4.
At this time, pressing carriage return key, the table will change into table shown in fig 3. If the selective
item “engine” is selected satisfactorily in fig 3, at this time, pressing menu key once again, the table
shown in fig 5 will appear.
The specific value of water temperature and voltage will display out this table, among them, unit of
water temperature is degree C, unit of voltage is V. At this time, pressing carriage return key of menu,
the table will change into table in fig 3. If selected item “hydraulic system” is selected satisfactorily in fig
3, pressing menu key at this time, the table of fig 6 will appear.
Page 31
This menu is power-adjustment menu, “power of system” is the general normal working condition.
Power co-efficient size can be adjusted by ascent key and descent key, at this time, pressing menu
key, the black triangle in figure will jump to “fine mode 1”, thus, operator can adjust the size of fine
mode1 through ascent key of menu and descent key of menu, pressing the menu key again, the black
triangle will jump to “fine mode 2” to get size of adjustment. At this time, pressing carriage return key,
the table will return menu of fig 3. If maintenance and repair system is selected satisfactorily in fig 3,
whereas menu key is pressed, the table such as fig. 7 will appear.
There are three sub-menus in this table, the first sub-menu is “checking and measurement of signal”,
the second sub-menu is “investigation table”, the third sub-menu is “trouble record”. When “checking
and measurement of signal” column are selected satisfactorily in black frame, pressing menu key, then
table of fig. 8 will appear.
Two- circuits signals can be checked and measured out in fig 8.when safety is not locked, the square
frame behind it will colourless; when safety is locked, the square frame will become black. Pressure
signal is the collected pressure signal of control oil circuit for automatic return low speed function of
engine. When driver does not operate excavator, the square frame will become colourless, at this time
pressing carriage return key, the table will return to menu shown as in fig 7. In fig 7, pressing ascent
key or descent key on menu to select the menu. When “investigation table” menu is selected
satisfactorily, pressing menu key, the table will enter into interface shown in fig 9.
Page 32
Shown as fig.9 the location covered by black frame in figure can be adjusted by ascent key of menu
and descent key of menu. Selection of black frame is selected in accordance with menu key. In fig.7, if
trouble record menu is selected satisfactorily by black frame, pressing menu key, it will
show previous and recent eight erroneous codes, including year, month and date
producing the erroneous codes, shown as in fig.10. If pressing menu key again at this time,
all erroneous codes will be cleared.
Contents shown in following table are representative meaning of the erroneous codes
Page 33
Pressing carriage return key under menu of fig.10, will return to tableau shown in fig.7; If pressing the
carriage return key again, will move back to tableau shown in fig.3.
In tableau of fig.3, if selecting upkeep record menu satisfactorily, pressing the
menu key, will enter into the upkeep record tableau shown as fig.11.
In fig.11, the designated item of black triangle just is upkeep which should be done, pressing carriage
return key, can return to menu in fig.3.In the third menu, if selecting delay to stop
operation of engine satisfactorily, pressing the menu key, system will enter into tableau shown as
fig.12.
Item covered by black frame is the frame is the selected item presently, when the first line “yes” is
covered by black frame, “yes” or “no” can be adjusted through up key or down key on menu, if it is
“yes”, when operation delays to stop running of engine, will shut down the engine; if it is “no”, when
operations delays to stop running of engine, don’t shut down the engine (don’t utilize engine-shutting
function in type WZ-2, WZ-3 excavator), till delay time is up, when power source of whole excavator is
shut down, the engine is shut down. Pressing menu key, when black frame selects the selected item
“minute” satisfactorily, length of delay time can be supposed through upper key and lower key on menu,
the longest calculating unit is 99 minutes. Pressing menu key, when black frame select the selected
item “operation” satisfactorily, there are two- kind selections, one is “yes”, other is “no”. Carry out the
selection work through upper key or lower key on menu possibly. When “yes” is selected work,
pressing menu key again, the table shown in fig. 13 will appear.
The time shown in above figure is the remaining time for delay to stop running of the engine, at this
time driver can insert key into engine running stopping position, then put key out. When record time is
00 minute 00 second, engine will stop automatically. If operator wants to end automatic shutdown
function as reckoning of time is still not up, it is necessary for operator to press the carriage return key,
at this time system will shut down the engine in advance, then inserting key to re-start up the engine.
When the selected item “encryption” is selected satisfactorily in fig 3, the table shown in fig. 14 will
appear if the menu key is pressed.
Page 34
When this table emerges, demanding that operator inputs four-digit engine-starting cipher code,
pressing the menu key to confirm after inputting of cipher code is finished (cipher code of new
excavator is 1234), if the cipher code is correct, the table shown in fig. 15 will appear.
Engine-starting cipher code cancelling column emerges in figure: two selected items
“yes” and “no” can be selected through pressing upper key、 lower key on menu; when “yes”
is selected, in engine-starting time , it will enter into tableau of fig.2 directly. If
“no” is selected,, it will remind operator of inputting cipher code in engine-starting
time, can inputting of cipher code is correct, can the engine start to enter into
tableau of fig.2 (Suggest that customer doesn’t set the engine-starting cipher code, only if necessary,
can the customer just re-set cipher code). If forget the cipher code, it is necessary to contact with
factory (keep always in mind: don’t forget cipher
code). If pressing menu key at this time, the selected item will enter into cipher code revision, this
column would show emptiness sometimes. Two-kind selected items “yes” and “no” will appear if
pressing upper key or lower key on the menu, when“yes”emerges, pressing menu key, the tableau of
fig.16 will appear.
At this time demand customer to input new four digits cipher code, pressing
menu key define the input cipher code after inputting work end, next it will enter into
tableau of fig.17
This tableau demands operator to re-input cipher code once then confirm correctness
of inputting result, this inputting of cipher code should coincide with preceding
inputting, if the both inputting are identical, it will enter into tableau of fig.15. Then
pressing carriage return key, it will withdraw from tableau of fig.15. If these cipher codes are not
identical, it will remind operator of erroneous cipher code, re-input the cipher code please.
2. Remember the systematic cipher code , only maintenance and repair personnel of factory can
unlock this cipher code if it is forgotten.
3. Sometimes system would present erroneous table possibly, at this time, pressing carriage
return key to secede, then re-enter into table.
Page 35
4. If the system hangs, there is all no response, even pressing carriage return key to secede,
then re-start it.
5. When unlocking the key, re-start engine after self –checking of system is normal.
6. It is necessary to delay one minute at least if you intend to re-start engine after engine is
shutdown.
7. When engine lies in automatic returning to idle speed, revolution of engine rises to working
state under idle condition, it is definite to wait until after revolution of engine stabilizes, re-start
to do heavy load work.
1. When inserting encryption dog into socket to enter into table of fig 3, the table of fig 18 will
appear.
Comparing fig. 18 with fig.13, we can see that the selected item “systematic revision” is surplus when
selecting this item satisfactorily and press menu key, we can see table shown in fig 19.
Excavator Type:
No. of excavator
Production date
In menu of fig.19, pressing menu key to select the item to be revised, the selected item is revised
through pressing upper key or lower key of menu. Among it,setting time should be longer than at
the time of just beginning of operating time setting,38 otherwise can’t be started up. The
operating time is total working time set by personnel of factory for this machine
when it departed from the factory. When working time exceeds operating time, system will
lock machine automatically. Unless encryption dog is inserted, otherwise it can’t be unlocked. It
is possible to bring about the specific cipher code in this menu,it is very convenient to unlock the
cipher code.
(2) When the encryption dog is inserted in menu shown in fig.5,it will increase
Page 36
engine revolution-displaying column in fig.20.
