POWERPLUS PP330E-IX EXCAVATOR

OPERATION & MAINTENANCE MANUAL

POWERPLUS GROUP INC., USA

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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.

For further information, please contact us via:

International Division
POWERPLUS GROUP PTE. LTD.
39 Ubi Crescent #05-00, Powerplus Building, Singapore 048587
Tel: (65) 63399333 Fax: (65) 63399933
Email: support@powerplus.us

POWERPLUS GROUP INC., USA

1521 East Grand Avenue, Pomona, California 91766, USA
Tel: (1) 909 6225 888 Fax: (1) 909 6225 828
Email: hq@powerplus.us

Website: www.powerplus.us

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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:

1. Idle the engine for 5 minutes after standing it up.

2. Avoid operation with heavy loads or at high speeds.

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.

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CONTENTS
A.SAFETY

1. Positions of Safety Signs..........................................................................................................8

2. General Precautious............................................................................................................... 10

2.1 Safety Rules............................................................................................................... 10

2.2 Safety Equipments..................................................................................................... 10

2.3 Locking the machine when leaving the seat............................................................. 10

2.4 Mounting and dismounting......................................................................................... 11

2.5 Fire prevention for fuel and oil................................................................................... 11

2.6 Precautious when handling at high temperature....................................................... 11

2.7 Protection against falling or flying debris................................................................... 11

2.8 Handling Accumulator............................................................................................... 12

2.9 Emergency exit from operator’s cabin....................................................................... 12

2.10 Installation of Accessories......................................................................................... 12

3. Precautious before operating................................................................................................. 13

4. Precautious after starting engine........................................................................................... 13

5. Precautious when operating.................................................................................................. 14

6. Parking the machine.............................................................................................................. 18

7. Battery.................................................................................................................................... 19

8. Lifting operations.................................................................................................................... 20

9. Precautious for maintenance.................................................................................................. 21

B.OPERATION

1. General view of machine........................................................................................................ 23

2. General view of control and gauges....................................................................................... 25

1. Functions of electronic monitor (For WJZ-7C types)................................................. 25

2.2 Functions of electronic monitor (For WZ-2 types)...................................................... 28

2.3 Functions of electronic monitor (For WZ-4 and WZ-5 types)..................................... 40

2.4 Functions of electronic monitor (WZ-7 and WZ-8 types)........................................... 43

2.5 Air Conditioner........................................................................................................... 54

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3. Pre-start Engine Checks........................................................................................................ 60

1. Walk-around check.................................................................................................... 60

2. Check before starting engine..................................................................................... 62

4. Starting Engine....................................................................................................................... 64

5. Moving machine off................................................................................................................ 64

1. Moving machine forward............................................................................................ 64

2. Steering machine....................................................................................................... 65

3. Swinging.................................................................................................................... 66

6. Stopping machine.................................................................................................................. 67

7. Operation of work equipment................................................................................................. 68

8. Mode of operation.................................................................................................................. 70

9. Prohibitions for operation....................................................................................................... 70

10. Precautious for operation................................................................................................. ..... 72

11. Precautious when travelling on up/downhill...................................................................... ..... 73

12. Precaution when traveling in mud.......................................................................................... 75

13. Work possible using hydraulic excavator............................................................................... 76

14. Bucket replacement...... ........................................................................................................ 76

15. Parking machine.................................................................................................................... 77

16. Stop Engine........................................................................................................................... 77

17. Check after stopping engine.................................................................................................. 78

C. TRANSPORTATION

18. Loading / Unloading Work...................................................................................................... 79

19. Precautious for loading ......................................................................................................... 81

20. Lifting machine method.......................................................................................................... 81

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D.LONG-TERM STORAGE

1. Before storage.......................................................................................................................82

2. During storage.......................................................................................................................82

3. After storage..........................................................................................................................82

4. Starting machine after long-term storage...............................................................................82

E.MAINTENANCE

1. Guides to maintenance......................................................................................................... 83

2. Outline of Electric/Hydraulic system..................................................................................... 84

3. Use of fuel, coolant and lubricants according to ambient temperature................................. 86

4. Standard tightening torques for bolts and nuts..................................................................... 87

5. Maintenance schedule chart................................................................................................. 88

6. Service procedures Standard tightening torques for bolts and nuts..................................... 91

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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.

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1. POSITIONS OF SAFETY SIGNS

1. Following warning indications and safety signs on this machine.

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.

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Safety Signs
1. Precautions for Operation, Examination and Maintenance
22-90-010001

2. Precautions prior to Operation 3. Warning for Operation Leaving Seat

22-90-010002 22-90-010003

1. Warning for High Electric Voltage

22-90-010004

1. Warning before Front Window Opening Operation

22-90-010005

2. Warning related to broken or Movable excavator body

22-90-010006

3. Warning before closing Operation Front Window

22-90-010007

4. Precaution Related to High-temperature Coolant and Hydraulic Oil

22-90-010008

5. Precaution during Use of Accumulator

22-90-010009

6. Precaution for Adjustment of Track Tension

22-90-010010
7. Precaution during Cable Treatment 12. Stop rotational during detection &adjustment
22-90-010011 22-90--010012

1. Emergency Exit 14. Fall Precaution

22-90-010013 22-90-010014

1. Fall Precaution 16. Safety distance from Swing area

22-90-010015 22-90-010016

1. Attention to Rig 18. Adjustment to Normal Engine Start

22-90-010017 22-90—010020

1. No Touch 20. Danger within Swing Area

22-90-010021 22-90—010023

1. Rotating Parts 22. High Temperature Parts

22-90-010024 22-90--010025

1. Fastening of Safety Belt 24. No Admission into This Area

22-90-010026 22-90—010027

1. No Touch 26. Keep Clear

22-90-01008 22-90--010029

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2. GENERAL PRECAUTIONS

2.1. SAFETY RULES

1. Only trained and authorized personnel can operate and maintenance the machine.

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.

5. Always follow all rules related to safety.

2.2. SAFETY FEATURE

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.

Safety lock lever-see parking machine.

Seat belt -see using seat belt.

Improper use of safety features could result in serious injury death.

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.

2.3. LOCKING THE MACHINE WHEN LEAVING THE SEAT

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.

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2.4.MOUNTING AND DISMOUNTING

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.

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.

2.5.FIRE PREVENTION FOR FUEL AND OIL

Fuel, oil and antifreeze can be ignited by a flame, keep them away from any flame or lighted cigarette.

Stop the engine and do not smoke when refuelling.

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.

Tighten all fuel and oil caps firmly.

