Kato REDGZM HD514MR-7 Instruction Manual Download | Manualshive

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Inspection and servicing of each part

4. Inspection and servicing of each part

4-1 Engine-related

(01E0-0295-0E)

4-1-1 Engine inspection and servicing

(01E0-0296-1E)

  (1) Take the engine inspection points from the "Inspection and servicing table".
  (2) Take the engine inspection methods from the separate engine manual.
  (3) Consumable part number

Refer to the "Consumable parts guide".

・

Always stop the engine before inspecting it.

If you inspect and service the engine while it

is running, you risk severe injury by trapping
your hands etc. in the cooling fan or fan belt.

・

Always open the engine hood completely and

engage the stopper when you open it.

・

Immediately after the engine stops each part

will be very hot and you risk burns if you
touch it. If you are going to open the engine
hood to inspect the engine, check that it has

cooled suﬃciently.

・

The sound absorbing material in the engine

compartment is designated as a safety part for
periodic replacement.

Inspect it at regular intervals and if any

damaged is discovered, then replace it even if
it is before the scheduled replacement time. If

it falls oﬀ, it could cause a ﬁre.

(01E0-0297-1E)

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Summary of Contents for REDGZM HD514MR-7

Page 1: ...the equipment etc All people who come into contact with this machine must read and be familiar with the contents of this manual Keep it in the machine so it will be available to anybody who needs it If you need a copy of this manual in another language ask your authorised KATO dealer 218621 Applicable serial No HD514MR 7 5102 HD514MRLC 7 5102 HYDRAULIC EXCAVATOR ...

Page 2: ...218621 背厚 13 mm 中 ...

Page 3: ... 2 Modiﬁcations If you modify the machine from the state in which it left our factory you may impair its safety or performance If you wish to make modiﬁcations we urge you to consult your authorised KATO dealer KATO bears no responsibility for accidents or malfunctions which arise as a result of unauthorised modiﬁcations 3 Optional parts and attachments Refer to the instruction manuals provided wh...

Page 4: ...sale or other circumstances the instruction manuals must be transferred together with the machine This manual has been written as a standard for general handling in speciﬁed operations It is not intended to cover its handling under special conditions and unusual circumstances Before attempting any operations not covered by this manual or when you are unsure of any aspect of its contents contact yo...

Page 5: ... of this manual further safety information and requirements are to be found on the safety signs on the machine and are contained in laws regulations ordinances insurance conditions and other sources You must also adhere to these conditions Further observe the safety regulations and laws of the country where the machine is used Please also refer to the separate instruction manuals ...

Page 6: ...ng measures taken in the Inspection Sheet Refer to the separate Service Manual for servicing procedures for breakdowns and disassembly 5 Product identiﬁcation number and engine serial number 01E0 0009 1E The product identiﬁcation number and engine serial number will assist in smooth administrative processing of orders for parts and servicing from your authorised KATO dealer so please provide these...

Page 7: ...oom cylinder Line hose for arm cylinder control valve boom piping boom piping arm cylinder Line hose for bucket cylinder control valve boom piping boom piping bucket cylinder Engine oil remote hose Additional attachment hose Cooling system Every 2 years or 4000 hours of operation whichever reaches sooner Heater hose engine air conditioner unit Inside the engine compartment Every 5 years Sound abso...

Page 8: ...E0 0021 0E Standard arm 2 50m Long arm 3 00m HD514MR 7 HD514MRLC 7 HD514MR 7 HD514MRLC 7 Overall height mm 2820 2820 2820 2820 Overall length mm 7470 7550 7460 7540 Minimum ground clearance mm 440 430 440 430 When the long arm is in the transport position T218601 002 0E ...

Page 9: ... 7 8 Speciﬁcations 8 2 General data 01E0 0023 0E ...

Page 10: ...3 00 m A Maximum digging radius mm 8450 8910 B Maximum digging depth mm 5540 6040 C Maximum digging height mm 9050 9380 D Maximum vertical wall mm 4560 5000 E Maximum dumping height mm 6690 7030 F Front minimum swing radius mm 2410 2770 Long arm range is in the digging position T218601 004 0E ...

Page 11: ...ed cab conﬁguration is 70dB A Measurement is obtained on a dynamic machine with the procedures and cab conditions as described in ISO 6396 2 Vibration level Measurement is obtained on a representative machine Hands Arms The root mean square accelerations applied to the hands and shoulder joints must not exceed 2 5m S2 Whole body The root mean square accelerations applied to the whole body must not...

Page 12: ... 10 MEMO ...

Page 13: ...Part names and terms 39 3 Explanation of the operation devices 43 4 Precautions on handling a new machine 81 5 Preoperational checks 82 6 Operation 83 7 Monitor 102 8 Lifting a load 131 9 Bucket replacement and reversal procedure 138 10 Handling under special conditions 144 11 Long term storage 148 12 Towing 150 13 Transportation 151 14 Machine hoisting procedure 155 15 Cab protective structure 15...

Page 14: ...ls 263 6 Track shoe selection 264 7 Track shoe types and applications 265 8 Procedures for multi position lever operation 266 9 Procedures for selector lever operation 268 10 Procedures for selector lever operation 270 Data ﬁle 1 Tightening torque table 273 2 Dimensions and weight 280 3 Consumable parts guide 284 4 Hydraulic circuit diagram 295 5 Electrical circuit diagram 296 6 Inspection sheet 2...

Page 15: ... the operation devices 43 3 1 Inside the cab 43 3 2 Control levers 55 3 3 Control panel 60 3 4 Switch panel 62 3 5 Backup switch panel 63 3 6 Radio 65 3 7 Handling the SCR system 67 3 8 Escape mode 69 3 9 Purge Rinse of the SCR system 70 3 10 Outside the cab 74 4 Precautions on handling a new machine 81 5 Preoperational checks 82 6 Operation 83 6 1 Starting the engine 83 6 2 Warm up running 85 6 3...

Page 16: ...cial conditions 144 10 1 Handling in cold conditions 144 10 2 Handling under extreme heat 145 10 3 Handling under a dusty or sandy environment 146 10 4 Handling near the sea shore 147 10 5 Handling in mud rain snow zones of high humidity on soft ground 147 10 6 Handling in rocky ground 147 11 Long term storage 148 12 Towing 150 13 Transportation 151 13 1 Preparations for transportation 152 13 2 Us...

Page 17: ...laws of the country where the machine is used 1 1 Preoperational precautions 01E0 0030 0E 1 1 1 General precautions T218341 006 0E 1 Carrying any licenses and certiﬁcates required Always carry any licenses and certificates required under the laws and regulations of the country where the machine is used 2 Wearing protective clothing and equipment When operating the machine do not wear clothing whic...

Page 18: ... in a well ventilated work area 5 Do not work when you are unwell Do not attempt to operate the machine when you are sick excessively fatigued or otherwise unwell 6 Do not leave tools shovels wire ropes points rags etc out of the toolbox If oil or fuel spills on hot surfaces rags etc they can be ignited by short circuit sparks or other cause and start a ﬁre 7 Read the instruction manual thoroughly...

Page 19: ...solvents If it is not possible to remove the dirt or if a safety sign is damaged or peeling replace the safety sign with new Refer to the parts list on the machine and order a new sign from your authorised KATO dealer to replace the safety sign When you replace a safety sign always check that it is identical to the original 10 Noise hazard Working for extended periods in the vicinity of loud noise...

Page 20: ...rettes and matches are completely extinguished before closing the lid Do not leave cigarette lighters in the cab High temperatures inside the cab could cause them to explode 12 Adjusting the operator s seat Adjust the operator s seat to ﬁt you before you start the engine Adjust the seat so that you can reach all control levers and pedals comfortably with your back resting on the seat back 13 Using...

Page 21: ...gments metal debris or other matter can be extremely dangerous if it hits the eyes or other parts of the body These can cause a serious accident Wear a helmet protective eyewear safety shoes a mask and gloves in locations where dirt or rock fragments could be thrown or when pins are inserted or removed Make sure all others are away from the machine when in operation 16 Attaching a head guard Alway...

Page 22: ...ld not only result in worse gas emissions but also could cause the machine to fail 3 Use ultra low sulfur diesel fuel with sulfur content of 10ppm or less If not engine stop may be caused Do not use any type of water remover 4 Exhaust gases will get signiﬁcantly hot during SCR system purging Therefore be careful not to park near flammable substances 5 Use low ash engine oil that meets API standard...

Page 23: ... Alteration of them such as welding drilling etc will deteriorate the function for a protective structure so never alter them Damage or deformation on them might also deteriorate the function Contact your authorised KATO dealer 1 1 2 Precautions on working environment 01E0 0032 1E 1 Always discuss the work plan with all those involved before you start When you arrive at a site discuss the work pla...

Page 24: ... objects Before you start work check with the ﬁrm in charge of the site for the existence and location of buried objects such as water and gas mains and high voltage cable ducts 4 No entry into the working area People objects etc should be absolutely prohibited from entering into the machine working area Always be aware of your surroundings while you work 5 Keeping good visibility 1 When you need ...

Page 25: ...r away all objects which hinder operation Make sure there is enough space not just for the swing radius on the counterweight side but also within the bucket movement area 8 Precautions when working near power cables If you are working close to power cables you can receive a shock even if the machine does not actually touch the cables When you are working near power cables strictly observe the foll...

Page 26: ...or receive instructions for appropriate emergency measures Evacuate others away from the machine Evacuate workers and other relevant site personnel away from the machine to prevent any secondary disasters If anyone becomes electrocuted let them escape on their own Attempting to help them may cause secondary disaster to spread from the electrocuted victim 3 After the incident be sure to have all eq...

Page 27: ...erational checks When you have finished preparing the work site carry out preoperational checks Refer to the section on preoperational checks 3 Detached attachments Place attachments which have been replaced and detached in a safe stable position where they cannot topple over ...

Page 28: ...uel Check that paper scraps or other ﬂammable materials are not scattered about or piled up near the engine 3 Start the engine from the operator s seat Always start the engine while seated in the operator s seat If you are not in the operator s seat when you start the engine you will not know the positions of the control levers or the condition of the monitor display so this is a dangerous practic...

Page 29: ... engine set the safety lock lever to the lock position before you leave the cab 1 2 2 Precautions on operation 01EE 0036 1E 1 Prohibition of operations other than those designated You are forbidden to attempt operations other than those designated in the instruction manual 2 Prohibition of unreasonable operations Familiarize yourself with the machine speciﬁcations and never attempt operations whic...

Page 30: ...ywhere other than in the seat 5 Riding on the bucket or hook is prohibited You must not allow anyone to ride in the bucket or hoist on the hook 6 Making the work site safe 1 Unstable ground surfaces increase the chance of tip over Slopes road shoulders and the edges of deep ditches are unstable so you should reinforce them before traveling over them If the weight and vibration of the machine cause...

Page 31: ... operations Undercutting cliﬀs is dangerous because it causes earth to fall Do not dig so deeply that the machine is undercut This makes the ground unstable and risks the machine falling 4 Keeping adequate visibility When working in dark places switch on the working lamps and place further illumination where necessary When visibility is bad due to fog snow rain or other conditions stop work and do...

Page 32: ... Beware of loose ground after rain earthquakes or blasting Take care to avoid crumbling cliffs and road shoulders or falling stones Always check whether there are any explosive charges which have not detonated yet 7 Prohibition of hoisting operations The practice of ﬁtting a wire rope to the bucket or other front attachment and using it for hoisting is prohibited When hoisting you may need a speci...

Page 33: ...e machine when it swings Always check that nobody is in the front and rear swing ranges Before swing sound the horn to warn people nearby 10 Do not allow the machine to hit anything Take care that the boom arm etc do not hit anything when working under a tunnel bridge or power cables or where there are limits on headroom in car park entrances etc or on front or rear swing radius 11 Determine a sig...

Page 34: ...rground or other enclosed space extend the exhaust pipe outdoors or ensure there is adequate air exchange by opening doors or windows to allow in plenty of exterior air 1 2 3 Dangerous operations which can damage the machine 01E0 0037 3E 1 Use of traction for digging is forbidden Do not work by digging the bucket into the ground and traveling backward as this puts unreasonable loads on the machine...