Page 37
(1) starting circuit
When turn starting switch to “switch-on”position,the stating switch B always is live terminal, at
this time, it connects terminals Br, ACC through, the terminal ACC connects with red line of oil
cut-off valve to keep action of coil,but the oil cut-off valve can’t be opened,at the same
time,computer controller system board gets electricity and outputs 24V current to
coil of battery relay through three-seconds self-checking later,making master contact of
battery relay close. When turn starting switch to“starting”position,terminal C is alive in short
time, the coil of starting
valve relay and oil cut-off valve gets electricity. Making the master contacts of two relays close,the
white line of oil cut-off valve is alive,making tensile coil of oil cut-off open,oil circuit is
opened. At the same time,coil of starting relay gets electricity to make starting
dynamo galvanize,begin work to start up engine. After starting switch returns to “switch-on”
position,terminal C doesn’t take current any longer. Main circuit of starting valve relay is
disconnected with that oil cut-off valve relay, the tensile coil cut-off valve is disconnected, but
holding coil still takes current
to make engine operate possibly. At this time, starting switch is locked automatically,and can’t be
turned to “starting” position, thereby preventing engine from restarting. (After engine is
started successfully,pay attention to no starting of engine any longer).
Page 38
(2) Charging circuit
After the engine is started,making use of belt to
drive AC-generator initial operating and to charge
battery through terminal B or to supply current to other
electrical equipment; at the same time, signal terminal
of generator is connected with computer controller
through R,showing indicating of normal charging.
( 4 ) Auto-control circuit
6. Set-making sensor:
(1)Temperature sensor:
Including water temperature sensor and hydraulic oil
temperature sensor.
Number of product:1/2-14 NPTF
Principle:when temperature rise,internal impedance valve of
sensor decreases.
(2)fuel sensor:
Number of product:175-06-35192
Principle:when fuel fluid level rises and decreases,the internal impedance valve of
sensor decreases.
(3)Machine oil pressure sensor:
Number of product:3846N-010-B
Principle:when machine oil pressure is ≥0.08Mpa±5﹪,the sensor circuit is
41
connected through ; when machine oil pressure is ≤0.08Mpa±5﹪,the sensor
circuit is cut off.
(4)Air filter sensor
2.3 Functions of Electronic Monitor ( WZ-4 and WZ-5 types)
WZ-4 and WZ-5 monitors may be divided into two parts, and Fig 1 shows the display
part, while Fig 2 displays the keyboard control part.
In the display part, it is further divided into A, B, C, D, and E five areas. Area A is the alarm area, and
the meanings it symbols represent are as follows:
Page 40
Area C is the area for display of engine rotational speed. (Standby)
Area D is the work time counting area. Work time counting begins as the symbol
flashes.
Area E is the area for display of oil level.
The key is the rotary locking key, and the rotary key is locked up when the indicator
light on it turns on. The locked rotary key is unlocked when this key is pressed and the indicator light
turns off. (Standby)
The key is the key for working light, and it may turn on, switch, or turn off the working
light when this key is pressed.
The key is the automatic return idling key. The automatic return idling function
plays its function when this key is pressed and the indictor light on it turns on, and at this point,
the speed may be returned to the originally set speed when the button of the right
control rod is pressed. The automatic return idling function will be shut down when the indicator light on
it turns off.
The key is the key for wiper. It may achieve the intermittent,
continuous, and closing functions of wiper, when this key is pressed.
The key is the wiper water spraying key. It begins to spray water
when this key is held down, and water spraying stops when this key is released.
Page 41
The key is the key for high and low running speeds. It may achieve the shift
between high and low running speeds when this key is pressed.
The key is the mute key. The alarm sound is prohibited when this key is pressed and
the indicator light on it turns on.
Page 42
2.4.Functions of Electronic Monitor (Models WZ-7 and WZ-8)
WZ-7(8) Model excavator monitor is characterized by simple and easy operation, and
its specific operations are described as follows:
Wherein in the top line is the menu enter key, is the menu descending
second line is mode descending key, is the mode ascending key, and on these
two keys are the mode indicator lights, indicating the positions of modes. Press the mode descending
key, for mode to descend, while press the mode ascending key, for mode to ascend. Through selection
the mode matching the operating mode, it may be easier to enter operation. Or turn the accelerograph
potentiometer on the armrest box on the right side, to select corresponding working mode.
L Idling Mode: The lowest idling of engine and it is required to return to under this mode when engine
is started or shut down each time.
B Breaking Mode: Applicable to breaking work.
F Fine Mode: Applicable to accurately controlled operation or hoisting work.
EO Economical Mode: Applicable to low-cost operations of low fuel consumption, and
the operations with priority on fuel saving. EO mode may be selected, to further select E1, E2, and E3
economical modes, to meet the user requirement for saving fuel to the maximum extent. After
E mode is set up each time, computer CPU may automatically remember the selected
mode.
P Fast-speed Mode: Applicable to heavy load operation. It is beneficial to engine
protection when used within a short time. When breaker is used, B Mode is to
be applied, and it is strictly prohibited to use P mode, as danger exists that breaker may possibly be
damaged
This key is for the automatic return idling function. When this
key is pressed and the indicator light on it turns on, it indicates that the
Page 43
automatic return idling function has been started. When driver does not operate the
machine, the system will automatically delay for 5
seconds and then automatically slow down the engine rotational speed to save fuel consumption. This
function will be cancelled if this key is pressed and the indicator light turns off. Each time when switch
is pushed, automatic deceleration will be switched between start and cancellation.
This is the select key for adjustment of hydraulic power, and
the system will work
according to the set power mode. When this key is pressed, it will shift between the
hydraulic powers, and the current power mode will be displayed on
the right lower corner of the screen.
This is the wiper key. It will be in the intermittent working status (INT) when this key
is pressed once, while this key is pressed once more, the wiper will be in the continuous working status
(ON), and if the key is pressed for a further time, the wiper will stop working (OFF). Each time when
switch is pushed, it will shift between INT →ON → (OFF) .
This is the 46 key for wiper water spraying. Water spraying of wiper begins work
when this key is held down, and it stops working when released. When wiper is stopped, if this switch
is pushed down, washing liquid for excavator window will be sprayed out, and
the
wiper will stop working at the same time after it has begun action for 6
seconds.
This is the key for working light and the screen switch key.
This is the key for double-speed running. When this key is pressed,
and the left
indicator light on it turns on, it indicates that running work is in the low-speed status Lo, and when this
key is pressed and the right indictor light turns on, it indicates that the running work is in high-speed
status Hi. Pay attention and make sure to run at the low speed when machine is to be
loaded or offloaded from trailer. Additionally, if running speed is to be switched between high
speed and low speed, the machine will drift to one side, even if it is running on a
straight line. So the machine must be stopped before speed is to be shifted.
This key is for shifting between automatic and manual accelerograph, and the
current status will be displayed on the lower part of display screen. When A is displayed, the mode
select key begins to play its function, and when M is displayed, the accelerograph may be manually
ascended or descended by pressing the menu ascending and descending or
accelerograph potentiometer. At this point, automatic idling is disabled. This is the
mute key. When there is an alarm, buzzer will send out sound alarm, and the buzzer will stop sounding
if this key is pressed at this point and the indicator light on it turns on.