2.6.PRECAUTIONS WHEN HANDLING AT HIGH TEMPERATURE

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.)

2.7.PROTECTIONS AGAINST FALLING OR FLYING OBJECTS

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.
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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.

The above mentioned aims at typical working conditions, and it may possible if required to additionally
fit other protective covers.

2.8. OPERATION OF ACCUMULATOR

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.

Never puncture the accumulator or expose it to flame or fire.

Do not weld any boss on the accumulator.

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 .

2.9.EMERGENCY EXIT FROM OPERATOR’S CAB

If it should become impossible to open the cab door, break the glass with the hammer and use it as
an emergency escape.

2.10. INSTALLATION OF ACCESSORIES

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.

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3. PRECAUTIONS BEFORE STARTING ENGINE

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.

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.

4. PRECAUTIONS AFTER STARTING ENGINE

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.

Operate the work equipment and check for any abnormality.

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).
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Travel in reverse direction

5.PRECAUTIONS WHEN OPERATING

It is dangerous to look around during operating. Always concentrate on your work.

Before travelling and swing, look around to see if t there are any people or rough grounds.

When travelling, always raise the work equipment.

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)

Travel Posture INCORRECT

                                        

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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.

4. Do not allow anyone near the machine on the worksite.

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.

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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.

11. When operating at night, do install lighting at the jobsite.

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.

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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.

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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.

6.PARKING THE MACHINE

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.

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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. 

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8. LIFTING OPERATIONS

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.

4. Do not turn when load is lifted.

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9. PRECAUTIONS FOR MAINTENANCE

 Do not lubricate when moving.

 Before carrying out maintenance, do as follows
 Park the machine on level ground
 Lower the bucket to the ground
 Operate the engine for 5 minutes at idle.
 Switch the key to OFF position and stop the engine.
 Operate each control lever several times to release the remaining pressure in the
hydraulic lines.
 Remove the key from the switch
 Attach the “DO NOT OPERATE” warning tag to the control lever

Cool down the engine.

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.

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.

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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.

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.

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B. OPERATION

1. GENERAL VIEW OF MACHINE

Parts of the machine, as indicated by arrows:

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2.GENERAL VIEW OF CONTROLS AND GAUGES

1. Radio / MP3 / CD Player 2. Sundries Box **

3. Air Conditioner Control Panel ** 4. Safety Lock **

5. Left Rig Control Rod 6. Horn Button Switch

7. Accelerator Pedal 8. Running Control Rod

9. Smoking Ash Box ** 10. Machine Monitor **

11. Forced Excavator 12. Right Rig Control Rod

13. Start Switch 14. Accelerograph Potentiometer **

15. Warning Light Switch ** 16. Standby Switch **

17. Standby Switch ** 18. Power Unit Interface **

Note: Those serial numbers in **in front may have different fittings because of different machine types
or spare parts.

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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

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FUNCTION OF GAUGE

1. Water Temperature 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.

4. Engine Oil Pressure:

This displays the engine oil pressure. If the engine oil pressure is normal, the signal does
not flash. If the engine oil pressure drops below the normal pressure, the monitor lamp
flashes. Stop the engine and inspect the engine oil level.

5. Engine Water Level Monitor:

This displays the water level. (Fig 2.5) During the normal operation, the signal does
not flash. If the water level is below the normal level, the signal flashes. At this item,
stop the machine and inspect it and add water.

6. Hydraulic Temperature Monitor:

This displays the hydraulic temperature. (Fig 2.6) During normal hydraulic temperature,
the signal does not flash. If the hydraulic temperature is over the normal range, the
signal flashes. Stop the machine and inspect the hydraulic level.

7. Hydraulic Level Monitor (option):

This displays the hydraulic level. (Fig 2.7) If the hydraulic fluid is in normal rang,
the signal does not flash. If the hydraulic level is below normal range, the signal
flashes. If this occurs, fluid stop the machine and inspect the hydraulic level.

8. Preheat Monitor: (Fig 2.8)

During cold weather engine start, set the key to the HEAT position, then the preheating
monitor lights up. (Option)

1.9 Charge Level:

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.
 

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1.10 Charge Level:

This monitor indicates the charge level (Fig 2.10).
If the monitor lamp flashes, check the V-belt tension.

 
1.11 Engine Speed Monitor:
This monitor indicates the rotational speed of the engine. Unit is revolution / minute.

1.12 Service Meter:

This meter shows the total operation hours of the machine.

FUNCTION OF THE BUTTON

2.1 The work pattern selector switch of the

excavator:
H mode (high strength is excavated): Suitable for
excavating the hard ground in short time

S mode (standard intensity is excavated): Pay the

utmost attention to the fuel and excavate.

L mode (slight intensity is excavated and levels the

land): Reduce engine speed, and flatten ground, etc. light
load works in a low noise.

After the excavator is started, the acquiescence mode

is S mode.

H key cooperates with M key, can choose the work

pattern freely. (Fig. 3. 1)

2.2 Speed selector switch.

Controls the travel speed of the excavator (Fig 3.2) Upon start-up, the
default mode is low speed.

2.3 The control of the automatic idling speed

After this key is pushed, the excavator enters the automatic idling speed state. (Fig 3.2) The operator
moves the control lever to the neutral position, AC2 controller reduces the speed of the engine
automatically. Therefore, while stopping the work, it can reduce consumption and noise of the engine.
The system will be disabled automatically if the control lever moves or the footboard works, and the
speed of the engine resume being correspondent to the settlement value of one of order of
accelerator.

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2.4 Mute Switch

According to the limits set in the table below:

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 line

is carriage return key of menu, is descent key of menu,   is ascent key of menu,
 
is menu key. On the second line is the descent key of throttle,   is the ascent key
of throttle, upper part on these both keys is indicating lamp of throttle, this lamp indicates

opening size of throttle.

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 key , rain

wiper lies in intermittent work state at this time,

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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.

  Work lamp button. Key is automatic return low speed function key, when
depressed this key and indicating lamp on it lights up, indicating that the automatic return low speed
function has already started up; when driver does not operate excavator, speed will be reduced to low
speed after automatic delay in five seconds. When this key is pressed and the indicating lamp
extinguishes, this functions cancels. Key is a two-speed key, key is pressed indicating lamp L
on its lights, travelling work lies in low-speed state at this time; when key is pressed again, in
indicating lamp H lights up, indicating that travelling work lies in high-speed state.   Key is the
silencing key; when a warning sound, the buzzer will give an acoustic warning, if keys pressed at this
time, when indicating lamp on it lights, then buzzer will stop. Key is swivel-locking key.