Page 35: ...in digging is prohibited Never knock the bucket into the ground and use the weight of the machine to assist in digging This can damage the machine body or tip over the machine 5 Hammering is prohibited Never use the bucket for hammering of pile driving operation This can damage the bucket and front attachments and it is also dangerous 6 Beware of digging diagonally If you dig with the upper struct...

Page 36: ... operation 20 7 When digging sideways make the ground under the machine level before starting work Projections under the track shoes cause high point loads which can bend them 8 Reckless operation will damage the machine ...

Page 37: ...machine on an incline If there is no alternative to parking on an incline use chocks so that the machine cannot move and dig the bucket into the ground 3 If you park the machine on a public road place warning signs so that the machine can be clearly distinguished from other vehicles Particularly at night you should place lights and signs for night use 4 Before leaving the cab after parking the mac...

Page 38: ...WARNING 1 For safe operation 22 5 Postoperational checks After you have finished work check all its parts and add lubricants and fuel as required If you ﬁnd any defective parts repair them immediately ...

Page 39: ...visible and easy to read If a safety sign is dirty use water or a neutral cleaner to remove the dirt Do not use gasoline or organic solvents If it is not possible to remove the dirt or if a safety sign is damaged or peeling replace the safety sign with new Refer to this section and parts list on the machine and order a new sign from your authorised KATO dealer to replace the safety sign When you r...

Page 40: ...81228180 11 Content Do not use fuel other than specified diesel fuel Location Beside the oil ﬁller port Part No 32E 75105000 12 Content Precautions on handling the battery Location Left machine compartment battery cover Part No 707 75112002 13 Content Precaution on removing the return ﬁlter cap Location Top surface of the oil reservoir Part No 767 75107001 ...

Page 41: ... handling the fuel ﬁlter Location Right machine compartment fuel pre ﬁlter Part No 899 81225992 20 Content Precautions when using the battery disconnect switch Location Left machine compartment battery cover Part No 899 81230512 22 Meaning There is a danger of injury from being hit and thrown by the attachments Stay away from the machine Location Both sides of the arm Part No 001 81302022 ...

Page 42: ... not open the cap when the radiator is hot Location Top surface of the radiator expansion tank Part No 001 81332002 26 Meaning There is a danger of being injured due to an explosion Do not drill weld hit or disassemble the muﬄer or put it near any ﬂame Location Right machine compartment muﬄer cover Part No 001 81322004 27 Meaning There is a danger of shock when handling the battery cables Read the...

Page 43: ...igh temperature part Location Right machine compartment muffler cover and top surface of the radiator expansion tank Part No 001 81332003 30 Meaning There is a danger of getting caught in rotating equipment such as belts and being injured Stop rotation completely before inspecting or servicing those parts Location Side of the radiator expansion tank Part No 001 81332018 31 Meaning There is a dange...

Page 44: ... 001 81302015 42 Content Precautions on the battery electrolyte and explosive gas Location Right machine compartment upper side of the battery Part No 707 75122001 44 Content Add hydraulic oil only Any other type of oil could cause a malfunction or ﬁre Location Top surface of the oil reservoir Part No 047 74903001 107 Meaning Be careful not to pinch your hand in the seat moving part Location Seat ...

Page 45: ...ing the engine and precaution against attachment contact Location Cab right window Part No 899 81205592 118 Content Matters to be strictly observed when you handle the machine and travel down a steep incline and climb up or down the trailer ramps Location Cab right window Part No 899 81205692 119 Content Precaution against battery depletion when the engine is not operated for a long time Location ...

Page 46: ...ow and rear window Part No 867 75008000 122 Content Precaution on opening and closing the front window Location Cab right window Part No 707 75108002 124 Meaning Operation prohibition during inspection and servicing Hang this sign on the control lever during inspection and servicing not to allow any other worker to start the engine or operate the machine Part No 707 75118001 ...

Page 47: ...ectrical wires could cause a shock Maintain a safe distance from electrical wires Location Cab right window Part No 001 81322007 129 Meaning There is a danger the parked machine might move accidentally causing injury due to being struck or caught between moving parts Before leaving the machine lower attachments to the ground use the safety lock lever to lock the control levers and remove the engin...

Page 48: ...ndow securely in the stowage position Location Cab right window Part No 001 81332020 131 Content Be careful of the lock lever position for opening closing the front window Location Front window Part No 54E 75134000 151 Content Precaution on breaker operation optional Location Cab right window Part No 899 81203092 ...

Page 49: ...he hand grips steps and track shoes Do not use any other than the hand grips to hold on to Do not jump onto or oﬀ the machine Do not get on or oﬀ the machine while it is in motion The ﬂoor hand grips steps track shoes etc are slippery when they have mud oil or snow on them so wipe them clean before you get on or oﬀ the machine If the hand grips or steps are damaged repair them If the attachment bo...

Page 50: ...ills wipe it up immediately Take care to ensure that no dirt or water gets into the fuel tank when you ﬁll with fuel Watch the level gauge of the fuel tank while you ﬁll with fuel so that the fuel does not pour out of the ﬁller port on the fuel tank Clean the cap strainer when you ﬁll with fuel After ﬁlling with oil refasten the oil cap Extra caution is required when inspecting or servicing the fu...

Page 51: ...fuel Diesel engine fuel should satisfy the following criteria Does not contain even ﬁne dust Has adequate viscosity Has a high cetane number Has good low temperature ﬂowability Has low sulfur content 10ppm or less Has low carbon residue Use standard automotive diesel fuels that meet the requirements above Never use diesel fuel that does not meet the requirements Doing so may prevent maximizing the...

Page 52: ...on for Standardization ISO ISO 22241 Do not dilute the DEF AdBlue or add any additives Doing so could not only result in worse gas emissions but also could cause the machine to fail 2 How to Store the DEF AdBlue Store the DEF AdBlue in a sealed container kept in a well ventilated location away from direct sunlight Be careful to prevent any dust or other matter from contaminating the DEF AdBlue Con...

Page 53: ...ﬁlling the DEF AdBlue tank NOTE DEF for ﬁlling DEF AdBlue in accordance with International Organization for Standardization ISO DEF tank capacity 46L As a general guideline replenish the DEF every fourth or ﬁfth time fuel is added Watch the DEF level meter on the monitor inside the cab while you replenish the DEF If the needle of the DEF level meter reaches F do not replenish the DEF more ...

Page 54: ...hen wipe it up immediately If left unremoved the urea components could crystallize making it diﬃcult to remove If the cap is diﬃcult to tighten due to crystallized urea around the ﬁller port of the DEF tank remove it with a cloth or other means rather than forcing the cap closed Vaporized ammonia might leak out when the cap is removed from the DEF tank Vaporized ammonia has an intense odor and esp...

Page 55: ...suit the work in hand Available attachments include the boom arm and bucket Front and rear left and right forward and reverse The end of the lower structure with the front idlers is deﬁned as the front and the end with the traveling motors and driving tumblers is deﬁned as the rear Left and right are determined accordingly Therefore whichever direction the upper structure is facing pushing the tra...

Page 56: ... 40 2 Part names and terms 2 2 2 Inside the cab 01E0 0050 1E ...

Page 57: ... 41 Part names and terms 2 Part names and terms ...

Page 58: ... 42 2 Part names and terms 2 2 3 Outside the cab 01E0 0051 1E ...

Page 59: ...he Control levers section for an explanation of the safety lock lever 01E0 0088 0E 1 Door To open the cab door from the outside pull the door lever to release the lock To open the cab door from the inside grip the lever on the door inner handle to release the lock To hold the door open ﬁx the door to the door lock securely To close the door release the lock using the door lock release lever then c...

Page 60: ... area is safe and then move the safety lock lever to the lock position At this time take great care about a falling object T218081 016 0E If the door is shut when the door key is in the lock position then the door will lock At this time be careful not to leave the key inside the cab A partially locked position is provided for safety when closing the door However the door is not completely sealed i...

Page 61: ...oulder and then turn it If you turn the key before it is fully inserted you could damage it Do not push the key strongly sideways while it is inserted as it could be bent 01E0 0092 1E 4 Front window The front window can be opened and stowed against the ceiling 1 How to open the front window Unlock the window by pulling the unlocking lever while holding the grip handle at the top of the front windo...

Page 62: ...dow by disengaging the lock pin located toward the right rear while using both hands to hold both the upper and lower front window grip handles and then releasing the auto lock by pulling the unlocking lever Keep holding both the upper and lower front window grip handles while slowly sliding the window downward Push forward on the grip handle at the top of the front window to lock the window in pl...

Page 63: ... the front window Also be sure to use the designated grip handles for the operation Attempting to open or close the window by holding someplace other than the designated grip handles could result in pinching a hand If the operator seat position is toward the front or high then the front window could hit the operator s head when closing or opening the window If so carefully open or close the window...

Page 64: ...fall down during operation T218081 019 1E 6 Roof window The roof window can be opened by pulling the locks on the left and right sides toward the interior holding the grip and pushing the window upward After you ﬁnish work close this window until it locks securely 01E0 0098 0E 7 Door window Grip and pull out the lock to slide open this window After you ﬁnish work always close the window ﬁrmly unti...

Page 65: ...fore stowing the front window Not doing so could cause damage from interference with front window T218081 020 0E 10 Operator s seat Adjust the seat to easiest position for you to operate the pedals and levers Do not adjust the seat while you are operating the levers because this is dangerous Move the safety lock lever to the lock position while adjusting the seat When you work the seat complete sl...

Page 66: ... angle of the seat back Pull the reclining lever and adjust using your body weight until the angle is right 4 Front and rear height levers You can adjust the height of the front or rear of the seat base independently Pull either of the levers and use your body weight to adjust the corresponding height front or back to the right level Front height lever The front edge rises or lowers pivoting about...

Page 67: ...levers 6 Seat complete slide lever Move the seat complete slide lever to the right to disengage the lock then slide the entire seat unit forward or backward You can adjust the position of the seat complete forward and backward without changing the positional relationship between the seat and the left right control levers 7 Weight adjustment dial optional Turn the dial to adjust the suspension ﬁrmn...

Page 68: ...e belt attachment bracket and belt are not defective in any way Replace it if it is worn or damaged Do not put on the seatbelt twisted 01E0 0103 0E 12 Hour meter This operates while the engine is running and indicates the cumulative total number of hours the machine has been running 13 Hot cool box The hot cool box can keep contents heated or cooled using the temperature setting switches of the ai...

Page 69: ...power supply ports Using a device that is not suitable for the power supply could cause a malfunction Do not use it to power the cigarette lighter T218341 130 0E 16 Emergency stop switch If the engine cannot be shut oﬀ using the starter switch shut the engine oﬀ by pressing the stop side of the emergency stop switch Once the engine has stopped switch the emergency stop switch back to the normal si...

Page 70: ... of the broken glass fragments when escaping T218081 022 0E 18 Fire extinguisher optional It is possible to mount a fire extinguisher behind the operator s seat Contact your authorised KATO dealer for installation 19 Drink holder The holder features a soft material that helps minimize swaying of cans and plastic bottles due to vibration and can hold a smartphone or other device securely without wo...

Page 71: ...ly into the lock or release position Do not operate the machine with the lever in an intermediate position Take care not to touch the control levers when getting on or oﬀ the cab Do not use the safety lock lever as a hand grip when getting on or oﬀ the cab Do not touch the control levers while moving the safety lock lever 01E0 0110 0E 2 Console lock lever Before starting work check that the consol...

Page 72: ...nd off and when cancelling warm up running Refer to the sections Engine warm up runnning and Auto slow mode settings for instructions on how to use this switch 5 High power switch Use this switch to work the machine at high power Refer to the section High power mode setting for instructions on how to use this switch Do not use the high power switch when working with the arm longer than the standar...

Page 73: ...achine forward Pull the left and right traveling control levers simultaneously to move the machine in reverse Be sure of the positions of the traveling motors when traveling When the traveling motors are turned to the front the directions of operation of the traveling control levers are reversed Before moving oﬀ check that the surrounding area is safe and sound the horn regardless of whether you a...

Page 74: ...certain level so that the engine which is mounted on this machine can keep the ingredient of the exhaust gas below the regulation level If you move the control lever suddenly for relief etc at engine low idling speed the engine could stall Avoid sudden lever operation at engine low idling speed If you cannot avoid sudden lever operation absolutely use the accelerator dial to raise the engine speed...