Page 44
2.Main Menu:
It enters into the main menu when key is turned on, and the following items will appear during
computer CPU self-examination:
1 Date & Time 2 Charging Indication 3 Air Filtration
4 Water Level 5 Engine Oil Pressure 6 Oil Stain
7 Oil-Water Separation 8 Hydraulic Oil Temperature Thermometer
9 Fuel Gauge 10 Water Temperature Thermometer
11 Hydraulic Power Indication 12 Preheating Indication
13 Automatic A/Manual M Indication
14 Contact Boost Indication 15 Error Code Indication
16 Total Working Time 17 Working Hour Counting
18 Time Counting Indication 19 Idling Warning
Remarks: For those serial numbers marked with ※in front, display items will differ
for different machine types.
the Time and Date displays the specific date and time values, with precision as ±5 minutes/month
at 25 , able to be set in Chinese and English display; When the Discharging
Indication flashes and the buzzer alarms in sound at the same time, it indicates that the engine
of this vehicle will not generate power possibly, and this indicator light turns on when
start switch is on ON position, while this light will turn off after the engine has been started. When
(3 ) the Air Filtration Indicator flashes and the buzzer alarms in sound at the same time, it indicates
that the air cleaner is too dirty, and it is required to shut down for clean up. When (4)
Page 45
the Water Level Indicator flashes and the buzzer alarms in sound at the same time, it indicates
that the water level for cooling water is too low, and it shall be shut down for
immediate examination. When ( 5) the Engine Oil Pressure flashes and the buzzer alarms in
sound at the same time, it means that the engine oil pressure of this excavator
is under anomalous condition, and it is to be shut down immediately for inspection.
This indicator light turns on when start switch is on ON position, while this light turns off after engine
has been started. When ( 6) the Oil Stain Indicator flashes and the buzzer alarms in sound at the
same time, it indicates that the hydraulic oil leading filter core is too dirty, and it is to be checked and
replaced. When (7) the Oil/Water Separation Indicator flashes and the buzzer alarms in sound at
the same time, it indicates that the water content in the oil/water separator is excessive, and it is to be
timely examined and cleaned. (8) the Hydraulic Oil Temperature Thermometer displays the
temperature of hydraulic oil and the pointer shall remain within the middle black
zone during working process. If pointer enters into (H) zone during operating process, it indicates that
the hydraulic oil temperature has reached over 102°C(215.6°F), and at this point the indicator for
oil temperature will flash and begin to alarm. The engine shall be shut down or be
operated at low idling speed, and wait for temperature of hydraulic oil to drop. When engine is
started, if pointer is at (C) position, the hydraulic oil temperature is below 30°C (77°F) ,
while the indication of hydraulic oil temperature is in white color, the excavator shall not be operated at
this point, before waiting until the oil temperature has risen to the 2nd grid. ( 9) the Fuel Gauge
displays the fuel level inside the fuel tank, and during the operating process, the pointer shall be inside
the black zone. It indicates that the remaining fuel inside the fuel tank will last less than one hour if the
pointer enters into (L) zone during operating process, and at this point, the indicator of oil level
turns on and begins to alarm. On this account, it is to be checked and fuel shall be
supplemented.
When start switch is turned to ON position, correct oil level cannot be displayed, which is
normal. ( 10 _ the Engine Water Temperature Thermometer indicates the temperature of engine
cooling water, and at the time of normal work, the pointer is inside the black zone. If pointer enters into
(H) zone during operating process, the overheating preventive protecting system functions, for engine
rotational speed to be dropped to low idling speed and the buzzer sounds at the same time. At this
point, it must be shut down for examination. When engine is started, if pointer is at (C) level, engine
water temperature displays in white color, the excavator shall not be operated at this time, before
waiting until oil temperature has risen to the 2nd grid. (11) the Hydraulic Power Display
will show the selected hydraulic power here. ( 12) the Preheating Indicator is used to show
that when engine is started under the ambient temperature lower than 0°C (32°F),
preheating is required. After the start switch is turned to HEAT (Preheating) position, the indicator
begins to turn on and it will indicate that preheating is completed after flash for about 30 seconds,
while it will turn off after another about 10 seconds. ○ 13 the Auto A/Manual M
Indicator is able for shift between automatic and manual accelerograph, to display the current
status. (14) the Contact Boost displays whether or not the contact boosting function is
being played. When the button switch on the right control rod for operation is pressed, this indicator will
display, and the excavating force will
be boosted up, while the pressure boost will be terminated in 8 seconds even if the button switch
keeps pushed down and this indicator will be displayed no more.
(15) the Error Code Display Zone, where the following contents are to be referred to for the
meanings represented by codes. (16) the Working Time is to display the total working time of
the machine. (17) the Working Time Subtotal, where time counting can be deleted
here, and by pressing the Enter key for as long as about 8 seconds, the
working time here will be reset. (18) the Working Time Counting Indication will begin to flash when
engine begins operation, while it indicates that working time counting is already stopped when this
Page 46
indicator stops flashing. ( 19) the Idling Alarm indicator is displayed here if engine idling exceeds 5
minutes, indicating that engine can be shut down, to avoid long-time operation, and to save fuel.
WARNING
These monitors are not the guarantee for machine status, and don’t simply depend
on monitors, when examination (daily examination) is made prior to start. It is required to get off the
machine and make direct examinations about respective items. If alarm monitor turns red, it is required
to stop operation as quick as possible and carry out proper examinations and maintenances.
It may lead to failure if alarm is overlooked.
E03 or E12 error code may appear if the external ambient temperature is too low or the
temperature of engine is too low, and this code shall disappear when temperature of
engine or temperature of hydraulic oil has risen to the 2nd grid.
Run the engine at low idling speed or shut down the engine, when it alarms
for temperature of hydraulic oil, and wait until the oil temperature is dropped and monitor display turns
normal.
It is required to shut down engine and check the lubricating system as well as the oil
level in the oil pan, to examine whether or not leak of engine oil exists and to take the
necessary actions, if it alarms for pressure of engine oil and the monitor turns
red
when the pressure of engine lubricant has been dropped to lower than the
normal
level.
It is required to stop operation and carry out examination, if it alarms for water level of engine and
the alarm light of monitor turns red, resume operation and display has turned normal.
3. Secondary Menu
The picture will appear as indicated in Fig 3 when menu key is pressed.
Page 47
When menu ascending or descending key is pressed, the black box in the figure
will corresponding move upward and downward, to select corresponding menu. In Fig 3, if
“System Configuration” is selected, at this time when menu key is pressed once more,
the picture as indicated in Fig 4 will appear.
Those displayed in Fig 4 include the vehicle type, vehicle number, date , electric control unit
version, Chinese and English switch, as well as number of Encryption Dog, and so on, in which
menu key may be switched and displayed in Chinese and English. At this point when Enter key is
pressed, the picture will be switched to the picture as indicated in Fig 3. If the option of “Engine” in
Fig 3 is selected, and the menu key is further pressed at this time, the picture as indicated in Fig 5 will
appear
In this picture, specific values of engine water temperature and voltage will be
displayed, in which the unit of water temperature is ℃ and the unit of voltage is V. In order to meet
customer requirement for saving fuel more easily to the maximum extent, the EO economical key
wherein may be selected for any of the E1, E2, and E3 economical modes when menu key is pressed.
Each time after E mode has been set, the computer CPU can automatically remember the selected
mode, and the selected E mode may be automatically pressed after machine is started for
operation. At this point when menu enter key is pressed, the picture will be switched to the picture as
indicated in Fig 3.
If the option of “Hydraulic System” in Fig 3 is selected, at this point when menu
key is pressed, the picture of Fig 6 will appear.
Page 48
This menu is the power adjusting menu, and means the condition of
This menu is the power adjusting menu, and means the condition of general
normal work. The size of power coefficient may be adjusted through the menu ascending and
descending keys, and at this point, it will jump to when the black triangle in
the picture of menu key is pressed, to adjust its sized.
Through the keyboard 4 key, hydraulic power suitable to current work may be
selected, and the computer CPU will automatically remember it, for work to be
performed as per the selected power when work is started next time. At this point when enter key is
pressed, the picture will return to the menu in Fig 3.
If “Maintenance System” is selected in Fig 3, while the menu key is pressed, the picture as shown
in Fig 7 will appear.