  Key is the fine work mode key, when key is pressed and indicating lamp L lights, system will work
according to the fine work mode 1 when key is pressed again, the indicating lamp H lights, the
system will work according to fine work mode 2 way; when key is pressed up, the two indicating
lamps do not light, the system will work according to system , the two following keys are the stand-by
keys.

Main Menu

1.Oil Lever 2. Water Temperature

3. Machine oil pressure 4. Preheating indication

5. Air filter blockage 6. Charging

7. Over low water level 8. Over high oil temperature

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
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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.

3. Erroneous code display block:

Representative meaning of erroneous code showed by erroneous code display block is

represented by following list:

E00 Showing short circuit of oil level sensor line

E01 Showing broken circuit of oil level sensor line

E02 Showing short circuit of water temperature sensor line

E03 Showing broken circuit of water temperature sensor line

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,

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and buzzer sounds at same time; both characters “oil level” flicker, and buzzer will sound
simultaneously when oil level warns.

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

Second – Class Menu

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:

Serial Number of excavator:

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.

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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.

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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

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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.

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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.

It is necessary to pay attention to following:

1. When pressing key, system may respond slowly.

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.

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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.

4. Personnel of factory can dispose operative table:

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

Work time setting: 0513.6

Operating time setting: 01300.3

Cipher code: 1234

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
engine revolution－displaying column in fig.20.
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5. Electrical equipment principle diagram of whole excavator，refer to fig.3－1，among it，it

includes mainly starting circuit 、changing circuit and operating －stopping circuit of engine，
refer to fig.21，as well as automatic control circuit of engine an pump，refer to fig.22.

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（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）.

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（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.

（3） Operation-stopping circuit

The starting switch is turning to “ closure ” position ， terminal ACC
de-electrified， holding of oil cut-off valve de-electrified， oil cut-off valve is cut-off to
make engine extinguish.

( 4 ) Auto-control circuit

There is a unique control system in this auto-control circuit.

Four work modes are set, measuring and checking of engine
revolution and practical revolution are controlled through computer
constantly, flow capacity if pump is adjusted through output of current
proportional solenoid valve to make engine, cylinder, pump and
valve realize optium matching, thus improve working efficiency within  
a great range. This auto-control circuit has automatic idle speed function,
no matter under which mode excavator works, the revolution of engine drops to 1200 r/min
automatically after all hand knobs stop operation three seconds, when an hand knob is operated, the
revolution of engine returns to set revolution automatically to achieve the goal of making full use of
engine power and fuel consumption reduction. Otherwise once after water temperature presents
warning work mode will be lowered automatically through CPU controller, it is possible to select work
mode after water temperature cools. Refer to fig3.1

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

Number of product：23Y -07D-00013

Principle：when core of air filter blocks，the sensor circuit is connected through .

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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:

Area B is the area for water temperature display.

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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.

In the keyboard control part in Fig 2

The function of this pattern is accelerograph control (Standby optional).

  is the accelerograph descending key, while is the accelerograph ascending key. L, F,

E, and P are four working modes.

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.

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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.

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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:

1. As indicated in Fig 1, this figure is the exterior drawing of the keyboard,

Wherein   in the top line is the menu enter key, is the menu descending

key, is the menu ascending key, and is the menu key.   in the
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 automatic return idling function has been
started. When driver does not operate the machine, the system will automatically delay for 5
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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.

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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) 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
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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 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.

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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.

Emergency Parking Item

It is required to stop operation when engine alarms for water temperature, overheating prevention
system begins automatic protection, and rotational speed of engine slows down, run the engine at low
idling speed until water temperature with monitor displays normally.

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.

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.

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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.

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.
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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.

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.
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Those indicated in the following table are the meanings represented by error codes.

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.

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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.

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.

Please key the 4 digit code

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.

Please key the 4 digit code

Wrong code

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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” 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.

Some Points of Attentions:

1. System may possibly react somewhat slowly, when key is pressed.
2. Please make sure to remember the system password, and the password can only be

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unlocked by the POWERPLUS’ s personnel if it is forgotten.

3. Error picture display may possibly occur with system sometimes. Press the enter key at this point
to exit, and then re-enter into the picture.
4. If the system is down and it makes no reaction when any key is pressed, please shut down the
machine, and restart it.
5. Make sure to start the machine after system self-examination has been normal, when key
has just been turned on.
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.

The pictures where operation of POWERPLUS’ s personnel is allowed:

1. The picture of Fig 18 will appear, when Encryption Dog is inserted into the plug and the picture of
Fig 3 is accessed.

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

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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.
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.

2.5 Operation of Air Conditioner

Control Panel (The modalities of air conditioner are different for different machine
types.)

（1） OFF Switch （2） Fan Switch （3） Temperature Control Switch

（4）Ventilation Opening Selector Switch （5）Auto Switch

（6）Fresh /Recycling Selector Switch （7）Display

（8）Air-conditioner Switch

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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

Switch (2) is used for adjusting air output, able to adjust air output into 6 grades.

Press ∧ switch, to increase air output ∨ switch, to decrease air output.

During automatic operation, the air output is automatically adjusted.

Temperature Control Switch

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.

Normally temperature is set at 25°C (77°F).

Ventilation Selector Switch

Switch (4) is used for selecting ventilation.
When Switch (4) is pressed, display on the Monitor Display (7) is switched and
display the air output from the ventilation opening.
If AUTO (Automatic) operation is selected, ventilation opening will be automatically
selected.
Ventilation openings at rear part (8 locations)
Ventilation opening on the surface part (1 location)
Ventilation opening on the bottom part (1 location)
Front-window ventilation opening (1 location)
Front-window ventilation opening (1 location)
Front-window ventilation opening (D2) can be opened or closed with hand.

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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.

Fresh/Recycling Selector Switch

This Switch (6) is used for switching air source between air recycling inside cab and
external in draft air.

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.

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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.

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.

Notices during use of air conditioner

1. When air conditioner is to be operated, make sure to start when engine is operating at low speed.
Don’t start air conditioner when engine is running at high speed, as this may cause damage to air
conditioner.
2. If water enters into control panel or sunlight sensor, it may cause accidental failure.
On this account, pay attention not to allow water to get on these parts. Additionally, keep these parts
away from open fire.

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

7. When engine antifreezing fluid is used as heat medium during air-conditioner heating
operation, it is required to use ammonia-phosphoric acid system free antifreezing fluid, to avoid
damage and corrosion to air conditioner.

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.

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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.