Page 75: ...d bucket before you use it in this way 08E0 0017 0E If you are backhoeing while the dozer blade is in front work with caution because the bucket could hit the blade if you move it while the arm is fully drawn in 08E0 0018 0E If you perform the compound operation including the dozer operation at low idling the engine could stall Use the accelerator dial to raise the engine speed to a medium speed o...

Page 76: ... few seconds for the monitor to go out even if the engine has stopped This is for circuit protection and is quite normal When you leave the operator s seat take the key with you ACC If you use the radio or other accessories for long periods while the engine is stopped the battery will run down Do not use the radio etc for long periods ON The APC system runs self diagnostic checks for approximately...

Page 77: ... once the maximum revolutions set for each mode in use is reached the engine speed will not rise further even if the dial is turned further NOTE If the auto slow one touch slow or automatic warm up functions is working the engine speed is predetermined without reference to the accelerator dial position Set the accelerator dial to the position when starting or stopping the engine 01E0 0120 0E ...

Page 78: ...onal If this switch is set to ON the buzzer sounds whenever you operate traveling controls 4 Accessory USB power supply port optional The USB power supply port can be used for device that requires 5V power 1 2 A 2 ports Only type A USB connectors can be connected Do not attempt to connect any other type of connector Only use the ports for devices that require up to 1 2 A of power per port or up to...

Page 79: ... the pump and control of the engine speed using the accelerator dial regardless of the type of malfunction When operating in the backup mode the engine may stall or produce black smoke more often than usual If the backup switch is used as instructed on the monitor be sure to contact your authorised KATO dealer Normally conﬁrm that the switch is in the AUTO position and close the cover T218081 028 ...

Page 80: ... If this swing lock system malfunctions and slewing operations can no longer be performed properly a message will appear on the monitor display If this message appears switch the swing lock release switch to the RELEASE position and contact your authorised KATO dealer When the swing lock system is normal never set the swing lock release switch to the release position It is dangerous because the sw...

Page 81: ... clock 7 SOUND button Adjusts the sound balance bass and treble 8 LCD display Displays the frequency clock etc 16EE 0111 1E 2 LCD display Name Function 1 Segment display large Displays the band name frequency clock and other alphanumeric information 2 Segment display small Displays frequency during FM 50 kHz step mode 3 ST indicator Illuminates to indicate stereo signal reception when FM1 or FM2 b...

Page 82: ...n DISP Short press Switches between display modes frequency clock frequency etc Switches adjustment parameter hours minutes enter Long press Switches to clock adjustment mode only if clock is displayed Sound adjustment PWR Short press Switches power OFF Long press AM FM Short press Switches between bands FM1 FM2 AM FM1 etc Long press VOL VOL Short press Adjusts volume 1 step up or down Long press ...

Page 83: ...the system is operated correctly 1 SCR system status display The status of the SCR system can be conﬁrmed based on the DEF level meter DEF indicator check engine lamp and message display If the above warning message is displayed on the monitor the engine output and speed will be successively restricted in stages and the engine speed will be eventually ﬁxed at a low idle speed Promptly take necessa...

Page 84: ...ictions can be conﬁrmed based on the warning display in the table below 1 If the DEF level is too low 2 If an SCR system error or DEF quality error occurs NOTE If the error is detected again within 40 hours after eliminating the error the switching time to severe operating restrictions will be shortened to 30 minutes The warning alarm beeps whenever the warning stage changes T218081 138 0E ...

Page 85: ...able the output restrictions NOTE The escape can be used a maximum of 3 times only once when severe operating restrictions are applied However the number of times diﬀers depending on the remaining time before the severe operating restrictions will be applied Once the escape mode is activated it is continued for 30 minutes and it cannot be stopped If the starter switch is turned OFF and then turned...

Page 86: ...013 0E 1 During automatic purging The automatic purging cycle occurs automatically approximately every 30 hours No other special operations are required during automatic purging so normal operations can be performed as usual The following message is displayed during automatic purging During automatic purging an auxiliary control system functions to ensure purging can be ﬁnished eﬃciently Consequen...

Page 87: ... PURGING STOPPED message will be displayed again to enable resuming T218341 015 0E 3 Automatic purging requested Automatic purging normally occurs automatically approximately every 30 hours but sometimes it does not occur depending on the water temperature and engine speed status If no purging has occurred for a certain period of time the warning alarm may beep with the following message displayed...

Page 88: ...e following procedure The following message is displayed during manual purging During manual purging the engine speed is ﬁxed at a medium speed regardless of the accelerator dial position Manual purging takes about 16 minutes to ﬁnish Note Purging time may vary depending on the external air temperature and other factors If the engine water temperature or hydraulic oil temperature is low the engine...

Page 89: ...time the following message may be displayed for a moment for 1 minute but that is normal After that the manual purging will be requested Purge the system manually according to the section 3 9 2 Manual purge control Regardless of the above if PURGE CONTROL ERROR message is displayed then purging is not possible If that occurs promptly contact your authorised KATO dealer T218341 020 0E NOTE During p...

Page 90: ...open each cover and engage the stopper securely Completely open the hood and toolbox cover If you open the cover of the machine on a slope or in a strong wind the cover could close unexpectedly causing injury Always close each cover and lock it before you start to travel or operate the machine Never travel or operate the machine with the cover open 01E0 0142 0E ...

Page 91: ...nd behind the machine from the seated position Stow the mirrors when transporting the machine T218081 193 0E 3 Grease pump The grease pump can be stowed in the left machine compartment Put the lever into the holder to stow the pump When stowing the grease pump make sure it does not contact the battery terminals Doing so may short the battery 01E0 0562 0E ...

Page 92: ...press the washer switch while the tank is empty or continue to hold the switch down for a long period you could cause the pump to break down so reﬁll the tank before it becomes empty 01E0 0144 0E 5 Aerial During transport rotate the aerial obliquely downward to the stowed position To use the radio rotate the aerial upward to the deployed position The aerial can only be rotated in the prescribed fo...

Page 93: ...information of the clock and the tuning information of the radio are lost Also do not turn the switch to the OFF position within 5 minutes after the engine stops Before starting the engine make sure that the switch is located at the ON position Never turn the switch to the OFF position when the engine is running Otherwise the electrical system may get damaged Do not turn the switch to the OFF posi...

Page 94: ... direction of the working lamp is changed retighten the swivel section bolt The working lamp might angle down during operation when working with the bolt untightened NOTE Tightening torque 16 7 18 6N m 170 190kgf cm 8 Toolbox The toolbox is not waterproof or dustproof Rain water dust sand or other matter can get inside the box Therefore do not store anything in the box that should not get wet or d...

Page 95: ... on the fuel tank NOTE Refer to the separate fuel pump instruction manual regarding the speciﬁcations performance etc Always ﬁll with fuel of the designated type and grade If you use a non recommended fuel performance will be impaired and a major accident could result Stop the engine and turn the starter switch to OFF before you start ﬁlling Park the machine in a well ventilated place and check th...

Page 96: ...tional Depending on the combination of attachments used the attachments could contact the rain visor and cause damage Be especially careful to confirm that there is no interference between attachments and the rain visor before staring operations T218081 034 0E ...

Page 97: ...urn ﬁlter Replace 100h Element Inspection and servicing section 4 2 4 After initial replacement replace every 1000 hours Drain ﬁlter Replace 100h Cartridge Inspection and servicing section 4 2 8 After initial replacement replace every 1000 hours Traveling motor reduction gear oil Replace 500h Gear oil Inspection and servicing section 4 3 3 After initial replacement replace every 1000 hours Swing m...

Page 98: ...r to the corresponding sections in the Inspection and servicing Set the machine level for the preoperational checks If you discover any damage breakdown or malfunction repair it immediately Do not leave it for later and do not start work before it is repaired For the inspection and replacement methods for the engine refer to the separate engine manual The inspection intervals for this machine are ...

Page 99: ...nnot start the engine unaided use the booster cables to start the engine referring to How to start the engine using the booster cables in the section Inspection and servicing Recharge the ﬂat battery before using it again If the safety lock lever is in the release position you cannot start the engine If the message ENG EMERGENCY STOPPED appears on the display press the normal side of the emergency...

Page 100: ...fail to start the engine turn the starter key to the OFF position before trying again 01E0 0161 0E NOTE If you don t turn the starter key back to the OFF position before restarting the engine the engine speed control will become unstable NOTE Even after the engine warming period is over the engine will run at medium speed for a few seconds 4 When there are no problems in the APC system and there a...

Page 101: ...celed but the hydraulic oil was not suﬃciently heated the message HYD OIL LOW TEMP is displayed on the monitor If this message is displayed on the monitor follow the procedure below for hydraulic oil warm up running You must pay particular attention to warm up running in winter and cold regions Excessively cold hydraulic oil can have an adverse eﬀect on hydraulic equipment If you start work before...

Page 102: ...turn it to the neutral position Repeat steps and until the HYD OIL LOW TEMP message disappears from the screen On the ﬁrst warm up operation do not move anything other than the arm and bucket 01E0 0167 0E Go slowly through each of the following operations 3 5 times to conﬁrm that each works correctly NOTE If you do not work through all of the above operations there may be lags in starting and stop...

Page 103: ...ors are turned to the front the directions of operation of the traveling control levers are reversed Before moving oﬀ check that the surrounding area is safe and sound the horn regardless of whether you are going to move forward or in reverse Do not move the control levers suddenly i e sudden moving off or stopping reversing levers These can cause the machine to tip over particularly on sloping ro...

Page 104: ...ily before beginning a spin turn 01E0 0179 0E 6 3 2 Precautions on traveling 01E0 0180 0E 1 When traveling always try to steer in the largest possible curves Avoid rapid spin and pivot turns and similar maneuvers because they have adverse eﬀects on the rollers track links and the frame etc In narrow places or rocky ground make many tacks to complete maneuvers 2 When traveling over long distances d...

Page 105: ...hen climbing out of water at a steep angle 15 degrees or steeper the back end of the upper structure can become immersed in water causing the radiator fan to splash the water If the fan splashes the water it can damage the fan by bending the blades Be very careful of the water level when climbing out of water 3 If water reaches the level of the swing gear bearing section inject grease into the bea...

Page 106: ...d and stones Running the lifted track shoe alternately forward and backward is a simple way to remove mud and stones NOTE Refer to the section Jack up procedure for the correct way to jack up the machine 6 3 4 Precautions on traveling on unﬁrm ground surfaces T218081 152 0E When you are traveling on unﬁrm ground surfaces such as sand and pebbles set the traveling mode selection switch to slow spee...

Page 107: ...the machine press the flat portion of the bucket s base slowly against the ground When doing so keep the angle between the arm and the boom in the range of 90 110 After jacking up always place a block or other secure support under the traveling frame for safety to support the machine Place the front attachment in a stable position stop the engine and move the safety lock lever to the lock position...

Page 108: ...es and keep to moving straight ahead wherever possible 3 Avoid turning while moving up or down a slope if at all possible Never change direction on sloping ground or attempt to traverse along the slope Descend to ﬂat ground and make a detour in order to travel safely 4 This machine is ﬁtted with a parking brake on each of the traveling motors but if you have no alternative but to park the machine ...

Page 109: ... for excavation is prohibited Never use swing force to push projections embankments stones etc with the side of the bucket Doing so could damage the machine Precaution when swinging on a slope Avoid swinging on sloped ground because you risk tipover or lateral sliding In particular inertia acts when swinging towards the bottom of a slope with a full bucket When working on a slope make the ground b...

Page 110: ...he safety lock lever to the release position 3 Sound the horn to warn the people nearby 4 Check the safety of your surroundings and then begin to swing 5 When you stop swinging return the control lever to its neutral position ...

Page 111: ...ing the arm the most eﬃcient range is with the arm angle between 45 forward and 30 towards the machine 3 Work with the arm when digging If you operate the arm and the bucket enters the ground operate the bucket cylinder so that the bucket points move parallel with the ground surface If the action of the arm becomes sluggish due to resistance to digging lift the boom slightly 4 Move the bucket poin...