This picture carries four sub-menus. The first one is “Signal Detection”, the second
one is “Meter Adjustment”, the third one is “Failure Record”, and the fourth one is “Rotational
Speed Amendment”. When “Signal Detection” is selected with black box, and menu key is
pressed, the picture in Fig 8 will appear.
In Fig 8, it is able to detect out whether or not the pressure signal is normal. Pressure signal is the
pressure signal of control oil circuit collected for the function of engine automatic return to
low speed, and the square box after if will turn black when driver is not operating the machine, while it
turns colorless when driver is operating the machine. At this point when enter key is
pressed, the picture will return to the menu as shown in Fig 7.
Page 49
In Fig 7, press the menu ascending or descending key to select menu, and when “Meter
Adjustment” menu is selected, it will enter into the picture of interface as shown in Fig
9, when menu key is pressed.
As indicated in Fig 9, the areas framed by the black box in the figure may all be adjusted with menu
ascending key and menu descending key. Selection of black box is achieved through pressing of menu
key. In Fig 7, if black box has selected “Failure Record” menu, it will display the most
recent 8 error codes when menu key is pressed, including the day, the month, and the year when
the error code occurred, as indicated in Fig 10. All the error codes will be deleted if menu key is further
pressed at this point.
Those indicated in the following table are the meanings represented by error codes.
Page 50
When enter key is pressed under the menu in Fig 10, it will return to the picture as indicated in Fig
7, while if “Rotational Speed Amendment” is selected, it will prompt initializing and
please wait, or initialization completed. It will return to the picture as shown in Fig 3 if
enter key is pressed once more. In the picture of Fig 3, if “Maintenance Record” menu is selected, it
will enter the picture of “Maintenance Record” as indicated in Fig 11, when menu key is pressed.
In Fig 11, the item pointed by the black triangle is namely the maintenance that should have been
made. Press enter key to return to the menu of Fig 3. In Fig 3, if “Wiper Setting” (Other Functions) is
selected, the system will enter into the picture as indicated in Fig 12, when menu key is pressed.
Page 51
In the figure, the length for interval of work time with wiper may be adjusted, and the adjustment will
be automatically remembered after setting.
When the option of “Encryption” is selected in Fig 3, the picture of Fig 13 will appear, when menu key
is pressed.
When this picture appears, operator is required to enter 4-digit machine power-on
password. Press the menu key for confirmation after password has been entered
(password for new excavator is 1234 or 0000), and if password is incorrect, the picture of Fig 14 will
appear, until the correct input of password, the picture of Fig 15 will show up.
Wrong code
Appearance of power-on password cancellation bar will in the figure: Pressing the
menu ascending and descending key may select the two options of “Yes” and
“No”, and it will directly enter into the picture of Fig 2 at power-on when “Yes” is selected. If “No”
Page 52
is selected, it will remind operator to enter password at power-on, and the machine can only be
started and it will enter into the picture of Fig 2 when password has been correctly entered. (It is
recommended that user not set power-on password, except when it is necessary.). Contact
POWERPLUS if password is
forgotten .If menu key is pressed at this point, the option will enter into password change, and
null will displayed in this bar sometimes.
The two options of “Yes” and “No” will appear when the menu ascending and descending keys
are pressed, and the picture of Fig 16 will appear, If menu key is pressed when
“Yes” appears.
User is required at this point to enter a new 4-digit password, and press menu
key for confirmation after input is completed. Then it will enter into the picture of
Fig 17.
In this picture, operator is required to enter the password one more time for
confirmation, while the password entered this time shall be consistent to the password entered last
time, and it will enter into the picture of Fig 15 when the passwords entered for
the two times are consistent. Then it will exit when enter key is pressed. It will prompt password
error and please re-enter password, if the two passwords are inconsistent.
Page 53
6. It is required to delay by at least one minute if the machine is to be restarted after shutdown of
engine.
7. When it is under the automatic return idling, and when engine rotational speed is rising to working
status under the idling state, make sure to start the heavy load work
after engine rotational speed has been stabilized.
8. Pay attention to waterproofness of electrical appliance parts. Don’t immerse the
accelerograph motor in water, and the areas of wiring and rotating shaft shall be
frequently lubricated.
9. Please turn off the cathodic switch of battery or the plug connectors of OEM engine prior to welding.
10. When monitor or accelerograph motor is to be replaced or wiring of accelerograph is to be adjusted,
it is required to carry out rotational speed amendment during system maintenance and to initialize the
engine rotational speed. Operation can only proceed with machine restarted after initialization has
been completed.
Through a comparison between Figure 18 & Fig 3, we may see that the option of “System
Modification” is added. The picture is indicated in Fig 19, may be seen when this option is selected
and the menu key is pressed
In the menu of Fig 19, press menu key to select the item to be modified, and press menu ascending
and descending keys to modify the option, wherein the running time is to be set longer than
the working time at the beginning, and otherwise the machine will fail to be started. Running
time is the total working time set by POWERPLUS ’ s personnel at factory delivery, and the system
will automatically lock up the machine if working time is longer than running time,
unless it is unlocked with Encryption Dog inserted. In this menu, specific password may be
displayed, thus to enable a very easy unlock of the password.
Page 54
2. When Encryption Dog is inserted, the display bar of engine rotational speed will
be added in the menu as displayed in Fig 5, as indicated in Fig 20.
3. This electrical control system will be upgraded continuously on this basis, with the requirement of
only change in software, instead of change of the complete set of circuits. It is subject to modifications
for persistent technical improvement without prior notice.
(1) OFF Switch (2) Fan Switch (3) Temperature Control Switch
(8)Air-conditioner Switch
OFF Switch
This switch (1) is used for turning off fan and air conditioner. When OFF switch is pressed, the set
temperature and air output are displayed on the monitor display (7), while the indicator lights on Auto
Switch (5) and Air-conditioner Switch (8) turn off, and operation is stopped.
Fan Switch
Page 55
Switch (2) is used for adjusting air output, able to adjust air output into 6 grades.
Switch (3) is used for controlling temperature inside cab, able to set temperatures
between 18°C (63°F) and 32°C (91°F).
Press ∧ switch, to increase the set temperature, and press to decrease set
temperature.
Page 56
Note 1: Airflow outflows from ventilation openings marked with ○.
Note 2: The ventilation opening for defroster may be opened or closed manually.
Auto Switch
When Switch (5) is used, air output, ventilation opening, and air source
(recycling/fresh) can be automatically selected according to the set temperature, and this switch may
also be used as the main switch for air conditioner. When Auto Switch (5) is pressed, the indicator light
on the top of the Auto Switch will turn on.
Normally, press this switch, and then use Temperature Control Switch (3) to set
temperature, and to operate air conditioner under the condition of automatic control. When automatic
operation is switched to manual operation, the switch may be operated to change
air output, ventilation opening, and air source (recycling/fresh).
When manual control is applied, the indicator light for Auto Switch will turn off.
When Switch (6) is pressed, the indicator light on the top of selector switch turns on, indicating the air
is being blown out.
During automatic operation, selection of internal air (recycling) and external air (fresh) is automatically
performed.
Display
This display is to show the statues of set temperature (a), air output (b), and
ventilation opening (c). When OFF Switch (1) is pressed, the display for set
temperature (a) and air output (b) turns off, and operation is stopped.
Page 57
Air-conditioner Switch
Switch (8) is used for turning on/off air conditioner (cooling, dehumidifying, and
heating). When fan is started (monitor display to show (b)), and the Air-conditioner Switch (8) is
pressed, air conditioner is turned on, the indicator light on the top of
Air-conditioner Switch turns on, and the air conditioner is started. However when fan is stopped, air
conditioner cannot be started.