The function for switching set temperature between °F (Fahrenheit) and °C (Centigrade)
Display of set temperature may be switched between °F (Fahrenheit) and °C (Centigrade).
When fan is turning, if the “∧” and “ ∨” part of the Temperature Set Switch (3) is pressed
for more than 5 seconds, temperature display will switch between °F (Fahrenheit) and °C
(Centigrade). (Pay attention to undisplayed units.)

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

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3. CHECK BEFORE STARTING ENGINE

3.1 Walk-around check

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.

3.2 CHECK BEFORE STARTING

WARNING

Do not open the radiator cap unless necessary. When checking the coolant, always check the radiator
tank when the engine is cold.

 Check coolant level.

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.

 Check oil level in engine oil pan, add oil.

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.

 Check fuel level.

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.

 Check oil level in hydraulic tank.

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

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directions to release. The oil level is normal between the H and L marks.

Do not add oil if the level is above the H line.

Remark

① Working around level (oil temperature 10℃ to 30℃)

② Normal working around H level (oil temperature 50℃ to 80℃)

 Check dust indicator.

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 electric wirings.

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:

☉Battery ☉Starting motor ☉Alternator

 Check for water and sediment in water separator, drain water.

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.

2. Tighten drain plug ③.

1. If the air is sucked into fuel line when draining and water, ensure to bleed air in the same manner
as for fitter.

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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

② Starting the engine

Pull fuel control pedal to the low idling position
(MIN) (not provided for some machines due to
difference in types, but accelerograph motor has to
be reset)
 Turn the key in starting switch to the START
position. The engine will start.
 When the engine starts, release the key in
starting switch ② . The key will return
automatically to the on position.
 If the engine will not start, wait for 2 minutes
before trying to start the engine again.
 Do not keep the starting motor rotating
continuously for more than 20 seconds.
 When starting in low temperature, hold
the key in starting switch ② at the HEAT position,
and check that preheating monitor ③ light up. After
approx 30 seconds, preheating monitor
③goes out to inform that the preheating
is completed. Turn the key in starting
switch ②to the START position to start  
the engine.

OPERATION AND CHECKS AFTER STARTING ENGINE

If the work equipment is operated without warming the machine up sufficiently, the response of
the work equipment to the movement of the control lever will be slow, and the work equipment may
not move as the operator desires, so always carry out the warming-up operation, particularly in cold
areas, carry out the warming-up operation.

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.

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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.

When the engine at medium

speed, turn the work mode switch
till strong excavator mode monitor lights up.

Set the lock lever to the FREE

position, and raise the bucket
from the ground.
 Operate bucket control lever and  
arm control lever slowly to move
the bucket cylinder and arm
cylinder to the end of the stroke.

 Carry out bucket and arm

operation for 5 minutes at full
stroke, alternating between bucket
operation and arm operation at 30
seconds intervals.

 When the work equipment is

retracted, tack care that it does
not interfere with the machine
body or ground.

 Check that there is no abnormal

exhausted gas color, noise, orvibration.  

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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.

5.1 MOVING MACHINE FORWARD

Pull fuel control lever towards the high idling

position to increase the engine speed.

Fold the work equipment and raise it 40～50cm

from the ground.

Operate right and left travel levers as follows

 
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.

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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.

Changing direction of machine

when stopped , turn to the left:
push the right travel level forward to
turn left when traveling forward, and
pull it back to turn left when traveling
in reverse. When turning to the right,
operate the left travel lever in the
same way.

Steering when traveling (left

and right travel levers both operated
in same direction) when turning to the
left: if the left travel lever is returned
to the neutral position, the machine
will turn to the left. When traveling to
the right, operate the right travel lever
in the same way.

When making counter-rotation

turn (spin turn) when turning left
using counter-rotation, pull the left
travel lever back and push the right
lever forward. When turning right
using counter-rotation pull the right
travel lever back and push the left
travel lever forward.
 

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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.

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6. STOPPING MACHINE
 Put the left and right travel levers ① in the neutral position, then stop the machine.

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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.

● Left work equipment control lever position

N NEUTRAL
① Arm out
② Arm out and swing right
③ Swing right
④ Arm in and swing right
⑤ Arm in
⑥ Arm in and swing left
⑦ Swing left
⑧ Arm out and swing left

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 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.

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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)

9. PROHIBITIONS FOR OPERATION

 If it is necessary to operate the work equipment control lever when
the machine is traveling, stop the machine before operating the work
equipment control level.
 If operating work equipment control lever when the machine is
automatic optimize speed, the speed can suddenly rise. Be extremely
careful when operating the control lever.
 Prohibited operations using swing
force: do not use the swing force to
compact soil or break earth mounds or
walls. When swing, do not dig the bucket
teeth in to the soil. The operation will
damage the work equipment.
 Prohibited operations using travel
force: do not leave the bucket dug in to
the ground and use the travel force to
excavate. This will bring excessive force
to bear on the rear of the machine.
 Precautions when operating hydraulic
cylinders to end of stroke: if the cylinder
is operated to the end of its stroke during
operations, force will be brought to bear
on the stopper in side the cylinder, and
this will reduce the life of the machine.
To prevent this, always leave a small
safety margin when operating the
cylinders.
 Prohibited operations using dropping
force of bucket: do not use the dropping
force of the bucket as a pickaxe, breaker
or pile driver. This will bring excessive
force to bear on the rear of the machine,
and will not only damage the machine,
but is also dangerous.

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 Prohibited operations using dropping

force of machine: Do not use the
dropping force of the machine for
digging.

 Digging rocky ground: It is better to

excavate hard rocky ground after
breaking it up by some other means. This
will not only reduce damage to the
machine but also make for better
economy.

1. Prohibited suddenly the movement

of the control lever when traveling in
high speed: ① Prohibited suddenly
the movement of the control lever,
this will operation can start the
machine suddenly. ② Avoid the
unexpected conversion of the gear
shift from forward to backward (the
opposite is also true) ③ Avoided
the gear shift is suddenly replaced,
for example, if suddenly parked from
closing to the speed of limit (the
operation of unclamping the gear
shift ).

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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)

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1 1. PRECAUTIONS WHEN TRAVELING UP OR

DOWN HILLS

When traveling, raise the bucket approx.

20~30cm from the ground.
a) When traveling over ridges or other
obstacles, keep the work equipment close
to the ground and travel slowly.

b) It is dangerous to turn on slopes or to

travel across slopes. Always go down to a
flat place to perform these operations. It
maybe longer, but it will ensure safety.

c) If the machine starts to slide or loses  

stability, lower the bucket immediately
and brake the machine.

d) Turning or operating the work equipment

when working on slopes may cause the
machine to lose its balance and turn over,
so avoid such operations. It is particularly
dangerous to swing downhill when the bucket
is loaded.