Page 112: ...sing the boom slightly and when the arm goes past the vertical position lower the boom slowly so that the bucket moves horizontally Never use swing for ground leveling because it is harmful to the boom and arm Do not level ground by traveling about and pressing the bucket repeatedly down onto the earth This method puts a great load on the machine and can cause a breakdown 01E0 0197 1E 6 5 4 Loadin...

Page 113: ...ch its position carefully 01E0 0200 0E 1 Refer to the Bucket replacement and reversal section when switching the bucket arrangement between shovel and backhoe work 2 During shovel work dig so that the arm cylinder is used to scrape oﬀ material Do not dig deep at one time but do as scraping oﬀ the face thinly 3 In areas prone to the inﬂow of groundwater a slope of 2 3 is convenient for drainage NOT...

Page 114: ... engine speed to a medium speed or higher about 1400min 1 before you perform the compound operation T218601 013 0E 2 Precautions on using the dozer blade 1 Watch out for collisions against the dozer blade Impact against the dozer blade can break it or the attached cylinder so beware of collisions with rocks and other obstacles 2 Precautions on using the dozer as a jack When you use the dozer blade...

Page 115: ...e boom cylinder during deep excavation If you are making a deep excavation while the dozer blade is in front work carefully to avoid damaging the boom against the dozer blade 4 Do not hit the bucket against the dozer blade when the dozer blade is in front ...

Page 116: ...mplete stop pull out the key from the starter switch If the engine cannot be shut oﬀ after above step stop the engine by pressing the stop side of the emergency stop switch Return the emergency stop switch back to the normal side after the engine has completely stopped If you stop the engine while the turbo system is hot oil residues will be carbonized which will cause wear to bearings and impair ...

Page 117: ... this is the normal noise of their operation 2 The control valves may make a noise when you operate the boom or arm but this is the normal noise of their operation 3 Vibration of the machine body may become strong when you start the engine or when the engine is near idling speed but if you raise the engine speed slightly this resonant vibration will cease 4 When the engine is idling and you operat...

Page 118: ... function correctly The monitor is accurately adjusted Humidity or dust may cause a malfunction so never take it apart or otherwise open the case If the display section shows a warning message indicating a malfunction during work or the preoperational checks follow the instructions and if necessary contact your authorised KATO dealer for advice on how to proceed The display is not intended to guar...

Page 119: ...ter startup only when equipped with a crane 2 Standard screen display NOTE Holding down the home switch results in the power mode switch being selected so that the wiper washer menu and home membrane switches can be selected or executed When the membrane switches are enabled each press of the home switch changes the selected switch in the following sequence power mode switch traveling mode switch ...

Page 120: ... and is suitable for experienced operators E mode Prioritizes fuel economy NOTE Given default settings the A mode is automatically selected when the system is started up To change the power mode or to specify starting up with the same power mode setting as the previous time the key switch was turned OFF touch Menu and then Startup Mode 4 Traveling mode switch This switch can be used to check the t...

Page 121: ...es 2 Attachment mode types and characteristics Bucket mode This mode is suitable for digging operations Breaker mode This mode switches the hydraulic oil flowrate to the flowrate specified during breaker operations Crusher mode This mode switches hydraulic circuits to those suitable for crusher operations NOTE The breaker and crusher modes are disabled if the hydraulic lines or other equipment for...

Page 122: ...ne speed decreased to the auto slow speed It increases to the speed set using the accelerator dial When the auto slow mode is active an auto slow icon is displayed where the slow down icon is displayed NOTE Be sure the accelerator dial is set to a speed higher than the auto slow speed whenever the auto slow mode is speciﬁed The auto slow mode is canceled if the accelerator dial is turned to a posi...

Page 123: ...own icon is displayed NOTE The speed setting for the one touch slow mode single click can be changed by touching Menu and then One Touch Slow Initially the speed is set to the low idle speed when shipped from the factory so that either single or double clicking changes the speed to the low idle speed 7 High power mode Digging force can be increased for about 10 seconds by pressing the high power s...

Page 124: ...lue zone The warm up mode starts automatically after starting the engine but if the engine coolant temperature is still too low after the automatic warm up mode is canceled then warm up the engine The engine coolant temperature is high when the needle is in the red zone If the engine overheat warning is displayed reduce the engine speed to a medium speed and wait for the coolant temperature to dec...

Page 125: ... For the oﬃcial number of operating hours refer to the hour meter shown on the right T218081 043 0E 16 Camera images This shows the images from the attached cameras Images from two cameras can be displayed simultaneously optional An indicator displayed on the screen indicates the image signal is normal If the full screen mode is speciﬁed by touching Menu and then Camera Image the camera image appe...

Page 126: ...r operating the machine T218081 142 0E 17 Light switch This switch illuminates the working lamps The light mode changes each time the light switch is pressed in the sequence OFF Light 1 Light 2 OFF The working lamp illumination status changes based on the light mode Light mode 1 The working lamp on the right side of the machine is illuminated Light mode 2 The working lamps on the right side of the...

Page 127: ...ng the wiper will stop To resume wiper operation close the front window and press the wiper switch again If you work the wiper while the front window is dry muddy or frosted the wiper could be damaged and the fuse might blow T218081 044 0E 19 Washer switch Washer ﬂuid is sprayed onto the front window and the wiper operates continuously as long as the washer switch is pressed The wiper will continu...

Page 128: ...een is displayed again Pressing one of the following menu switches displayed on the menu screen displays the corresponding menu NOTE By holding down a menu switch when the menu screen is displayed menus can be selected by pressing the wiper washer or menu switches Wiper or washer switch Changes the selected menu switch Menu switch Executes the selected menu switch ...

Page 129: ...the usage hours have exceeded the replacement period 2 Maintenance items Lists items that require maintenance 3 Page up down switches Scrolls up or down through the list to display hidden items 4 Return switch Returns to displaying the menu screen 22 Usage time Displays the cumulative time since the last time it was reset The value can be reset after replacing the corresponding ﬁlter or oil by pre...

Page 130: ...0 4500 Service meter A Not speciﬁed Not speciﬁed Service meter B Service meter C T218341 026 0E The swing gear oil and DEF ﬁlter replacement periods vary depending on the model For the swing gear oil replacement period refer to 3 4 Greasing chart For DEF filter replacement periods refer to 4 1 5 DEF pump ﬁlter and 4 1 6 DEF tank suction ﬁlter T218341 027 0E The replacement period value can be chan...

Page 131: ...orking at night then use the light switch to adjust the brightness with the working lamps illuminated The changes will not aﬀect monitor brightness when the working lamps are not illuminated 25 Camera image settings The image displayed in the camera image display area can be changed 1 Camera 1 selection switch Displays the image from camera 1 2 Camera 2 selection switch Displays the image from cam...

Page 132: ... 116 7 Monitor 7 Selected camera image Outputs the selected camera image NOTE The displayed image can also be changed by touching the camera image ...

Page 133: ...m speed 2 auto slow mode 4 Enter switch Enters the speciﬁed auto slow speed value 5 Return switch Returns to displaying the menu screen without entering changes to the auto slow speed value The medium 1 and 2 speed levels diﬀer depending on the model T218081 145 0E 27 One touch slow setting The engine speed for the one touch single click slow mode can be changed to any speed value 1 One touch slow...

Page 134: ...te and time settings Be sure to adjust the time setting if an incorrect time is displayed Adjust the time setting by pressing the corresponding increase decrease switches Press to increase or to decrease the setting Press the enter switch to enter the time setting Press the return switch to cancel any setting changes and return to the menu screen The displayed date time is updated after pressing t...

Page 135: ... 047 0E 3 Breaker mode settings can be changed Breaker ﬂowrate display Displays the speciﬁed ﬂowrate value The indicated ﬂowrate diﬀers depending on the model Breaker ﬂowrate increase decrease switches Increases or decreases the ﬂowrate The maximum ﬂowrate minimum ﬂowrate and amount of change diﬀer depending on the model Pressure setting display Displays the speciﬁed relief valve pressure setting ...

Page 136: ... is required to change the pump merging circuit mode or pressure setting For more details contact your authorised KATO dealer 5 Startup mode settings These settings can be used to change the mode speciﬁed for after turning the starter key switch ON Startup power mode switch This can be used to select the power mode speciﬁed for after startup For a description of each mode refer to 2 Power mode typ...

Page 137: ...tion is displayed Engine hour meter Indicates the cumulative number of hours the engine has been operated since the setting was last reset Idling time Indicates the cumulative number of hours the engine was running without a control lever being operated since the setting was last reset Fuel consumption Indicates the average fuel consumption rate since the setting was last reset Engine rpm Indicate...

Page 138: ...nditioner operation screen 1 Air outlet mode switch This switch can be used to change the air outlet location Touch the air outlet mode switch The selectable air outlet modes are displayed Touch the desired air outlet mode bi level for example The air outlet mode switch indicator changes ...

Page 139: ...s canceled if the air outlet mode is changed 2 Interior exterior air mode switch This switch can be used to switch between recirculating the interior air or intaking exterior air Touch the interior exterior air mode switch The selectable candidate modes are displayed Touch the desired mode interior air mode for example The interior exterior air mode switch indicator changes Switching between the i...

Page 140: ...ed and air outlet mode When OFF the air conditioner is controlled manually 5 Air conditioner ON OFF switch This switch is operated to switch the air conditioner ON or OFF The air conditioner operation is enabled when ON When switched ON the air conditioner operating mode is set to the same mode that was speciﬁed when the air conditioner was last switched OFF If the switch is OFF air conditioner op...

Page 141: ...ioner will start operating in manual mode fan speed level Lo 7 Temperature setting increase decrease switches The cab temperature can be speciﬁed by pressing these switches Each press of the temperature setting increase switch increases the temperature setting by 0 5 C Each press of the temperature setting decrease switch decreases the temperature setting by 0 5 C The temperature setting can be ch...

Page 142: ...es are generated they can be viewed by pressing the next or previous page arrows The message page number and total number of pages are displayed A maximum of eight messages can be displayed Some measures require an operation after reading the message For such messages a checkbox is displayed that must be checked to enable the OK button Pressing the OK button executes various actions ...

Page 143: ...ill continue to sound until the starter switch is turned to the OFF position Stop the engine Contact your authorised KATO dealer ENG OVERHEATED STOP ALARM The engine has overheated An alarm sound is emitted if this screen is displayed The engine will not shut OFF until the engine water temperature decreases below a specified temperature The alarm sound can be shut OFF by checking the checkbox and ...

Page 144: ...properly if the backup switch is in the backup position switch it back to the auto position FAILED TO STOP ENG USE EMERGENCY STOP SWITCH Displayed if the engine does not shut off when the starter switch is turned OFF After shutting the engine off move the emergency stop switch back to the normal position Use the emergency stop switch to shut the engine oﬀ Contact your authorised KATO dealer SCR SY...

Page 145: ...l times Replenish the DEF ECU ERROR BACKING UP Displayed if an ECU error occurs and engine speed and output are restricted Contact your authorised KATO dealer PURGE CONTROL ERROR Displayed if a purge control error occurs Contact your authorised KATO dealer MANUAL PURGE REQUESTED START PURGE Displayed if manual purging is required Promptly purge manually OPENING FRONT WINDOW Displayed if the wiper ...

Page 146: ...d as follows Press the quick accelerator switch Turn the accelerator dial to a medium speed or higher and move the levers ELECTRIC SYSTEM ERROR Displayed if an open or short circuit occurs in a switch or other such circuit Various modes do not function normally Contact your authorised KATO dealer ECU ERROR Displayed if an ECU error occurs Contact your authorised KATO dealer MANUAL PURGING Displaye...

Page 147: ... 131 Lifting a load 8 Lifting a load 8 Lifting a load 01EE 0601 0E 8 1 Precautions on lifting 01EE 0602 0E 8 1 1 Precautions on lifting a load using the hydraulic excavator T218621 010 0E 1 HD514MR 7 ...

Page 148: ... 132 8 Lifting a load 2 HD514MR LC 7 ...

Page 149: ...pping the ring When lifting a load with the bucket hook be careful not to let the sling wire rope etc contact the bucket etc If the wire rope contacts the bucket when lifting a load it can lead to wire rope damage resulting in a major accident 01E0 0225 0E 2 Determine signals for the lifting operation designate a signaler and follow the instructions of that signaler 3 Set the machine level on the ...