3. It is required to keep the sunlight sensor clean, and from anything around it,
in
order to enable a normal work of automatic function for the air conditioner, and
otherwise, it may affect the function of sunlight sensor.
4. When refrigerator is used, cab shall keep ventilated frequently, and ventilation as well as
refrigeration shall be performed every hour when air conditioner is to be running for
a long time.
5. When refrigerating effect of air conditioner is not satisfactory and it is lacking of refrigerant, make
sure to invite professionals to fill the refrigerant of the same model, and filling quantity shall be
controlled according to actual status.
6. Pay attention not to keep the temperature in cab too low, and it is relatively suitable for
temperature to be adjusted to the degree when it feels slightly cool (lower than
external temperature by 5-6 °C) after entering the cab
Self-diagnostic Function
It can carry out diagnosis about failures with various sensors and devices used on air
conditioner.
1. Press OFF Switch (1). The temperature setting and air output display on the crystal
display will turn off, and the operation will stop.
2. At the same time press the “∧” and “∨” part on the Temperature Set Switch (3) at
least for 3 seconds, failure diagnostic mode will display on the part of crystal display.
Page 58
When more than one failure are detected out, press the “∧” or “∨” part of
the
Temperature Set Switch (3), to display failures in turn.
When failure diagnosis is completed, then press OFF Switch (1), to recover normal display. If any
anomaly is detected out with self-diagnostic function, please contact the dealer for examination and
maintenance.
Resetting, is applicable for the use of erasing failure code when new air conditioner is used or after
failure is removed, and simultaneously press the Internal Air Switch and External Air Switch (6) for
more than 3 seconds, the failure code can be erased.
Detection on Filling Quantity of Air-conditioner Refrigerant (The filling quantity is generally 900±50g
before delivery from factory and it varies along with the difference in lengths of respective machine
types.)
Proper-amount Filling: Air bubbles are present on the sight glass of drying tank at the instant moment
when air conditioner is started, and they will gradually vanish until transparent.
Over-dose Filling: Air bubbles are not present on the sight glass of air
conditioner
(including the instant moment when air conditioner is started), and air conditioner will
automatically stop after operation for a period of time. Refrigerating effect is not
satisfactory.
Under-dose Filling: Air bubbles are always present on the sight glass of air
conditioner, and the refrigerating effect is not satisfactory.
Simple Method for Discovery of Failures
Page 59
Page 60
3. CHECK BEFORE STARTING ENGINE
WARNING
Leakage of oil or fuel, or accumulation of flammable material around high temperature parts,
such as the engine muffler or turbocharger, may cause fire.
Before starting the engine, look around the machine and under the machine
to check for loose nut or bolts, and check the condition of the work equipment and hydraulic
system. Check also for loose wiring, play, and collection of dust at places, which reach high
temperature.
Check that there are no cracks, excessive wear, or play in the work
equipment, cylinders, linkage, or hoses. If any abnormality is found, repair it.
Remove dirt and dust from around engine, battery, and radiator.
Check for leakage of water or oil around engine.
Check for oil leakage from hydraulic equipment, hydraulic tank, hoses, joints.
Check the under carriage (track, sprocket, idler, guard) for damage, wear, loose bolts, or
leakage of oil from rollers.
Check for damage to handrails, loose bolts.
WARNING
Do not open the radiator cap unless necessary. When checking the coolant, always check the radiator
tank when the engine is cold.
Open the rear door on the left side of the machine and check that the cooling
water level above 10mm of the radiator inner element. If the water level is low, add
water through the water filler to the middle level.
The oil lever should be between the H and L marks on dipstick.★when checking the oil level after
the engine has been operated, wait for at least 15 minutes after stopping the engine before checking. If
the machine is at an angle, make it horizontal before checking.
After opening filler cap, the dipstick will rise. If breather hole on the cap is clogged, the pressure
in the tank will drop and fuel will not flow. Clean the hole from time to time.
Start the engine at low speed, retract the arm and bucket cylinder, then lower the boom, set the bucket
teeth in contact with the ground, and stop the engine. Within 15 seconds, after stopping the
engine, move each control lever (for work equipment and travel) to the fun stroke
in all
Page 61
directions to release. The oil level is normal between the H and L marks.
Remark
If the red piston in dust indicator appears, clean the air cleaner element. After cleaning, press the
knob of dust indicator to return the red piston to its original position.
Check for damage of the fuse and any sign of disconnection or short circuit in the electric wiring.
Check also for loose terminals. Check the following points carefully:
The water separator separates water fixed in the fuel. If float ② is at or above
red line ①, drain the water according to the following procedures:
1. Loosen drain plug ③ and drain the accumulated water until the float reaches
the bottom.
1. If the air is sucked into fuel line when draining and water, ensure to bleed air in the same manner
as for fitter.
Page 62
4. STARTING ENGINE
① Preparation before starting
First check (see preparation before starting the machine)
Set the safety lock lever is at the loose position
Do not suddenly operate the lever when the hydraulic oil temperature is below 20℃ The most
suitable temperature for the hydraulic oil is 50℃~80℃, but in order to extend the life of
the machine, the temperature must be raised to at least 20℃ before starting work. Do not suddenly
accelerate the engine before the warming-up operation is completed. Do not run the
engine at low idling or high idling continuously for more than 20 minutes. This can cause
leakage of the turbocharger .
After warming up the machine, check that each gauge and monitor lamp is in the following
condition. Engine water temperature gauge inside green range, fuel gauge inside green
range; engine oil pressure monitor out; charge level monitor out.
Page 63
Pull fuel control lever ① to the
center position (between LOW IDLING
and HIGH IDLING) and run the engine
at medium speed for about 5 minutes
with no load.
Page 64
5. MOVING MACHINE OFF
WARNING
Before operating the travel levers, check the direction of the track frame. If the
sprocket is at the front, the operation of the travel levers is reversed.
① When the sprocket is at the rear of the machine, push the levers
forward slowly or press the front of travel pedal to move the machine off.
② When the sprocket is at the front of the machine, put levers
backward slowly to move the machine off, or press the rear of travel
pedal to move the machine off.
Remarks
At low temperature, warm-up operation shall be thoroughly carried out, if the running speed
of machine is anomalous.
Additionally, if the underpart of vehicle body is blocked with mud, and running speed of machine is
anomalous, the dirt and mud on the underpart of vehicle body shall be removed.
With regard to machines fitted with running alarm (optional), sound of alarm unit
shall be examined.
Page 65
5.2 STEERING MACHINE
Use the travel level to change
direction. Before operating the travel
levers, check the direction of the
sprocket. If the sprocket is at the front,
the operation of the travel levers is
reversed. Avoid suddenly change of
direction as far as possible. In particular,
when carrying out counter -rotation
(spin turn), stop the machine first
before turning.
Page 66
5.3 SWINGING
When operating the swing, check that the area around the machine is safe.
Operate left work equipment control lever ③ to swing the upper structure.
Page 67
6. STOPPING MACHINE
Put the left and right travel levers ① in the neutral position, then stop the machine.
Page 68
7. OPERATION OF WORK EQUIPMENT
The work equipment is operated by the right and left work equipment control levers.
The left work equipment control lever operates the arm and swing, and the right work
equipment control lever operates the boom and backer.
The movements of the lever and work equipment are as shown in the diagrams
on the down. When the levers are released, they automatically return to the neutral
position and the work equipment is held in place.
★ After stopping the machine, if the work equipment returns to the neutral position, even fuel
control pedal is set high position.
Page 69
Right work equipment control lever position
N NEUTRAL
① Boom down.
② Boom down, bucket dump.
③ Bucket dump.
④ Boom up, bucket dump.
⑤ Boom up.
⑥ Boom up, bucket curl.
⑦ Bucket carl.
⑧ Boom down, bucket curl.