If such operations have to be carried out, pile soil to

make plat form on the slope so that the
machine can be kept horizontal when
operating.

e) Do not travel on slopes of over 30° as

the machine may overturn.  

If excavator is running on a slope exceeding

15° , the rig shall be folded into the position
as indicated in the following figure.

 
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 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

lower the engine speed.

 When traveling up a steep hill of more

than 15°, set the work equipment in the

position shown in the diagram on the right.

 Breaking when traveling downhill

To brake the machine during downhill runs,

 

put the travel lever in the neutral position.

This will cause the brake to be automatically

applied.

 If shoes slip

When traveling uphill, if the shoes slip or it

is impossible to travel uphill using the force

of the track only, it is possible to use the

pulling fore of the arm to help the machine

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.

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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.

When one side is stuck

Use the bucket to raise the track, then lay boards or logs
and drive the machine out. If necessary, put a
board under the bucket also.★When using the boom or
arm to raise the machine, always have the bottom of
the bucket in contact with the ground.
(Never push with the teeth). The angle between the
boom and arm should be 90 °to 110°.The same
applies when using the inverting bucket.

● When both sides are stuck

When the tracks on both sides are stuck in mud and
the machine will not move, lay boards as explained
above, and dig the bucket in to the ground in front.
Then pull in the arm as in normal digging operations and
put the travel levers in the FORWARD position to pull the
machine out.

13. WORK POSSIBLE USING HYDRAULIC  

EXCAVATOR
In addition to the following, it is possible to further increase the range of
applications by using various attachments.
 BACKHOE WORK
When condition of the machine is as shown in
the diagram at right, each cylinders maximum
pushing excavation force is obtained when the
bucket cylinder and link, arm cylinder and arm
at 90°
Use this angle effectively to optimize your
work efficiency.
When excavating, the range for excavating
with the arm is from a 45°angle away from the
machine to a 30°toward the machine.
There maybe some differences depending on
the excavation depth, but try to use within the
above range rather than going all the way to the
extreme end of the cylinder stroke.
 SHOVEL WORK
A shovel is suitable for excavating at a position higher than
the machine. Shovel work is performed by attaching the
bucket in the reverse direction.
 DITCHING WORK
Ditching work can be performed efficiently by attaching a
bucket to match the width of the ditch and then setting
the tracks parallel to the line of the ditch to be excavated.
To excavate a wide ditch, first dig out both sides and
then finally remove the center portion.
 LOADING WORK
In place where the swing angle is small, work
efficiency can be enhanced by locating the dump truck in
a place easily visible to the operator.
Loading is easier and capacity greater if you begin from the front of the
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dump truck body than if loading is done from the side.

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.

 
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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.

 Put left and right travel levers ① in

the neutral position. The machine stops.

 Pull the engine speed pedal ② to

idling fuel control.

 Lower the bucket horizontally until

the bottom touches the ground.

 Set safety lock lever in the Lock position.

 
16. STOPPING ENGINE

★ If the machine is abruptly stopped before it has cooled down, engine

life may be greatly shortened. Consequently, do not abruptly stop the
engine apart from an emergency. In particular , if the engine has
overheated, do not abruptly stop it but run it at medium speed to
allow it to cool gradually , and then stop it.
 Put the engine at low idling speed for about 5 minutes to
allow it go gradually cool down.
 Turn the key in start switch ① to the
OFF position and stop the engine.
 Remove the key from starting switch ①

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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

Always lock the following places:

★ Door of operator’s cab. Always remember to close the window.

★ Fuel tank filter port.

★ Engine hood.

★ Battery box cover.

★ Left side door of the machine.

★ Right side door of the machine.

★ Hydraulic tank filter port.

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C.TRANSPORTATION

When transporting the machine, observe all related lows and regulations and be careful to assure
safety.

18. LOADING, UNLOADING WORK

● 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.

● Never change the direction of travel when on the ramps. If it is necessary to change
direction, drive off the ramp and correct the direction, then drive on to ramps again.

● 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.

When loading or unloading, always use ramps or a platform and

carry out the operations as the follows.
Properly apply the brakes on the trailer and
insert blocks beneath the tires to ensure that it
does not move. Then fix the ramps in line with
the centers of the trailer and the machine. Ensure that
the two sides are at the same level as
one another. Make the angle of the ramps a
maximum of 15. Set the distance between the
ramps to match the center of the tracks. Set the
travel switch to the “LO” position.

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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.

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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.

● When transporting the machine, place rectangular timber

underneath the front and rear track shoes to prevent the
machine from moving about. Also, hold it down with chains
or rope. Be particularly careful to ensure that the machine
does not slip sideways. Place rectangular timber under one
end of the bucket cylinder to prevent it touching the ground,  
thereby saving it from possible damage.

20. METHOD OF LIFTING MACHINE

Do not lift the machine if there is someone on the machine. Guarantee that the steel rope
has enough intensity that can bear the machine. Only the machine is adjusted into the
following postures could carry on promotion. Otherwise there is a danger that the car body
overbalances probably. Do not make the top rotate while promoting the machine. Rotate the
work equipment to make it in sprocket, and then keep undercarriage and swing parts to turn
parallel when promoting. While promoting the machine, pay attention to that the machine must keep
the balance When promoting the machine, according to the following procedure to operate it
on the flat ground.

 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.

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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.

When putting the machine in storage for a long time, do as follows.

● 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.

4. STARTING MACHINE AFTER LONG-TERM STORAGE

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.
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● 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

Perform maintenance work on hard, flat ground.

● Check service meter

Check the service meter reading every day to see if for any necessary maintenance to be
carried out.

● Keeping the machine clean

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.

● Be careful of hot water and oil

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

* Turn off the engine starting switch.

* Do not apply more than 200 V continuously.

* Connect grounding the cable within 1 m from the area to be welded.

* 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.

● Precautions when washing machine

* 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.

 Dusty worksite

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* Inspect the dust indicator to see whether the air cleaner is blocked up. Clean the air cleaner at
shorter intervals than specified.

* Clean the radiator core frequently to avoid clogging.

* Clean and replace the fuel filter frequently.

* Clean electrical component, especially the staring motor and alternator, to avoid accumulation
of dust.

● Avoid mixing oil:

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.

2.OUTLINE OF ELECTRIC SYSTEM

● 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.

● Never remove or disassemble any electric components installed in the machine.