Page 150: ...he load as low as possible 1 If you travel with the load suspended carry the load in front 2 Carry the load at a height where the bottom is not more than 0 3m above the ground 3 Keep traveling speed less than 3 0km h 0 84m s 4 Conﬁrm that the travel surface is ﬂat 1 or less and ﬁrm 5 If you travel with the load suspended travel in a manner that minimizes load swing and if any problem occurs stop t...

Page 151: ...d load check that there are no people or obstructions within the swing radius and sound the horn as a warning to avoid hitting anybody etc with the load and try to swing slowly 10 If you attach a hook after taking delivery of the machine contact your authorised KATO dealer ...

Page 152: ... 8 3 1 Wire rope 01E0 0229 1E 1 A wire rope used for lifting must have a factor of safety of at least six 6 2 Replace the wire rope in any of the conditions below 1 When 10 or more of the component wires excluding filler wires in one pitch are broken 2 When the diameter has reduced by 7 or more of the nominal diameter 3 When the wire rope has twisted into a kink ...

Page 153: ... time of manufacture 3 The reduction of diameter of the cross section of the lifting chain link must be less than 10 of the diameter at the time of manufacture 4 There must not be any cracks 8 3 3 Inspection 01E0 0231 0E 1 Inspect the wires chains and other lifting accessories and confirm that there is nothing abnormal about them before you lift a load 2 In periodic independent inspections examine...

Page 154: ...ying out team operations such as pin insertion and cylinder extension retraction take care to work safely with good exchange of signals and communication between all those concerned 01E0 0235 1E 9 1 1 Removal 01E0 0236 1E 1 Rest the bucket to be replaced on ﬁrm level ground Fig NOTE When you are extracting the pins make sure that the bucket is only resting lightly on the ground If it is pressed st...

Page 155: ... holes ⓑ and insert the steel bushes into the holes Line the arm tip holes up with the bucket holes ⓑ which have the steel bushes inside and insert bucket pin B Fig NOTE The ﬁt is good enough to ensure that the pin can be inserted as long as the centers of the holes are aligned so do not hit the pin or otherwise apply excessive force Line the pin up with the rotation stopper hole and check the pin...

Page 156: ... the bucket moves your hand or ﬁnger could be severed 01E0 0239 0E When mounting the bucket check to ensure that the steel bushes are ﬁtted in place The arm tip and tipping link have dust seals ﬁtted on both ends so take care not to damage them when inserting the pin When attaching the locknuts leave a gap of 2mm 01E0 0240 2E ...

Page 157: ...f it is pressed strongly against the ground the resistance on the pins will be increased making them harder to extract 2 Roll the pin seal O rings onto the bosses of the bucket Fig 3 Remove the retaining nuts and bolts and extract bucket pins A and B Fig 4 Raise the boom slightly and separate the bucket from the arm Fig 5 Remove the pin seal O rings Take care not to get grit or mud on the extracte...

Page 158: ...herwise apply excessive force Line the pin up with the rotation stopper hole and check the pin s orientation before you insert it 5 Fit the pin seal O rings onto the inside of the bosses of bucket holes ⓑ insert the steel bushes into the holes and raise the boom or the arm to lift the bucket Then adjust the cylinders so that bucket pin A can be easily inserted into the bucket holes ⓑ which have th...

Page 159: ...et play T218341 030 0E This machine is equipped with a mechanism for adjusting play on the bucket This mechanism uses the successive insertion of shims to eliminate the play in the connection between the arm and the bucket which builds up due to wear This has the multiple eﬀect of maintaining the sealing condition of the O rings and delaying the advance of wear increasing the longevity of bushes p...

Page 160: ...ance but could also cause a serious accident Such problems are not subject to guarantee 01E0 0251 1E 2 Lubricant Replace the lubricant used in respective equipment with low viscosity lubricant Refer to 3 3 Recommended lubricants table in the inspection and servicing section regarding specified viscosities 3 Long Life Coolant To prevent the water freezing during shipping for delivery Long Life Cool...

Page 161: ...st drain all water from the engine and radiator at the end of work Place a clear sign to warn No coolant to avoid problems the next morning 5 If there is water on the part of the key which you insert into the lock of the toolbox or elsewhere it could freeze overnight and jam the lock Always wipe water oﬀ the part for the key 10 2 Handling under extreme heat T218081 210 1E When using this machine u...

Page 162: ...ironment T218081 051 0E 1 After using the machine in a dusty or sandy environment check for blockages in the air cleaner element more frequently than the usual inspection interval and wash or replace the element early 2 Always keep the hydraulic oil and fuel ﬁller caps securely closed so that dust and sand cannot enter the hydraulic equipment 3 Keep the pins bushes and other greased parts clean an...

Page 163: ...rical devices and hydraulic cylinders to prevent corrosion Also grease with care 10 5 Handling in mud rain snow zones of high humidity on soft ground 01E0 0257 0E Humidity and mud attack paint wiring and metal parts causing corrosion When working under site conditions such as these keep the machine as dry as possible and grease it thoroughly and carefully 10 6 Handling in rocky ground 01E0 0258 0E...

Page 164: ...itch to the OFF position When you turn the battery disconnect switch to the OFF position all electric circuits are cut oﬀ and the time information of the clock and the tuning information of the radio are lost T216801 067 0E 4 Coolant If there is any risk of the coolant freezing mix it with antifreeze Normally the coolant is mixed with Long Life Coolant so no change should be required 5 Storage pos...

Page 165: ...f engine oil and coolant and top them up if necessary Thoroughly wipe the anti corrosion oil oﬀ the cylinder piston rods After starting the engine and running it for an adequate warm up period go through the motions of traveling swing and digging several times until each part moves smoothly ...

Page 166: ...et out of soft ground etc by its own traction or for towing heavy loads attach wire ropes of adequate strength to the traveling frame and pull Place wooden blocks between the wire ropes and the traveling frame to prevent chaﬁng damage to either side Perform towing operation slowly at 1 km h or less within a few meters Allowable towing force 109000 N 11100 kg 2 How to tow light objects Use the brac...

Page 167: ...ading the machine Never use the front attachment to jack up the machine for loading and unloading the machine as this is extremely dangerous Keep the angle of the ramps to 15 or below Arrange the gap between them so the center line of the machine will lie on that of the trailer and that the track shoes of the machine will pass along the center of each one Use ramps which have an ample margin of st...

Page 168: ...es and other conditions along your intended route In particular check limitations on the operating weight and height of the machine imposed by bridges tunnels etc 3 Selection of the truck and trailer Choose a truck or trailer that is suitable for the operating weight and overall height width and length of the machine 4 Position for transportation Always rotate the aerial obliquely downward before ...

Page 169: ...ns Adjust the wire rope positions for securing the machine within the range indicated below Use four wire ropes of the same length Use a shackle that meets or exceeds JIS B 2801 SB38 standards minimum operating load capacity of 88 3 kN in four locations Use wire ropes with a nominal diameter of at least 31 5 mm minimum breaking strength of 672 kN as speciﬁed in JIS G 3525 IWRC6 Fi 29 in combinatio...

Page 170: ...ection and position If you attempt to turn or swing while on the ramps there is a strong danger that the machine will fall oﬀ If turning or swing is required retreat to level ground turn or swing as necessary then climb the ramps Check that the door is locked in place whether it is open or closed Do not open or shut the door while the machine is on the ramps 01E0 0269 0E 6 Take care when moving ov...

Page 171: ...yone else to do so 01E0 0271 0E 1 Start the engine and set the machine to the speciﬁed hoisting position 2 Move the safety lock lever to the lock position 3 Stop the engine check around the operator s seat for safety and then leave the machine Close the front window side window and door 4 Check that the engine hood and machine compartments are securely closed 5 Attach wire ropes to the designated ...

Page 172: ...8611 017 0E The cab excluding the demolition cab conforms to ISO 12117 2 ROPS and ISO 10262 top guard FOPS level I without the cab guard installed When the cab guard is installed on the demolition cab it conforms to ISO 10262 top guard FOPS standards T218611 020 0E ...

Page 173: ...icants added at the factory 177 3 3 Recommended lubricants table 179 3 4 Greasing chart 181 3 5 Oiling chart 183 4 Inspection and servicing of each part 184 4 1 Engine related 185 4 2 Hydraulic system related 213 4 3 Travel related 226 4 4 Swing related 229 4 5 Front attachment related 230 4 6 Electrical system related 232 4 7 Air conditioner related 238 4 8 Cab and control system 245 ...

Page 174: ...mic performance Refer to the inspection and servicing points and methods described below and observe them correctly 1 Regular independent inspection Draw up an inspection and servicing schedule and implement it 2 Keeping independent inspection records The regular independent inspection must be carried out the results recorded and preserved 3 Repair of broken or malfunctioning parts If you discover...

Page 175: ...our authorised KATO dealer is forbidden 6 Repairs to the boom and arm require special techniques Contact your authorised KATO dealer 7 Wear protective clothing and equipment Wear a helmet protective goggles safety boots gloves etc when inspecting and servicing the machine Metal splinters can fly off when you are using a hammer or grinder so always wear proper protective clothing and equipment when...

Page 176: ...eck with thick paper or wood shavings Do not detect oil leakage by naked hand or ﬁnger Wear protective goggles to protect your eyes If oil penetrates your skin consult a doctor well experienced immediately 11 Precautions on replacing seals etc After you remove an O ring or other seal wash the surfaces on which it was ﬁtted before you ﬁt the replacement Before you fit an O ring or other seal check ...

Page 177: ...breakdowns 15 Dispose of waste oil carefully If you dispose of waste oil used ﬁlters and other waste products of the machine carelessly you will cause environmental pollution When you drain waste oil from the hydraulic equipment or oil reservoir catch it in a proper container Waste oil is environmentally harmful Dispose of it thoughtfully Never allow it to pour onto the ground or dump it in stream...

Page 178: ... work carefully to avoid wetting the electrical equipment 18 Precautions when working in high places When you are working in high places take precautions to avoid falling oﬀ Keep the area you are standing on tidy no tools scattered around and clean wipe oﬀ any spilled oil or grease and walk carefully to avoid slipping When climbing and descending use the hand grips and platforms and always keep yo...

Page 179: ...s from hot paint Employ a qualified welder for the job and carry it out in a properly equipped place 23 Basic precautions before welding Turn the starter switch to OFF Turn the battery disconnect switch to the OFF position Cut away the paint from the area to be welded so that it cannot produce gas Attach an earth connection within one meter of the weld point with no O rings or bearings between the...

Page 180: ...isconnect switch to the OFF position wait for at least 5 minutes after the starter switch is set to the OFF position 25 The equipments are hot immediately after the engine stops The equipments are hot immediately after the engine stops so you could be burned if you touch them In particular the engine silencer oil reservoir coolant radiator sliding parts hydraulic equipment pipes etc will be very h...

Page 181: ...ock all inspection covers If you leave the inspection covers open they can swing shut suddenly when the wind blows and trap ﬁngers etc When you open an inspection cover or cab door always use the stopper to lock it securely in the fully open position When there is a strong wind do not open the door or covers 29 Prevent ﬂying parts The grease inside the adjuster cylinder is under high pressure Igno...

Page 182: ...d carry out each inspection item when one of the times is reached whichever occurs sooner If you discover any damage breakdown or malfunction repair it immediately Do not leave it for later and do not start work before it is repaired For the inspection and replacement methods for the engine refer to the separate engine manual The inspection intervals for this machine are based on standard operatio...

Page 183: ... 166 2 Inspection and servicing table 1 Part names for inspection and servicing ...

Page 184: ... 167 Inspection and servicing table 2 Inspection and servicing table ...

Page 185: ... 168 2 Inspection and servicing table ...

Page 186: ...very 6 months or 500h Yearly or 1000h Oil Part to change Reference section Pre operationa Operation section Inspection and servicing section General appearance External dents or damage Inspect 4 External damage of devices and equipment Inspect 4 Looseness of bolts and nuts Inspect 4 Looseness short circuit or damage of the wiring Inspect 4 Engine related Engine and engine mounting Does the engine ...