★ PHENOMENA THAT ARE NOT FAILURES
Note that the follow phenomena are not failure.
When the arm is pulled in, the speed of movement will drop momentarily when the arm is more
or less vertical.
The arm speed will drop momentarily when the bucket teeth are more or less horizontal.
When starting or stopping the swing, noise will be emitted from the brake valve.
When going down a steep slope at low speed, a noise will be emitted from the travel motor.
Page 70
8. THE CHOICE OF THE WORK MODE
H or P Mode (High-strength excavation): Applicable to excavation of hard ground within a
short time.
S or E Mode (Standard-strength excavation): Excavation performed in priority
consideration of fuel.
L or F Mode (Slightly strength excavation and flattening ground: Engine rotational speed
slowed down, for rolling ground surface, and other light-load works under low noise.
After excavator is started, the default mode is S mode.
With H key and M key in cooperation with each other, working mode may be
freely
selected. (Fig 3.1)
Page 71
Prohibited operations using dropping
force of machine: Do not use the
dropping force of the machine for
digging.
Page 72
10. PRECAUTIONS FOR OPERATION
Precautions when traveling: when traveling
over obstacles such as boulders or tree stumps,
the machine (in particular, the under carriage)
is subjected to a large shock, so reduce the
travel speed and travel over the obstacle at the
center of the tracks. As far as possible, remove
such obstacles or avoid traveling over them.
Precaution when travel in high speed: When
traveling over ground or ground with big stone,
so travel in middle or low speed.
Permission water depth: Do not immerse the
machine in water by more than the permissible
depth (under center of carrier roller①). When
driving the machine out of water, if the angle of
the machine exceed 15°, the rear of the upper
structure will go under water, and water will be
thrown up by the radiator fan. This may cause
the fan to break. Be extremely careful when
driving the machine out of water. In addition,
for parts that have been immersed in water for a
long time, pump in grease until the old grease
comes out from the bearings (around the bucket
pins)
Page 73
1 1. PRECAUTIONS WHEN TRAVELING UP OR
DOWN HILLS
Page 74
When traveling down steep hills, use the travel lever and fuel control
lever to keep the travel speed low. When traveling down slopes of more than
15°, set the work equipment in position shown in the figure on the right, and
applied.
If shoes slip
travel uphill.
If engine stops
If the engine stops when traveling uphill, move the travel levers to the neutral position, lower the bucket
to the ground. Stop the machine, and then start the engine again.
Precautions on slopes
If the engine stops when the machine is on a slope, never use the left work equipment control lever
to carry out swing operations. The upper structure will swing under its own weight. Do not
open or close the door on the cab if the machine is on a slope. This may cause a sudden change in the
operating force. Always keep the door locked.
Page 75
12. PRECAUTIONS WHEN TRAVELING MUD
Always operate carefully to avoid getting stuck in mud. If the machine dose get stuck in mud,
use the following procedures to get the machine out.
14. REPLACEMENT AND INVERSION OF BUCKET
Stop the machine on a firm, flat surface. When performing joint work,
make clear signals to each other and work carefully for safety’ s sake.
RELACEMENT
① Lace the bucket in contact with a
flat surface.
② Remove the stopper bolts and nuts,
then remove pins A and B, and remove
the bucket.
③ Align the arm with holes ① and
the link with holes ②, then coat with
grease and install pins A and B.
④ Install the stopper bolts and nuts
for each pin, the grease the pin.
INVERSION
① Place the bucket in contact with a
flat surface.★When removing the
pins, place the bucket so that is it
in light contact with the ground. If
the bucket is lowered strongly to
the ground, the resistance will be
increased and it will be difficult to
remove the pins.
② Remove the stopper bolts and nuts,
then remove pins A and B, and
remove the bucket.
③ Install the bucket inversely after
the bucket is inversed, correct the
inclination and direction of the
retaining pin holes ① and ② ,
and stabilize the bucket securely.
④ Align the arm with holes ① and
the link with holes ②, then coat
with grease and install pins A and
B . ★ Install the O-tings into
retaining hole ① of the arm and
bucket. When installing the bucket,
the O-tings are easily damaged, so
fit the O-tings on the boss of the
arm end as shown in the diagram.
When knocking the pin, move the
O-tings down to the regular
groove.
⑤ Install the stopper bolts and nuts for
each pin, and then grease the pin.
Page 77
15.PARKING MACHINE
Avoid stopping suddenly. Give yourself ample room when stopping. When stopping the machine,
select flat hard ground and avoid dangerous places. If it is unavoidably necessary to park the
machine on a slope, insert blocks underneath to the track shoes. As an additional
safety measure, thrust the bucket into the ground.
16. STOPPING ENGINE
Page 78
17.CHECK AFTER STOPPING ENGINE
Walk around the machine and check the work equipment, paintwork, and under carriage, and
check also for leakage of oil or water. If any abnormalities are found, repair them.
Fill the fuel tank.
Check the engine compartment for paper and debris. Clean out any paper and debris to avoid
a fire hazard.
Remove any mud stuck to the under carriage.
LOCKING
★ Engine hood.
Page 79
C.TRANSPORTATION
When transporting the machine, observe all related lows and regulations and be careful to
assure safety.
● Loading or unloading the machine can be a dangerous operation, so be particularly careful. When
loading or unloading the machine, run the engine at low idling and traveling speed.
● Make sure the ramp has sufficient width, length and thickness to enable the
machine to be safely loaded and unloaded. If the ramp sags appreciably, reinforce it with
blocks, etc.
● When loading or unloading the machine, park the trailer on a flat firm roadbed.
Keep a fairly long distance between the road shoulder and the machine.
● Remove the mud from the undercarriage to prevent the machine from slipping to the side on
slopes.
● Ensure the ramp surface is clean and free of grease, oil ice and loose materials.
● When turning the machine on the trailer, the machine’ s footing is unstable, so
carry out the operation slowly.
● Always check that the door on the cab is locked, regardless of whether it is open
or closed.
● Do not open or close the door on ramps or on a platform. This may cause a sudden change in the
operating force.
● When loading or unloading the machine with the automatic functions, automatic stopping may
cause a sudden speed change. Avoid loading or unloading the machine in the course of automatic.
Page 80
Turn the swing lock switch ON to apply the
swing lock.
Set in the direction of the ramps, lower the work
equipment as far as possible without letting it hit
the trailer, then travel slowly to load or unload the
machine. When on the ramps, do not operate any
lever other than the travel lever.
Load the machine correctly in the specified
position on the trailer.
Page 81
19. PRECAUTIONS FOR LOADING
After loading to the specified position, secure the machine as follows.
● Fully extend the bucket and arm
cylinders, then slowly lower the boom.
● Stop the engine and remove the key from the starting switch.
Start the engine, then rotate the top swing parts, and make the work
equipment in the back of the machine.
Extend the bucket cylinder and the
arm cylinder fully; use boom
cylinder, and make the work
equipment go to ground according to
right picture.
Through the steel rope of the first
and second needle of front machine
and the first and second needle of
back machine.
Adjust the angle of the steel rope to
30~40 °, then lift the machine
slowly.
After the machine leaves the ground,
stop first, make the machine promote
slowly after coming to a complete
stop.
Stopping the engine, check around the driver's cab,
there should not be any object, then left the machine.
Close the door of driver's cab and blocked the glass.
Page 82
D.LONG-TERM STORAGE
1. BEFORE STORAGE
★ To prevent the cylinder rod when the machine is not being used, set the work equipment in
the posture shown in the diagram. This prevents rusting of the cylinder rod.
● Wash and clean each part, then store the machine indoors. If you must keep
the machine outdoors, place it on a level place where it will not be subjects and other
natural disasters, and keep it covered.
● Completely fill the fuel tank, lubricate and change the oil before storage.