● Be careful to keep the electric system free of water when washing the machine or when it rains.

OUTLINE OF HYDRAULIC SYSTEM

● 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”.

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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.

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3.USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE

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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.

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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 before starting

Check oil level in engine oil pan, add oil
Check fuel level, add fuel
Check oil level in hydraulic tank, add oil
Check dust indicator
Check electric wirings

Every 100 hours service

Lubricating
Boom cylinder foot pin (2 points)
Boom foot pin (2 points)
Boom cylinder rod end (2 points)
Arm cylinder foot pin (1 point)
Boom-arm coupling pin (1 point)
Arm cylinder rod end (1 point)
Bucket cylinder foot pin (1 point)
Arm-link coupling pin (1 point)
Arm-bucket coupling pin (1 point)
Link coupling pin (2 points)
Bucket cylinder rod end (1 point)
Bucket –link coupling pin 1 points)
Check oil level in swing machinery case, add oil
Drain water and sediment from fuel tank

Every 250 hours service

Check oil level in final drive case, add oil
Check level of battery electrolyte
Change oil in engine oil pan, replace engine oil filter cartridge
Lubricate swing circle (2 points)
Check fan belt tension, adjust
Check air conditioner compressor belt tension, adjust

Every 500 hours service

Replace fuel filter cartridge and additional fuel filter cartridge
Check swing pinion grease level, add grease
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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

Every 1000 hours service

Change oil in swing machinery case
Exam all the fasteners of turbocharger
Exam the windage of rotor for turbocharger
Examining tension rate of engine belt and replacing the belt
Replacing fuel in terminal transmission case

Every 2000 hours service

Clean hydraulic tank strainer
Clean, check turbocharger
Check alternator, starting motor
Check engine valve clearance, adjust

Every 4000 hours service

Check water pump

Every 5000 hours service

Change oil in hydraulic tank

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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.

● Replacing hydraulic element

On new machines, replace the element
after the first 100 to 150 hours, and then
carry out further replacement of the
element according to the table on the right.

● Change oil in hydraulic tank

Change oil according to the table on the
right.

● Replacing additional filter element for

Breaker

Use a guideline of 250 hours for use of the

breaker (operating ratio for the breaker:
50% or more), and replace the element
according to the table on the right
 

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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

6.2 WHEN REQUIRED

1. Check, clean and replace air cleaner element
Never clean or replace the air cleaner element
with the engine running. When using pressure air
to clean the element wear safety glasses or
goggles to protect the eyes.

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.

Cleaning or replacing outer element

 open the front door on the left side of the
machine, removing wing nut ② and take
out element ③. To prevent entry of dirt
and dust, cover the air connector side of
the rear end of the air cleaner with a clean
and cloth and adhesive tape.
 Clean the air cleaner body interior and the
cover.
 Direct dry compressed air (less than 7Kg /cm 2)
to element from inside along its folds, then direct it from  
outside along its folds and again from inside.
① Remove one seal from the outer element whenever
the outer element had been cleaned.
② Replace the outer element which has been cleaned 6 times repeatedly or used
throughout a year. Replace the inner element at the same time.
③ Replace both inner and outer elements when the dust indicator red piston
appears soon after installing the cleaned outer element even though it has not
been cleaned 6 times.
④ Check inner element mounting nuts for looseness and, if necessary, retighten.
⑤ If small holes or thinner parts are found on the element when it is checked
with an electric bulb after cleaning replace the element

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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.

2. CLEAN INSIDE OF COOLING SYSTEM  

WARNING
Soon after the engine has been stopped, the coolant is hot and can cause personal injury.
Allow the engine to cool before draining water.
Since cleaning is performed while the engine is running, it is very dangerous to enter the rear side of
the machine, as the machine may suddenly start moving. If the under cover is left removed, it may
interfere with the fan. While the engine is running, never enter the rear side of the machine.
Never remove the radiator cap when the engine is at high temperature. Steam blowing up from the
radiator could cause personal injury. Allow the engine to cool until the radiator filler cap is cool
and remove the filler cap slowly to al low pressure to be relieved.
 Clean the inside of the cooling system change the coolant and replace the
corrosion resistor according to the table below.

 Use a permanent of antifreeze shall be ammonium-phosphoric acid system free environment-

friendly antifreezing fluid, to avoid corrosion to air conditioner.
If, for some reason, it is impossible to use permanent type antifreeze, use an antifreeze containing
ethylene glycol.
 When decided the radio of antifreeze to water, check the lowest temperature in the past, and
decided from the mixing rate table given below.
It is actually better to estimate a temperature about 10℃ lower when deciding the mixing rate.
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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

Install the undercover.

Add cooling water until it overflows from the water filler.
To remove the air in the cooling water, run for five minutes at low idling, then for another five minutes
at high idling. When doing this, leave radiator cap off.
Stop the engine, wait for about three minutes, add cooling water up to near the radiator water filler
port, and then tighten cap

3. Check and tighten track shoe bolts

If the machine is used with shoes bolts loose,
they will break, so tighten any loose bolts
immediately.

First tighten to a tightening torque of 50±5Kgm,

then check that the nut and shoe are in close contact
with the link contact surface.  
After checking, tighten a further 120±10°

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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

4. CHECK AND ADJUST TRACK TENSION

Carry out this operation with two workers. The operator must move the machine in
accordance with the signals from the other worker. The track tension is checked with
the chassis raised, so it is extremely dangerous if the machine is lowered by mistake
during the inspection. Never move the machine while anyone is carrying out
measurements.

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.

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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.

When loosening tension

It is extremely dangerous to release the grease by any method except the procedure given below.
 Loose plug gradually to release the grease.
 Turn plug a maximum of one turn.
 If the grease does not come out
smoothly, move the machine backwards
and forwards a short distance.
 Tighten plug.
 To check that the correct tension has
been achieved, move the machine
backwards and forwards.
 Check the track tension again, and if
the tension is not correct, adjust again.
 

5. REPLACE BUCKET TEETH (HORIZONTAL TYPE)

Replace the teeth before the wear reaches the adapter.
It is dangerous if the work equipment moves by mistake when the teeth are being
replaced. Set the work equipment in a stable condition, then stop the engine and apply
the locks securely to the levers.
 Place a block under the bucket bottom so that the pin of tooth can be
knocked out with a hammer. Carry out full stroke operation of the control
levers within 15 seconds after the engine has stopped. After confirming that
the work equipment is in a stable condition, set so that the bottom face of
the bucket is horizontal.

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 Place a bar on the pin head and strike

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.