Page 187: ...nd intercooler cores ﬁns expansion tank and reserve tank Inspect and clean 4 1 14 Coolant Check for dirt and check oil level 4 1 14 Replace 1 Coolant 4 1 14 Radiator cap function Inspect 4 1 14 Water leakage from each part including check for damage or deterioration to hoses Inspect 4 1 14 Fan damage and attachment status Inspect 2 Air intake system Air cleaner element outer Inspect 4 1 13 Clean 4...

Page 188: ...r 4 1 6 SCR system Inspect 5 Separate engine manual Exhaust system Device to prevent diversion of carbon monoxide and other gases EGR valve Inspect and wash 5 Separate engine manual EGR cooler Inspect and wash 5 Separate engine manual Hydraulic system related Oil reservoir Hydraulic oil Check for contami nation 4 2 1 4 2 5 Check oil level 4 2 1 4 2 5 Replace 2 Hydraulic oil 4 2 5 Suction strainer ...

Page 189: ...spect 2 Oil leakage Inspect 2 Track roller Wear deformation Inspect 2 Attachment bolt Inspect 2 Oil leakage Inspect 2 Sprocket Wear deformation Inspect 2 Attachment bolt Inspect 2 Track shoe Tension Inspect and adjust SG 4 3 2 Cracked links Inspect 2 Worn pins Inspect 2 Loose bolts Inspect 2 Traveling motor reduction gear Abnormal noise on traveling Inspect 4 2 1 Oil leakage Inspect 4 2 1 Reductio...

Page 190: ... 3 4 Cylinder pin bottom end Grease 6 EG 3 4 Cylinder pin rod end Grease 6 EG 3 4 Deformation cracks Inspect 2 Worn points Inspect 4 5 1 Replace Point 4 5 1 Wear and looseness of the side cutters Inspect 4 5 2 Replace Side cutter 4 5 2 Boom Bending cracks Inspect 2 Foot pin Grease 6 EG 3 4 Cylinder pin rod and bottom ends Grease 6 EG 3 4 Arm Bending cracks Inspect 2 Boom and arm connection pin Gre...

Page 191: ...nspect 6 1 7 1 Meter etc Check action 7 1 Mirror Adjust and inspect 3 10 Seatbelt Inspect 3 1 Replace Every 3 years Belt 3 1 Washer ﬂuid Inspect 7 1 Add Washer ﬂuid 3 10 Action of the door and cover locks Inspect 3 1 Air conditioner and heater related Air conditioner Cooling and heating Inspect 7 1 Defroster Inspect 7 1 Simpliﬁed inspection Refrigerant volume Inspect Every 3 months 4 7 6 Looseness...

Page 192: ... avoid the entry of dirt moisture etc with the lubricant 4 Work in a clean dry workplace so that dirt moisture etc do not enter the machine during the lubrication process 5 Always add the same brand of lubricant Mixing diﬀerent brands could be detrimental due to chemical reactions or other eﬀects For various reasons the recommended lubricants listed in this manual are subject to change without not...

Page 193: ...that currently in use 3 When hydraulic oil has been replaced extract the air from the pump and wait until all bubbles have disappeared from the oil reservoir then run the pump unladen at low speed to expel the air from inside the pipes If there are air bubbles mixed with the hydraulic oil when you operate the machine damage to the pump and various other problems will result 4 Replace the air breat...

Page 194: ...ctual agreement The hydraulic oil brand and ISO VG number is indicated on a label applied to the top of the oil reservoir 2 Engine oil The following engine oil is added at the factory as determined by contractual agreement Name Code Type added at the factory Standard Engine EO Engine oil DH 2 or equivalent 10W 40 SAE 10W 40 JASO DH2 T218341 109 0E 3 Long Life Coolant ...

Page 195: ...ylinder pin rod end Grease EG Showa Shell Sekiyu Alvania EP Grease 2 Boom cylinder pin bottom end Grease EG Showa Shell Sekiyu Alvania EP Grease 2 Bucket cylinder pin rod end Grease EG Showa Shell Sekiyu Alvania EP Grease 2 Bucket cylinder pin bottom end Grease EG Showa Shell Sekiyu Alvania EP Grease 2 Boom and arm connection pin Grease EG Showa Shell Sekiyu Alvania EP Grease 2 Boom foot pin Greas...

Page 196: ...ature has a great impact on hydraulic equipment so if for example you are using hydraulic oil displaying an ISO viscosity grade number of VG46 listed in the Recommended lubricants table pay attention to the following temperature range Operating conditions Temperature range hydraulic oil Action Hazardous start temperature 10 C or less Use oil for cold regions Starting and preparation temperature 10...

Page 197: ...Super 10W 40 DH 2 Low ash engine oil CJ 4 DH 2 T218341 038 0E 2 Viscosity of the engine oil The viscosity of the engine oil SAE can have a major influence on startability performance and oil consumption Using the engine oil with inappropriate oil viscosity could cause premature wear or seizure of the engine or an accident Select the engine oil with the viscosity that is appropriate for the given o...

Page 198: ...tion or daily If using any attachment besides the original KATO bucket breaker crusher etc grease the attachment pins every 10 hours of operation or daily The attachment pins are the four pins at the end of the arm which include the rod end bucket cylinder pin If digging in water after ﬁnishing operations each day grease all parts that were under water 01E0 0561 4E ...

Page 199: ...o obstructions nearby 01E0 0291 0E 3 4 2 Swing motor reduction gear greasing procedure T218341 039 0E Use bearing grease EG Approx 0 5 L of Showa Shell Sekiyu Alvania EP Grease 2 is supplied at the factory For topping up or changing of grease use the equivalent of the above grease Greasing interval Every 1000 hours of operation or yearly After delivery of a new machine grease should be injected af...

Page 200: ... 183 3 Lubrication Lubrication 3 5 Oiling chart 01E0 0293 0E ...

Page 201: ...ection to check for leaks of oil or water 1 Inspection of the exterior 1 Dents or damage of covers etc 2 External damage of devices and equipment 3 Looseness of bolts and nuts 4 Looseness short circuit or damage of the wiring If you notice abnormal noise or vibration from any covers etc stop the engine immediately and investigate the cause If you notice a smell of burning scorching or fuel after s...

Page 202: ...it is running you risk severe injury by trapping your hands etc in the cooling fan or fan belt Always open the engine hood completely and engage the stopper when you open it Immediately after the engine stops each part will be very hot and you risk burns if you touch it If you are going to open the engine hood to inspect the engine check that it has cooled suﬃciently The sound absorbing material i...

Page 203: ...re checking the oil level Clean around the oil ﬁller port before you add oil so that no dirt etc will enter with the oil Choose the right engine oil for the outside air temperature in the region Insert the oil level gauge carefully to prevent bending it Bending the oil level gauge could cause it to deform Spilled engine oil can cause ﬁre so wipe it away immediately T218601 042 0E 1 Pull out the oi...

Page 204: ... add oil slowly Adding oil above the FULL mark on the oil level gauge could cause the engine to run poorly After adding oil wait for at least 10 minutes before double checking the oil level on the oil level gauge Add oil carefully Spilling engine oil on the alternator drive belt during ﬁlling could damage the belt or even cause an accident T218601 043 0E 1 Clean the area around the oil ﬁller cap t...

Page 205: ...gauge Dispose or process drained oil in accordance with the methods speciﬁed in regulations T218341 042 0E 8 At least 10 minutes after adding engine oil set the accelerator dial to the position start the engine and let it idle for 5 minutes Do not operate any levers or dials during that time Also check the drain cock and other areas for any engine oil leakage 9 Shut oﬀ the engine and let it rest f...

Page 206: ... oil ﬁller cap to prevent debris from getting in the oil Remove the oil ﬁller cap 2 Place an oil catch pan under the oil pan and oil ﬁlter 3 Remove the oil pan drain cock to drain the oil 4 Remove the element using a specialized oil ﬁlter wrench 5 Apply a thin coat of clean engine oil on the gasket of the new element 6 Install the new element Screw in the element until the gasket contacts the seal...

Page 207: ...n accordance with local laws and regulation where the machine is used If it cannot be disposed of properly on your own consult a service provider for the engine manufacturer 2 Replacement interval Every 500 hours of operation 3 Consumable part number Refer to the Consumable parts guide ...

Page 208: ...aust color and exhaust status 2 Inspection of the SCR system Check that the DEF hoses and cooling water hoses are connected securely and that there is no crack bending or damage on them Check that the DEF AdBlue or cooling water is not leaking from the DEF tank DEF pump DEF injector DEF hoses or cooling water hoses 1 Inspection of the DEF hoses and cooling water hoses At the time of preoperational...

Page 209: ...sed air the SCR system could malfunction T218341 048 0E 1 Set the starter switch to the OFF position and wait for at least 5 minutes until the pump operation is stopped At that time do not turn the battery disconnect switch to the OFF position or remove the battery cable Doing so could cause blockage in the DEF lines 2 After placing a pan under the DEF pump loosen the cover to remove the ﬁlter ele...

Page 210: ... to replace the suction ﬁlter at the bottom of the head unit assembly Do not replace the DEF tank suction ﬁlter immediately after stopping operation The cooling water is hot enough to cause burns so perform work after the temperature has been allowed to drop T218601 035 0E 2 Replacement interval Every 4500 hours of operation 3 Consumable part number Refer to the Consumable parts guide ...

Page 211: ...tion and replacement intervals for the fuel system 1 Inspection for fuel leakage and fuel hoses Every 60 hours of operation or weekly 2 Discharge of water and deposits from the fuel tank Every 500 hours of operation or 6 months 2 Consumable part number Refer to the Consumable parts guide ...

Page 212: ...m work after the temperature has been allowed to drop Be careful not to spill any fuel If fuel is spilled thoroughly wipe it up Do not scratch or otherwise damage the ﬁlter case which could cause fuel leakage Do not use a parts cleaner or alcohol based water remover If such agents contact plastic parts such as the ﬁlter case they can cause cracking that could lead to fuel leakage T218341 053 0E 1 ...

Page 213: ...ir Due to risk of ﬁre never smoke use a cigarette lighter or use any other ignition source while bleeding the fuel system of air Always shut oﬀ the engine as well 01E0 0577 0E Be careful not to spill any fuel If fuel is spilled thoroughly wipe it up Do not scratch or otherwise damage the ﬁlter case which could cause fuel leakage Do not use a parts cleaner or alcohol based water remover If such age...

Page 214: ...rted let it run at idle for 5 seconds 6 Slowly increase the engine speed and hold that condition for 3 minutes 7 Let the engine run at its maximum speed Repeat these steps several times 8 Check for any fuel leakage Make sure there is no fuel leaking around the ﬁlter case Leaking fuel could cause a ﬁre 01E0 0573 0E NOTE The fuel comes out of the air bleeder plug while bleeding the fuel system of ai...

Page 215: ...has been allowed to drop Be careful not to spill any fuel If fuel is spilled thoroughly wipe it up Do not scratch or otherwise damage the ﬁlter case which could cause fuel leakage Do not use a parts cleaner or alcohol based water remover If such agents contact plastic parts such as the ﬁlter case they can cause cracking that could lead to fuel leakage T218341 057 0E 1 Loosen the drain plug and air...

Page 216: ...he drain plug 2 5 0 5N m 0 25 0 05kgf m Note that the cartridge contains fuel in it During removal use care not to allow the surrounding area to be dirtied with the fuel and be careful about an open ﬂame 02E0 0042 0E 4 Bleed the system of air See 4 1 8 4 Bleeding the system of air 6 Replacement procedure 1 Place a container under the fuel ﬁlter for catching spilled fuel 2 Close the tab of the fuel...

Page 217: ...e O ring with a new one Apply a thin coat of engine oil to the new O ring and fit the O ring to the case Use the O ring provided with the new ﬁlter element 01E0 0596 0E 8 Install a new genuine element from KATO with the hole facing upward Be careful not to damage the O ring by twisting it when installing the ﬁlter case Do not reuse the ﬁlter element 01E0 0571 0E 9 Install the ﬁlter case by turning...

Page 218: ...impact on the environment paper plastic etc always dispose of elements in accordance with local laws and regulations If it cannot be disposed of properly on your own consult a service provider for the engine manufacturer Only replace the element with new genuine parts from KATO Do not use the element beyond the specified replacement period Doing so could cause the fuel injection system to malfunct...