● Apply a thin coat of grease to metal surface of the hydraulic piston rods.
● Disconnect the negative terminals of the battery and cover it, or remove it from the
machine and store it separately.
● If the ambient temperature is expected to drop below 0ºC, always add antifreeze
to the cooling water.
2. DURING STORAGE
Operate the engine and move the machine for a short distance once a month so that a new film of oil
will be coated over movable parts and component surface. as well as have respective parts of the rig
to be fully lubricated, At the same times, also charge the battery. Also carry out cooler operation in
the case of machines equipped with an air conditioner. or 5~10 minutes, and at the same
time disconnect the cathodic switch, or the cathodic connection terminal.
3. AFTER STORAGE
Carry out the following procedure when taking the machine out of long-term storage.
Switch on the cathodic switch or connect the cathodic connection terminal.
● Wipe off the grease from the hydraulic cylinder rods.
● Add oil and grease to all places.
When starting the machine after a long-term storage, first cancel the automatic
warming-up function as follows.
● Turn the starting switch key to the ON position.
● Turn the fuel control dial from the low idling (MIN) position to the full (MAX) position, hold it
there for 3 seconds, then return it to the low idling (MIN) position and start the engine.
E. MAINTENANCE
1. GUIDES TO MAINTENANCE
Check the service meter reading every day to see if for any necessary maintenance
to be carried out.
Always keep the machine clean. This make it easier to find parts causing problems.
Keep in particular grease fittings, breathers and oil level gauges clean and avoid foreign matters from
getting in them.
Draining hot oils and coolants and removing their filters immediately after the engine stops are
hazardous. Allow the engine to cool. If the oil has to be drained when it is cold, warm up the oil to a
suitable temperature (approx. 20-40℃) before draining it.
● Fuel strainer
If your machine is equipped with a fuel strainer, do not remove it while fueling.
● Welding instructions
* Avoid seals or bearings from being between the area to be welded and the position of grounding
point.
* Do not use the area around the work equipment pins or the hydraulic cylinders
as the grounding point.
● Checking undercarriage
When working in rocky areas, check for damage on undercarriage and looseness, flaws, wear and
damage in bolts and nuts. Loosen the track tension a little when working in such areas.
* Never spray steam or water directly on the connectors and mechatronics parts.
* Do not allow water to get on the monitors inside the operator’s cab.
* Never spray steam or water directly at the radiator or oil cooler portions.
Page 84
Dusty worksite
* Inspect the dust indicator to see whether the air cleaner is blocked up. Clean the air cleaner at shorter
intervals than specified.
* Clean electrical component, especially the staring motor and alternator, to avoid
accumulation of dust.
Never mix oils of different brands. If you have only oil that is a different brand
from the one that is used in the machine, do not add it but replace all the oil.
● If the wiring gets wet or the insulation is damaged, the electric system leaks
and this could result in hazardous malfunction of the machine.
● Service relating to the electric system are ①check of fan belt tension, ②check of damage or
wear in the fan belt and ③check of battery fluid level.
● Be careful to keep the electric system free of water when washing the machine or when it rains.
● During operation and after operation is ended, the temperature of the hydraulic
system still remain high. In addition, high hydraulic pressure is applied to the system.
Take care when inspecting and maintaining the hydraulic system. ① stop the machine
on level ground, lower the bucket to the ground, there is no pressure applied to the cylinder
circuit. ②Always stop the engine. ③when carrying out inspection or maintenance of the hydraulic
circuit, always bleed the air form the hydraulic tank to remove the internal pressure.
● When the high-pressure hose, etc. is removed, check the O-ring for damage. If necessary, replace
it.
● The accumulator is charged with high-pressure nitrogen gas. For the handling procedure, see
“Handling accumulator”.
Page 85
WEAR PARTS LIST
Wear parts such as the filter element, buck teeth, etc, are to be replaced at the time of periodic
maintenance or before their abrasion limits. The wear parts should be changed
correctly in order to use the machine economically.
Page 86
3.USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE
Page 87
4. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS
This sheet is suitable for mechanical 10.9 standard. This sheet is not suitable for plastic parts, seal part,
and other.
Page 88
5. MAINTENANCE SCHEDULE CHART
Maintenance Item
Initial 250 hours service (only after the first 250 hours)
Replace fuel filter cartridge and additional fuel filter cartridge (option)
Check engine valve clearance, adjust
When required
Check, clean and replace air cleaner element
Clean inside of cooling system
Check and tighten track shoe bolts
Check and adjust track tension
Replace bucket teeth
Adjust bucker clearance
Check and adjust air conditioner
Check swing pinion grease level, add grease
Clean and inspect radiator fins, oil cooler fins and condenser fins
Replace hydraulic filter element
Chang oil in drive case
Clean internal and external air filters of air conditioner system
Page 90
MAINTENANCE INTERVAL WHEN USING HYDRAULIC BREAKER
For machine equipment with a
hydraulic breaker, the hydraulic oil
deteriorates faster than for normal bucket
digging operations, so set the maintenance
intervals as follows.
Page 91
6. SERVICE PROCEDURE
6.1 INITIAL 250 HOURS SERVICE
Carry out the following maintenance only after the first 250 hours.
Replace fuel filter cartridge
Check engine valve clearance, adjust
Checking
Whenever the red piston in dust indicator ①
appears, clean the air clean the air cleaner element.
After cleaning, press the indicator, the red piston
go neutral position.
Page 92
Replacing inner element
First remove the cover and the outer element,
and then remove the inner element.
To prevent dust from getting in, use a clean
cloth or tape to cover the air connector (outside).
Clean the air cleaner body interior, and then
remove the cover installed in step 2.
Fit a new inner element to the connector and
tighten it with nuts. Do not clean and reinstall
an inner element.
Install the outer element and fix it with the
wing nut.
Antifreeze is flammable, so keep it from any flame.
Service procedure
Open drain valve at the bottom of the radiator to drain the water. Remove drain plug in the cylinder
block when draining the water.
After draining the water, close drain valve and drain plug and fill with city water.
Open drain valve and drain plug, run the engine at low idling, and flush water through the system for 10
minutes.
When doing this, adjust the speed of filling and draining the water so that the radiator is always full.
While flushing water through the system, watch carefully that the water inlet hose does not come out of
the radiator water filler.
After flushing, stop the engine, open drain valve and drain plug, then close it again after all the water
has drained out.
After draining the water, clean with a flushing agent.
After cleaning, open drain valve and drain plug to drain all the cooling water, then close them and fill
slowly with clean water.
When the water is near the water fill port, open drain valve and drain plug, run the engine at low idling,
and continue to run water through the system until clean colorless water comes outs.
When the water is completely clean, stop the engine, close drain valve, wrap the drain plug with seal
tape, then close drain plug
Page 94
Order for tightening
Tighten the bolts in the order shown in the diagram
on the right. After tightening, check that the nut and
shoe are in close contact with the link mating surface
The wear of pins and bushings on the undercarriage will vary with the working
conditions and soil properties. It is necessary to continually inspect the track tension
so as to maintain the standard tension.
Inspection
Raise the chassis with the boom and arm.
When doing this, operate the levers slowly.
Measure the clearance between the bottom of
the track frame and the top of the track shoe at a
position that is safe even if the chassis should
come down.
Standard clearance: 303±20mm
Place to measure: between 4th and 5th
Track roller from sprocket.
Adjustment
Grease inside the adjusting mechanism is under high pressure. Grease
coming from plug ① under pressure can penetrate the body causing
injury or death. For this reason, do not loosen plug ① more than one turn.
Do not loosen any part other than plug ①. Furthermore, do not bring your
face in front of the plug ①.
Page 95
When increasing tension
Pump in grease through grease fitting ② with a grease gun.