6. ADJUST BUCKET CLEARANCE

 Set the work equipment to the
position in the diagram at right, stop
the engine and set the locked
position.
 Shift O-ring of the linkage and
measure the amount of play (a).
Measurement is easier if you move
the bucket to one side or the other so
all the play can be measured in one
place.
 Loosen the four plate fixing bolts
and loosen plate. Because it uses
split shims, you can carry out the
operation without removing the bolts
entirely.
 Remove shim corresponding to the
amount of play (a) measured above.

[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

Tighten the four bolts

If the bolts are too stiff to tighten, pull
out stopper bolt for easier tightening

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7. CHECK AND ADJUST AIR CONDITIONER

Check level of refrigerant

If the liquid gets into your eyes or on your
hands, it may cause loss of sight or frostbite,
so never loosen any part of the refrigerant
circuit.

If there is a lack of refrigerant (Freon 134a),

the cooling performance will be poor. When
operating the cooler, check the filling quality
of refrigerant from the inspection window
mounted on the condenser unit reservoir.
 Transparent basically, can see bubbles
flowing. When the speed of the engine
raises or reduces, bubbles will
 
disappear gradually and become
transparent. Correct.
 There will be bubbles flowing
transparent. Sometimes white bubbles
appear . Refrigerant level low.
 Slight fog fluid will appear . No
refrigerant basically.
 The air quantity of the cooler is the
maximum, (the door opened), even
the engine rotates idling.
Refrigerant overage.

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.

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Inspection and maintenance items list for cooler

6.3 CHECK BEFORE STARTING

WARNING

Do not open the radiator cap unless necessary.

When checking the coolant,
always check the radiator reserve tank when
the engine is cold.
 Check oil level in engine oil pan, add oil
The oil level is below the H and L
marks on dipstick. ★ When checking
the oil level after the engine has been
operated, for at least 15 minutes after
stopping the engine before checking. If
the machine is at an angle, make it
horizontal before checking.

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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.

Check oil level in hydraulic tank

Run the engine at low speed,
retract the arm and bucket cylinders,
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 (work equipment and
travel) to full stroke in all directions
to release the internal pressure. The
oil level is normal if between the H
and L marks. Do not add oil if the
level is above the H line.
REMARK
The oil level will vary depending upon the oil
temperature. Accordingly, use the following as
a guide:

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 when oil temperature is near the circumstance temperature (10℃ to 30℃):

around L level
 when oil temperature is near the normal operation temperature (10℃ to 30℃):
around H level

 Check dust indicator

If the red piston has appeared, clean or replace the element immediately. After
checking, cleaning, and replacing, press the knob of dust indicator to return the red
piston to its original position.

 Check electric wirings

Check for damage of the fuse and any sign of disconnection or short circuit in the
electric wiring. Check the following points carefully.

① Battery
② Starting motor
③ Alternator

 Check for water and sediment in water separator, drain water

The water separator separates water mixed in the fuel. If float ② is at or above red line ①, drain the
water according to the following procedure:

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.

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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.

 Boom cylinder foot pin (2 points)

 Boom foot pin (2 points)

 Boom cylinder foot rod end (2 points)

 Arm cylinder foot pin (1 points)

 Boom-arm coupling pin (1 points)

 Arm cylinder rod end (1 points)

 Bucket cylinder foot pin (1 points)

 
 Arm-link coupling pin (1 points)

 Arm-bucket coupling pin (1 points)

 Link coupling pin (1 points)

 Bucket cylinder rod end (1 points)

 Bucket-link coupling pin (1 points)

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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.

DRAIN WATER AND SEDIMENT FROM FUEL TANK

1. Carry out this procedure before operating the machine.
2. Prepare a container to catch the fuel that is drained.
3. Open valve at the bottom of the tank and drain the sediment and water that has
accumulated at the bottom together with fuel. When doing this, be careful not to
get fuel on yourself.
2. When only clean fuel comes out, close drain valve.

NOTICE :Never use trichlene for washing the inside of the tank.

6.5 EVERY 250 HOURS SERVICE

Check oil level in final drive 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 starting the operation.
If there is still pressure remaining inside the case, the oil or plug may fly out . Loosen
the plug slowly to release the pressure.
1. Set the OILL mark at the top, with the plug F
and plug P perpendicular to the ground surface.
2. Remove plug F using the handle. When the oil
level reaches a point 10mm below the bottom of
the plug hole, the correct amount of oil has been
added.
3. If the oil is too low, install plug F, operate the
travel levers, and drive forward or in reverse to
rotate the sprocket one turn. Then repeat step 2 to
check again.
4. If the oil level is still too low, add the gear oil
through the hole in the plug E until the oil
overflow from the hole.
5. After checking, install plug and tighten it.
Tighten torque: 98±10N²m (10±2Kg²m)  

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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.

CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL

FILTER CARTRIDGE
The oil is at high temperature after the engine has been operated, so never change the oil
immediately after operations. Wait for the oil to cool down before changing it.
1. Place a drain container under drain plug located on the bottom of the machine.
2. Loosen drain plug slowly to avoid getting oil on yourself, and drain the oil.
3. Check the drained oil, and if there are excessive metal particles or foreign material, please
contact your service department.
4. Install drain plug.
5. Open the engine hood. Using the filter wrench from the upper side of the engine, turn filter
cartridge counter-clockwise to remove it. In particular, if this operation is carried out
immediately after stopping the engine, a large amount of oil will come out，so wait for 10
minutes before starting the operation．
6. Clean the filter holder, coat the packing surface of a new filter cartridge with
engine oil (or coat it thinly with grease), then install it to the operation. Notice:
Confirm that no remnants of old packing still adhere to the filter holder as this may
result in oil leakage.．
7. When installing，tighten until the packing surface contacts the seal surface of the
filter holder，then tighten it up 1/2 of a turn．
8. After replacing the filter cartridge, add engine oil through oil filler until the oil level is between the H
and L marks on dipstick.
9. Run the engine at idling for a short time，then stop the engine, and check that the oil level is
between the H and L marks on the dipstick．
Even if the machine has not been operated for 250 hours, the oil and filter cartridge must be
replaced when the machine has been operated for 6 months．
In the same way, even if the machine has not been operated for 6 months, the oil and
filter cartridge must be replaced when the machine has been operated for 250 hours.

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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.