Page 219: ...or tighten it to the speciﬁed torque after the gasket comes into contact with sealing surface Cartridge tightening torque 25N m 3 Bleed the fuel system of air See 4 1 8 4 Bleeding the system of air 4 Start up the engine and inspect for any fuel leakage Make sure there is no fuel leaking around the main fuel ﬁlter Leaking fuel could cause a ﬁre T218341 060 0E NOTE Be sure to dispose of the cartridg...

Page 220: ...r occurs or the engine stops and the problem is not resolved by replacing the fuel filter element then replace the supply pump strainer integrated with the joint bolt Joint bolt tightening torque 14 6 24 6N m The supply pump strainer is built into the joint bolt that is installed in the supply pump inlet Do not attempt to remove the internal strainer The integrated joint bolt cannot be disassemble...

Page 221: ...efully catch the fuel that spills out from the pump during disassembly and prevent it from spilling on the engine for example Also be careful of ignitions sources T218341 134 0E 2 Use diesel fuel to clean the ﬁlter element removed and use compressed air to blow away any debris or other matter 3 Install the cover Use a wrench to tighten it all the way Be sure to verify that the cover properly seale...

Page 222: ...inage procedure Open the drain cock in the bottom of the fuel tank to drain water out Close the drain cock after draining the water 2 Water drainage interval Water drainage interval Every 500 hours of operation or 6 months Diesel fuel is used in this machine as fuel It is highly ﬂammable and therefore very dangerous so handle with care 01E0 0314 0E ...

Page 223: ...g put the outer element 1 back in place and attach the cover 2 with the valve 3 facing directly downward Wear protective goggles when using compressed air When using this machine under severe conditions shorten the cleaning and replacement intervals accordingly If the message indicating air cleaner blockage is displayed on the monitor you should clean the element even if it is not yet the schedule...

Page 224: ... checks 2 Coolant level inspection At the time of preoperational checks 3 Coolant replacement Every 2 years 4 Cooling system cleaning Every time the coolant is replaced 5 Long Life Coolant KATO Diesel Long Life Coolant non amine 6 Long Life Coolant addition volume Add KATO Diesel Long Life Coolant at 50 concentration 7 Coolant adding Add the coolant through the ﬁller cap on the top of the reserve ...

Page 225: ... Add tap water to the reserve tank until the water level reaches the speciﬁed level Close the cap on the reserve tank Start up the engine and let it idle for 20 minutes Then shut oﬀ the engine and after it has cooled suﬃciently drain the water 3 Adding coolant Close the radiator drain cock and the engine water drain plug Fill the expansion tank with coolant until the coolant level reaches the lip ...

Page 226: ...heater circuit as well Set the temperature setting and blower fan to their maximum settings Also warm up the engine at about 1500rpm or higher until the water temperature indicator stabilizes coolant water temperature of about 90 C If the water temperature does not increase conﬁrm that air has been bled from the heater lines such as by having someone watch the radiator to check for warm air being ...

Page 227: ...Long Life Coolant within the concentration range between 50 60 If it is 60 or more the freezing temperature becomes higher If the Long Life Coolant concentration is too high the reduced cooling ability can cause overheating Adjust the concentration to an appropriate level for the outside temperature Long Life Coolant is added at 50 concentration when shipped from the KATO factory If you top up the...

Page 228: ...edure If dust or dead plants build up on the radiator core oil cooler core or intercooler core their cooling effect is drastically reduced and this can cause overheating 1 Detach the protector net to clean any dust from the front side of it using 0 2MPa 2kgf cm2 or less of water or compressed air from a distance of 20 30mm away and keeping it as perpendicular as possible 2 If dead plants etc are w...

Page 229: ...ate engine manual for the method of cleaning the cooling system When the radiator coolant is hot it could spray out dangerously when you take the radiator cap oﬀ possibly causing burns If you have to take the radiator cap oﬀ wait until the coolant has had time to cool and slowly loosen the cap to allow pressure to dissipate before you remove it Check the coolant level and top up with the coolant f...

Page 230: ...d relief settings of the control valve and brake valve The bolts holding hydraulic equipment in place are under an extremely high force so they are tightened to the right torque In case of trouble contact your authorised KATO dealer Special bolts are used for attachment of hydraulic equipment so you should not use normal commercially available ones which might cause breakdowns If the hydraulic oil...

Page 231: ...ction procedure 1 Fill the oil reservoir with hydraulic oil to the regulation level 2 Open the drain ports on the top of the pump 3 Pour hydraulic oil in through both ports to ﬁll the pump casing 4 Tighten both joints and hoses and run the pump unloaded at engine low speed 5 Loosen both joints and hoses a little and extract the air from the pump casing 6 After conﬁrming that the air is out tighten...

Page 232: ...r vary with the type of the machine If you use the breaker be sure to use the high performance filter Always use the genuine KATO filter element An imitation element is not guaranteed for performance and durability If the worst comes to the worst it could be damaged early and have an adverse eﬀect on the hydraulic equipment If an imitation ﬁlter is used the hydraulic equipment is not guaranteed 01...

Page 233: ...t of the ﬁlter case Hold the spring and put the underside of the element on the inside ﬂange of the ﬁlter case for about ten minutes to drain the oil from the ﬁlter assembly 01E0 0329 0E 3 After pulling out the element assembly put the removed cover onto the ﬁlter case to prevent entry of dirt or dust into the reservoir Do not replace the element in a dusty workplace The wind contains dust so take...

Page 234: ...ty it makes the lower part of the center bolt of the element assembly dirty If the tray is not washed thoroughly the hydraulic oil could be contaminated by the dirt so caution is required 01E0 0331 0E 5 Extract the snap pin from the center bolt on the top of the element assembly 6 Unscrew the castle nut to remove the spring from the center bolt 7 Extract the safety valve from the center bolt ...

Page 235: ...hich is prepared in advance 2 Cover the washed parts with a cloth etc which is prepared in advance to prevent dirt adhesion 3 Check the O ring If it is damaged or stretched replace it with new one 7 Assembly of the element assembly Follow the procedure below to assemble the new element 1 Prepare the clean paper or cloth for element assembly 2 Assemble the element to the center bolt 3 Attach the sa...

Page 236: ...1 5kgf m If the tightening force on the castle nut is insuﬃcient the ﬁlter can not work eﬃciently Tighten it to the regulation torque 01EE 0333 0E 5 Insert the snap pin into the center bolt 6 Hold the plate spring and store the element assembly into the ﬁlter case When storing the element assembly into the ﬁlter case keep the element not to come into contact with the other parts so that the elemen...

Page 237: ...er or crusher replace the standard ﬁlter element with a high performance type as described in the Optional equipment When you have replaced the return filter you should allow a running in period of approximately 10 minutes at engine low speed with the control levers in their neutral positions with no load applied 01E0 0335 0E 4 2 5 Hydraulic oil replacement T218341 070 0E 1 Oil level check Check t...

Page 238: ...e the machine gently for 10 15 minutes moving the cylinders evenly then put the machine in hydraulic oil ﬁlling position and recheck the level The oil level should lie between the H and L lines on the level gauge Do not top it up beyond the H level Do top it up if it is below the L level Always top up with new oil of the exact same brand and name Do not mix with other oil products Always extract a...

Page 239: ...ngine stops so wait until it cools to 40 C and less before you start work 01E0 0325 0E 1 Replacement procedure 1 Press on the rubber cap to extract the pressurised air inside the reservoir 2 Turn the cover about 90 clockwise and remove the cap turning counterclockwise Then turn the cover counterclockwise to remove and detach the element 3 Place a new element and fastepn the cover turning clockwise...

Page 240: ... parts guide 4 2 8 Replacement of the drain ﬁlter cartridge 01E0 0336 3E 1 Cartridge replacement procedure 1 Relieve air pressure in the reservoir 2 Use the speciﬁed wrench to remove the cartridge 1 3 When ﬁtting a new cartridge coat the packing surface with clean hydraulic oil and turn the cartridge through approximately 2 3 of a turn after the packing contacts the seal surface 4 Start the engine...

Page 241: ...e seal surface 4 Start the engine and check that no oil leaks through the seal surface Tightening torque for the cartridge 29 4 39 2N m 3 0 4 0kgf m You cannot wash the cartridge and reuse it Always use a new genuine KATO ﬁlter cartridge 01E0 0337 1E 2 Element replacement interval Replacement interval Every 1000 hours of operation or yearly 3 Consumable part number Refer to the Consumable parts gu...

Page 242: ... is potentially highly dangerous Strictly observe the following points Never pierce the accumulator or bring it near a ﬁre or other source of heat Do not weld a boss etc onto the accumulator When disposing of the accumulator the enclosed gas must be released Contact your authorised KATO dealer T218341 133 0E An accumulator is ﬁtted in the control circuit as a pressure accumulation device If the st...

Page 243: ...ck shoe tension inspection and adjustment T218341 072 0E Check that the there is no too much slack or tension in the track shoes Track shoes are adjusted by using the adjuster cylinders to move the front idlers backward or forward 1 Measuring the amount of slack When you are adjusting track shoe tension jack up each side separately and slightly drive the jacked up side shoe to measure the amount o...

Page 244: ...e track shoe After adjustment screw the drain plug in Tightening torque 196N m 20kgf m If you loosen the plug too much it could ﬂy under the high pressure of the grease inside Do not unscrew the plug by more than one turn Do not face towards the plug as you ﬁt it If the track shoe did not loosen order a repair from your authorised KATO dealer 01E0 0348 0E 3 To check whether the track shoe tension ...

Page 245: ...gear as shown in the diagram 2 Remove the level plug 3 Pour gear oil in through the oil ﬁller hole until it pours out from the level hole 4 Screw the plugs back in to prevent oil leakage Tightening torque 98 1 19 6N m 10 2kgf m NOTE Refer to the recommended lubricants table for the brand of gear oil Allow at least ten minutes after traveling before you measure the oil volume You may use any brand ...

Page 246: ...may need to be overhauled Contact your authorised KATO dealer 01E0 0356 0E 1 Oiling method 1 Remove the level gauge pour gear oil in through the oil ﬁller port and use the level gauge to check that oil is at regulation level NOTE Refer to the recommended lubricants table for the brand of gear oil You may use any brand of gear oil but you should use one brand consistently and avoid mixing diﬀerent ...

Page 247: ...tooth Then insert the pin lock into the tooth ﬁt the new point and insert the pin to complete ﬁtting The pin lock is made of rubber so replace it each time If you use the same one repeatedly the point may drop oﬀ 01E0 0360 0E NOTE The pin can be inserted easily from above or below After inserting the pin knock the point up down left and right several times with a hammer If the pin is not properly ...

Page 248: ...move the side cutters If the bolts are corroded in place and cannot be removed melt them away to cut down 3 Clean and smooth the attachment surfaces and attach new side cutters Use new bolts nuts and spring washers NOTE Side cutter attachment bolt tightening torque 423N m 43 2kgf m 4 5 3 Lifting hook inspection optional 01E0 0362 0E Inspect the hook for wear cracks and deformation the hook mountin...

Page 249: ...e engine stops Do not turn the battery disconnect switch to the OFF position or remove the battery cable Doing so could cause blockage in the DEF lines Before you turn the battery disconnect switch to the OFF position or remove the battery cable wait for at least 5 minutes after the starter switch is set to the OFF position 7 When detaching the battery cable always begin with the negative terminal...

Page 250: ...el Do not top up beyond the UPPER level 2 Battery terminal inspection Check for loose terminals and clean away dirt and corrosion 1 If the terminals are covered with whitish powdery corrosion wash it with away with boiling water If corrosion is severe use a wire brush or sandpaper to scrape it away 2 After cleaning the terminals coat them in a thin layer of grease 3 Speciﬁc gravity inspection Full...

Page 251: ...s of the battery voltage capacity as the broken down machine has Also use the right booster cables and clips for the battery capacity If you use high voltage sources such as those for welding equipment or if you use a battery of a diﬀerent voltage you will damage the electrical equipment When you are trying to start the engine switch oﬀ all lights and accessories on the machine which has failed to...