To check that the correct tension has been achieved, move the machine backswords and forwards.
Check the track tension again, and if the tension is not correct, adjust it again.
Continue to pump in grease until S becomes 0 mm. if the tension is still loose, the pin and bushing
are excessively worn, so they must be either turned or replaced.
the bar with a hammer to knock out pin.
Remove tooth.
Clean the mounting face. Fit a new
tooth in the adapter, push in pin partially
by hand, and then lock it with a hammer
to install the tooth to the bucket.
[Example]
In the case of play of 3mm, remove two
1.0mm shims and one 0.5mm shim. Play
becomes 0.5mm. For shim, two types of
1.0mm and 0.5mm are used. When play
is smaller than one shim, do not carry out
any maintenance
Page 97
7. CHECK AND ADJUST AIR CONDITIONER
REMARK
When there are bubbles, the refrigerant gas
level is low, so contact your refrigerant dealer
to have refrigerant added. If the air
conditioner is run with the refrigerant gas
level low, it will cause damage to the
compressor.
Check in off-season
When not used for a long period,
operate the cooler for 3 to 5 minutes once a
month to supply lubricant to each component
of the compressor.
Page 98
Inspection and maintenance items list for cooler
WARNING
Page 99
Check fuel level
Use sight gauge on the front face of the tank to check that the tank is full.
After adding fuel, tighten the cap securely. If breather hole on the cap is clogged, the
pressure in the tank will drop and fuel will not flow.
Clean the hole from time to time.
around L level
when oil temperature is near the normal operation temperature (10℃ to 30℃):
around H level
① Battery
② Starting motor
③ Alternator
1. Loosen drain plug ③ and drain the accumulated water until the float reaches
the bottom.
2. Tighten drain plug ③.
3. If the air is sucked into fuel line when draining and water, bleed air in the same manner as for the
fuel filter.
Page 101
6.4 EVERY 100 HOURS SERVICE
LUBRICATING
Set the work equipment in the greasing posture below, and then lower the work equipment to the
ground and stop the engine. Using a grease pump, pump in grease through the
grease fittings shown by arrows. After greasing, wipe off any old grease that was pushed out.
Page 102
CHECK OIL LEVEL IN SWING MACHINERY CASE, AND ADD OIL
WARNING
The oil temperature is at high temperature immediately after the machine
has been operated. Wait for the oil to cool down before carrying out this check.
1. Remove dipstick and wipe the oil from the dipstick with a cloth.
2. Insert dipstick fully in the guide.
3. When dipstick is pulled out, if the oil level is between the H and L marks of the gauge, oil level is
proper.
4. If the oil does not reach the mark on dipstick, add engine oil through dipstick hole.
5. If the oil level exceeds the H mark on the dipstick, loosen drain valve to drain the excess oil.
6. After checking oil level or adding oil, insert the dipstick into the hole and
install air bleeding plug.
NOTICE :Never use trichlene for washing the inside of the tank.
Page 103
CHECK LEVEL OF BATTERY ELECTROLYTE
To avoid gas explosions, avoid fire or sparks near the battery.
Battery electrolyte is dangerous. If it gets in your eyes or on your kin, wash it off with large amount of
water, and consult a doctor.
Carry out this check before operating the machine.
1. Open the battery box cover on the right side of the machine.
2. Remove cap, and check that the battery electrolyte is up to the UPPER LEVEL line. If the level is
low, add distilled water to the UPPER LEVEL line. If the battery electrolyte is spilled, have dilute
sulphuric acid added.
3. Clean the air hole in the battery cap, and then tighten the cap securely.
Page 104
LUBRICATE SWING CIRCLE (2 POINTS)
Lower the work equipment to the ground.
Using a grease gun, pump in grease
through the grease fittings shown by
arrows.
After greasing, wipe off all the old grease
that was pushed out.
Page 105
6.6 EVERY 500 HOURS SERVICE
Maintenance for every 100 and 250 hours should be carried out at the same time.
REPLACE FUEL FILTER CARTRIDGE
Set the container to catch the fuel under the
filter cartridge.
Using a filter wrench, turn filter cartridge ①
and ④ counter clockwise to remove it.
Clean the filter holder, fill a new filter
cartridge ① with clean fuel, coat the
packing surface with engine oil, then install it
to the filter holder.
When installing, tighten until the packing
surface contacts the seal surface of the filter
holder, then tighten it up 1/2 of a turn. If the
filter cartridge is tightened too far, the
packing will be damaged and this will lead to
leakage of fuel. If the filter cartridge is too
loose, fuel will also leak from the packing, so
always tighten to the correct amount.
After replacing the fuel filter cartridge, bleed the air. Bleed the air according to the following
procedures.
Page 106
CHECK SWING PINION GREASE LEVEL
Prepare a scale
Remove bolts ① (2 bolts) on the top of the revolving frame and remove cover ②.
Insert a scale into the grease and check that the height of the grease in the portion
where the pinion passes is at least 12mm. Add more grease if necessary.
Check if the grease is milky white. If it is milky white, it is necessary to change the grease.
The total amount of grease is 14.6L(13.1kg).
Install cover ② with bolts ①.
Check if the grease is milky white. If it is milky white, it is necessary to change the grease.
Screw in the oil filler cap and install the cover.
Check for oil leakage and wipe off any spilled oil.
NOTICE
The normal cleaning interval is 5000 hours. However, if the filters are used at a dusty site, shorten this
interval.
Page 108
CHECK ALL TIGHENING PARTS OF TURBOCHARGER
Contact your service department to have the tightening portions checked.
Page 109
6.10 EVERY 5000 HOURS SERVICE
Maintenance for every 100,250,500, and 1000 hours should be carried out at the
same time.
Change oil in hydraulic tank.
Bleed air from the hydraulic circuit.
1. Air bleeding procedure
1) Loosen air bleeding plug ①,
and check that oil oozes out
from the air bleed plug. If oil
does not ooze out from the
plug, remove the drain hose
from the pump case, and add
oil through drain port ② to
fill the pump case with
hydraulic oil. Oil will release from the dose when it is removed, so secure the mouth of the hose
at a place higher than the oil level inside the hydraulic tank.
2) After completion of the air bleed operation, tighten air bleeding plug ①, then
install the drain hose.
NOTICE
If the drain hose is installed first, oil will spurt out from the hole of plug ①.
If the pump is operated without filling the pump case with hydraulic oil, abnormal
heat will be generated and this may lead to premature damage of the pump.
2. Starting engine
Start the engine according to “START ENGINE”.
Keep running the engine at low idling for 10 minutes, and carry out the following
procedure.
3. Bleed air from cylinders
a) Run the engine at low idling, and extend and retract each cylinder 4-5 times
without operating it to the end of its stroke. (Stop approx.100mm (3.9in)
before the end of the stroke)
b) Next, operate each cylinder to the end of its stroke 3-4 times.
c) After this, operate each cylinder 4-5 times to the end of its stroke to
completely bleed the air.
NOTICE
If, at first, the engine is run at high speed or the cylinder is operated to the
end of its stroke, the air inside the cylinder may cause damage to the piston
packing or other parts.
3. Bleed air from swing motor
1) Run the engine idle at a low speed, and then loosen hose of S position and
confirm that oil flows
Page 110
NOTICE
When doing this, do not
operate the swing.
2) If oil does not flow out,
stop the engine and
fill the motor case
with hydraulic oil
through the hose of S
position
3) After completion of
the air bleed operation,
tighten the hose of S position.
4) Run the engine at low idling, and swing 2 or more times slowly and
uniformly to the left and right.
NOTICE:
If the air is not bled from the swing motor, the bearings of the
motor
may be damaged.
If it is necessary to replace the safe valve of the swing motor,
please
contact service department.
Page 111