CHECK FAN BELT TENSION, ADJUST

Checking
The belt should normally deflect by about
5-6mm when pressed with the finger (with a
force of approx.6kg) at a point midway
between the fan pulley and tension pulley.
Adjusting
 Loosen bolts and nuts ①, ② and ③.
 Loosen the lock nut and move tension
pulley ④ with adjustment bolt ③ so
that the belt deflects about 5-6mm (with a
force of approx.6kg).
 Tighten the bolts and nuts ⑤, ① and
②, to fix tension pulley ④ in position.
 Check each pulley for damage, wear of
the V -groove, and wear of the V -belt. In
particular, check that the V -belt
is not touching the bottom of the
V -groove.
 Replace 2 belts if it has stretched, leaving
no allowance for adjustment, or if there is a  
cut or crack on belt.
 When the new belt is set, re-adjust it after
operation for an hour.

CHECK AIR CONDITIONER COMPRESSOR BELT TENTION, ADJUST

Checking
The belt should normally deflect by about 5~8mm when pressed with the finger (with a force of approx. 6kg)
at a point midway between the drive pulley and compressor pulley.
Adjusting
 Insert a tension adjusting bar wrapped with cloth or another cushioning material between brackets ③
and ④.
 Loosen bolts ① and ②.
 Move bracket ④ with the tension adjusting bar so that the deflection of the belt will be 5~8mm.
 Tighten bolts ① and ② to secure bracket ④. Then take out the tension adjusting bar.
 Check each pulley for damage, and check the V -groove and V -belt for wear. In particular, check that
the V -belt is not contacting the bottom of the V -groove.
 If the V -belt is elongated and cannot be adjusted any further, or if there are any-cuts or crack,
replace the V -belt.
 After replacing the V -belt, carry out the adjustment again after one hour of operation.

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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.

Normal air bleeding procedure

1. Add fuel to the fuel tank until full (to FULL mark on the fuel gauge).
2. After replacing filter cartridge ①, loosen joint bolt ③.
3. Loosen the knob of feed pump ②, and move it up and down about 50~60 times
to cause fuel to overflow until bubbles do not come out from the joint bolt any
more.
4. Tighten joint bolt ③.
REMARK:
When the engine stops because of running out of fuel, also operate the feed pump according to the
above procedure to bleed air.

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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.

CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS AND

CONDENSER FINS
 Open the engine hood and rear door on the left side of the machine. Loosen 4
bolts and remove the radiator front cover.
 Blow off mud, dust or leaves clogging the radiator fins and oil cooler fins using
compressed air. At the same time, clean the net in front of the oil cooler. Clean
the condenser fins on machines equipped with the air conditioner. Steam or
water may be used instead of compressed air. After cleaning, install the cover
with bolts ①.
 Check the rubber hose. Replace with a new one if the hose is found to have
cracks or to be hardened by ageing. Further, check hose clamps for looseness.

REPLACE HYDRAULIC FILTER ELEMENT

 Remove the cap from oil filler, and release the internal pressure.
 Loosen 4 bolts, then remove cover ①. When doing this, the cover may fly out
under the force of spring ②, so hold the cover down when removing the bolts.
 After removing spring ② and valve ③, take out element ④.
 Clean the removed parts in diesel oil.
 Install a new element in the place where old element ④ was installed.
 Set valve ③ and spring ② on top of the element.
 Set cover ① in position, push it down by hand, and install the cover with the
mounting bolts.
 Screw in the oil filler cap and install the cover.
 Check for oil leakage and wipe off any spilled oil.
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CHANGE OIL IN FINAL DRIVE CASE

(only after for first 500 hours, then every 1000 hours)
CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER SYSTEM
 Remove the filter cover and pull out the filters.
 If there is oil on the filter or it is extremely dirty, wash it in a neutral washing agent. After
washing it, dry it completely before using it again.

NOTICE
The normal cleaning interval is 5000 hours. However, if the filters are used at a dusty site, shorten this
interval.

6.7 EVERY 1000 HOURS SERVICE

Maintenance for every 100,250 and 500 hours should be carried out at the same time.
CHANGE OIL IN SWING MACHINERY CASE
 Set an oil container under drain valve under the machine body.
 Loosen drain valve under the body, drain the oil, and then tighten the drain valve again.
 Remove dipstick and bleeding plug. Add the specified amount of engine oil through
gauge hole.
 After refilling, install bleeding plug.
 Wipe off oil on the dipstick with a cloth.
 Insert dipstick into the gauge pipe thoroughly and then pull out it again.
 When the oil level is between the H and L marks, on dipstick, it is normal. If the oil does not
reach the L mark, add more oil through oil filler.
 If the oil level exceeds the H mark, drain the excess engine oil from drain valve, and check
the oil level again.

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CHECK ALL TIGHENING PARTS OF TURBOCHARGER

Contact your service department to have the tightening portions checked.

CHECK PLAY OF TURBOCHARGER ROTOR

Contact your service department to have the tightening portions checked.

CHECK ALTERNATOR BELT TENSION AND REPLACE

ALTERNATOR BELT
Special tools are required for inspection and replacement of the alternator.
Contact your service department for inspection and replacement.

CHANGE OIL IN FINAL DRIVE CASE

 Set the machine with plug and plug perpendicular to the ground surface.
 Drain the oil from drain plugs on both sides of the machine. After draining, tighten the
drain plugs.
 Then, supply new gear oil through oil filler respectively to the specified level.
 When the oil overflows from the hole of plug, install plug. Tightening torque of plugs
98±10N.M.

6.8 EVERY 2000 HOURS SERVICE

Maintenance for every 100,250,500 and 1000 hours should be carried out at the
same time.

CLEAN HYDRAULIC TANK STRAINER

 Loose 4 bolts, and then remove cover. When doing this, then cover may fly out under the
force of spring, so push the cover down when removing the bolts.
 Pull up the top of rod, and remove spring and strainer.
 Remove the dirt stuck to strainer, and then wash it in clean diesel oil or flushing oil. If
strainer is damaged, replace it with a new one.
 Refit strainer by inserting it into tank projecting part.
 Install cover with bolts.

CLEAN, CHECK TURBOCHARGER

Contact your service department to have the tightening portions checked.
CHECK ALTERNATOR, STARTING MOTOR
The brush may be worn, or the bearing may have run out of grease, so inspect or
repair. If the engine is started frequently, carry out inspection every 1000 hours.
CHECK ENGINE VALVE CLEARANCE, ADJUST
Special tool is required for removing and adjusting the parts.

6.9 EVERY 4000 HOURS SERVICE

Maintenance for every 100,250,500,1000 and 2000 hours should be carried out at
the same time.
Check water pump:
Since the pulley may have play, oil may leak, water may leak and the drain hole may
be clogged, contact your service department for inspection or replacement.

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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

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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 110