Page 252: ...ck or engine earth terminal of the broken down machine 5 Check the connections of the booster cables then start the engine of the assisting machine and increase its speed 6 Start the engine of the broken down machine If it does not start wait at least two minutes and try again 2 Booster cable disconnection procedure 1 Disconnect one end of the black booster cable from the engine block or the engin...

Page 253: ...r Refer to the Consumable parts guide 4 6 4 Fuse replacement T218081 179 0E The fuse box is located on the left rear of the cab If a fuse blows investigate the cause and repair the problem before replacing the blown fuse with another of the same related capacity Use the fuse extractor on the rear side of the fuse box to extract the old fuse Never use fuses of other than the rated capacity or wire ...

Page 254: ...blow and protect the circuit if a large current ﬂows in the circuit between the batteries and the fuse box due to a short circuit or other problem If there is no abnormality in the fuses and a problem occurs in the electrical system the high current fuse has blown Contact your authorised KATO dealer and replace the high current fuse after the problem has been repaired 1 Consumable part number Refe...

Page 255: ...and the amount of refrigerant ﬁlled in at the time of factory shipment are shown on the label attached on the cover behind the operator s seat Always have air conditioner repairs performed by your authorised KATO dealer Always have it disposed of by a reputable waste disposal company If laws or regulations in the country where the machine is operated specifies how chloroﬂuorocarbon gases must be u...

Page 256: ...r matter from accumulating on the evaporator or heater core Periodically remove the ﬁlters to inspect them and clean them by lightly hitting them to the extent it does not damage the plastic frame If ﬁlter blockage is not resolved by cleaning or there is signiﬁcant deterioration or damage install a new replacement ﬁlter 1 Removing and installing ﬁlters 1 Internal air ﬁlter location behind the seat...

Page 257: ... be reduced If the fan belt is loose it can cause overheating and battery depletion 4 7 4 Inspection for blockage in the radiator and condenser T218341 116 0E If the radiator and condenser are clogged with mud insects etc the passage of air will be obstructed causing overheating and reduced cooling performance Clean them regularly according to the section 4 1 14 Cooling system 7 Radiator core clea...

Page 258: ...uorocarbon gases must be used or managed then comply with such requirements If not then regular inspection is recommended Main inspection items The refrigerant piping connecting parts marked with are connections between each device and refrigerant hoses or piping Check them for leakage or damage intensively If laws or regulations in the country where the machine is operated speciﬁes how you must d...

Page 259: ...pment 1 0 kg The air conditioner circuit is ﬁlled with gas at high pressure Use the appropriate equipment to release gas before you undo pipes or compressor parts Filling with refrigerant gas and other service tasks require special tools and instruments and should only be attempted in a properly equipped KATO dealer 541D 0098 1E Running the air conditioner when it does not contain refrigerant gas ...

Page 260: ... 243 243 4 Inspection and servicing of each part Inspection and servicing of each part 4 7 7 Electrical circuit diagram for the air conditioner 01EE 0607 0E ...

Page 261: ... 244 244 MEMO ...

Page 262: ...ly operate each lever and pedal independently to inspect the resulting movement of the corresponding components If a control lever or pedal is tilted rather than in the neutral position adjust it before starting operations If the machine moves diﬀerently than the operated direction of each control lever or pedal then immediately shut oﬀ the engine and contact your authorised KATO dealer T218081 18...

Page 263: ... 246 4 Inspection and servicing of each part 4 8 3 Rear view camera T218341 078 0E Check if the rear view camera lens is dirty If dirty clean the lens to ensure a sharp image ...

Page 264: ...en working with optional attachments 260 4 1 Grab fork 260 4 2 Stranger bucket 262 5 Speciﬁcations and compatibility of bucket models 263 6 Track shoe selection 264 6 1 Track shoe selection method 264 7 Track shoe types and applications 265 8 Procedures for multi position lever operation 266 8 1 Procedures for multi position shifting 266 8 2 Replacing the operating pattern label 267 9 Procedures f...

Page 265: ...1 091 0E 1 1 Attachment mode settings T218081 185 0E Move the switch to the mode corresponding to the attachment being used 1 Bucket mode Mode best suited for digging operations 2 Breaker mode Switches the hydraulic oil ﬂow rate to the ﬂow rate speciﬁed for breaker operations 3 Crusher mode Switches to hydraulic circuits best suited to crusher operations ...

Page 266: ... on the both sides of the arm are in the ON position and that the stop valve B on the body is in the OFF position 2 Use the attachment mode switch to select the crusher mode 3 Move the control pedal lock pin to ⓐ free position and lock pin to ⓐ position then press the pedal forward or backward to operate the attachment Stop valve open closed and attachment mode switch combinations for each operati...

Page 267: ...ock position and use the pedal as a footrest 2 Stop valve This valve blocks the ﬂow of hydraulic oil One stop valve A is installed to each side of the arm and one stop valve B on the body ON Hydraulic oil ﬂows OFF Hydraulic oil stops 3 When the hydraulic breaker unit is mounted The control pedal lock pin positions should be pin to ⓑ pin to ⓐ When you press the pedal forward the oil ﬂow path follow...

Page 268: ...rd the oil path follows the white arrows Make sure that the stop valves A are in the ON position and that the stop valve B is in the OFF position When you have ﬁnished working with the attachment take your foot oﬀ the pedal If you rest your foot on the pedal you could inadvertently press it and move the attachment in a dangerous way When the lock pin is in the free position ⓐ position put your foo...

Page 269: ...the plugs from each pipe and hose 5 Extract attachment pins A and B and mount the hydraulic attachment 6 Switch the stop valves A which are mounted on the pipes of the arm sides to the ON positions 7 Start the engine and check that there is no oil leakage or abnormal vibration before you start work 1 4 2 Changing from the hydraulic attachment to the bucket T218601 022 0E 1 Rest the hydraulic attac...

Page 270: ...er read the instruction manual for the hydraulic breaker unit thoroughly and be sure you fully understand its contents The machine s speciﬁcation stability working range transport height etc is altered when an optional attachment is mounted Contact your authorised KATO dealer for details 3 Beware of contamination with impurities When the hydraulic breaker is not mounted the pipe adapters on the ar...

Page 271: ... when using the hydraulic breaker 2 Never use the hydraulic breaker for anything other than its original purpose Do not use the hydraulic breaker for anything other than breaking materials The main applications of the hydraulic breaker are demolition of concrete structures breaking of paved road surfaces for roadworks breaking rocks and small scale digging in mines and quarries 3 Never use the chi...

Page 272: ... elsewhere 6 Limit continuous impacts to one minute If one minute of continuous impacts in one place fails to break an object try again from a diﬀerent impact point If you continue striking without a break the oil temperature will rise causing accumulator malfunction and deterioration of the cylinder seals so take care to observe this time limit 7 Never use swing force to push or strike objects Do...

Page 273: ...t which will damage seals and allow water to enter and contaminate the hydraulic oil causing further damage to the hydraulic equipment 11 We urge you to use the breaker in front of or behind the machine Use of the breaker to the sides will shorten the lifespan of the travel system such as the track shoes etc 12 Never use downward stabbing force to stab the breaker into the target The breaker is he...

Page 274: ...l 01E0 0401 1E 3 1 Precautions on crusher operation T218081 096 0E 1 Mount protective equipment Impacts of the crusher scatter fragments so the front guard and head guard should be mounted to protect the operator and the front window should always be closed Wear a helmet and goggles when using the crusher 2 Never use the crusher for anything other than its original purpose Do not use the crusher f...

Page 275: ... other high places Work with care to avoid rubble falling onto the machine 6 Precautions when working on the ﬂoors of buildings and other structures Conﬁrm that the ﬂoor is strong enough before you start work Remember that in some operations the load on the floor can exceed the weight of the machine 7 Keep the machine on level ground Ensure that the machine is standing on ﬂat ground before you sta...

Page 276: ...il and return ﬁlter If you change attachments frequently the oil will become dirty more quickly than usual Observe the condition of the hydraulic oil regularly and change it and the ﬁlter more frequently than usual if necessary 10 Dangerous operation leading to damage the machine Do not work with the following methods which can cause the accident or damage to the machine itself Take special care o...

Page 277: ... 259 3 Crusher operation Crusher operation 3 Gouging using the cylinder stroke end 4 Rough and harsh crushing ...

Page 278: ...applications Industrial waste processing Demolition related processes 2 Do not move the cylinder all the way to the end of its stroke Stop a little before the end of the stroke 3 Never use swing force to strike and break objects Using swing force to strike and break objects will break the grab fork and the machine 4 Never grip with only one side of the fork ...

Page 279: ...g with optional attachments 5 Never push the fork into the ground to lift the machine and change direction 6 Striking is prohibited Do not use the grab fork to strike blows against the ground or anything else because the impact could break the grab fork or the body of the excavator ...

Page 280: ...T218621 022 0E 1 Main applications Demolition Industrial waste processing 2 Incorrect use To preserve safety and the lifespan of the machine do not work with the following methods 1 Working with swing force 2 Closing the sub bucket with the boom and arm fully extended 3 Striking ...

Page 281: ...gging digging and loading of sand gravel clay and normal soil For light digging digging and loading of loose dry soil and mud The density of material for loading should not exceed the guideline value of 1600kg m3 For loading only loading of loose dry soil The density of material for loading should not exceed the guideline value of 1100kg m3 Usable within warranty Unusable outside warranty 02E0 009...

Page 282: ...s on extremely rough ground with large obstacles such as loose stones and fallen trees set the traveling speed to slow B Normal or soft soil Not usable on extremely rough ground with large obstacles such as loose stones and fallen trees Fast speed and slow speed may only be used on ﬁrm level ground If it is absolutely necessary to traverse obstacles reduce the traveling speed to around half of slo...

Page 283: ...LC 7 Type Triple grouser shoes Track shoe width 500 600 Application General soil standard Soft soil optional Body speciﬁcations Operating weight kg 14500 14600 Body weight kg 12100 12200 Cab height mm 2820 2820 Minimum ground clearance mm 430 430 Overall track shoe length mm 3740 3740 Overall track shoe width mm 2490 2590 Ground pressure kPa 43 36 kgf cm2 0 44 0 37 T218601 025 0E 1 These ﬁgures ar...

Page 284: ...turn oﬀ the engine T217201 054 0E 8 1 Procedures for multi position shifting T217201 055 1E 1 When the machine has come to a halt turn oﬀ the engine and move the safety lock lever to the lock position 2 Loosen the wing bolt and shift the lever to the desired operating pattern position 3 After setting the operating pattern retighten the wing bolt by hand to secure the lever Do not use a wrench 4 Sw...

Page 285: ...ect operation Be sure to conﬁrm that the lever inputs correspond to the machine outputs If the machine action does not correspond to the operation assigned to each lever continued operation is likely to result in serious physical injury If the machine actions do not correspond to the lever operations either replace the operating pattern label with the appropriate label or shift the multi position ...

Page 286: ... and turn oﬀ the engine T217451 077 0E 9 1 Procedures for selector lever shifting T217451 078 0E 1 When the machine has come to a halt turn oﬀ the engine and move the safety lock lever to the lock position 2 Pull the lever lock and shift the lever to the desired operating pattern position 3 After setting the operating pattern release the lever lock and secure the lever 4 Switch to the desired oper...

Page 287: ... operation Be sure to conﬁrm that the lever inputs correspond to the machine outputs If the machine action does not correspond to the operation assigned to each lever continued operation is likely to result in serious physical injury If the machine actions do not correspond to the lever operations either replace the operating pattern label with the appropriate label or shift the selector lever suc...

Page 288: ...he engine T217451 077 0E 10 1 Procedures for selector lever shifting T217451 078 0E 1 When the machine has come to a halt turn oﬀ the engine and move the safety lock lever to the lock position 2 Loosen the wing bolt and shift the lever to the desired operating pattern position 3 After setting the operating pattern retighten the wing bolt by hand to secure the lever Do not use a wrench 4 Switch to ...

Page 289: ...t operation Be sure to conﬁrm that the lever inputs correspond to the machine outputs If the machine action does not correspond to the operation assigned to each lever continued operation is likely to result in serious physical injury If the machine actions do not correspond to the lever operations either replace the operating pattern label with the appropriate label or shift the selector lever su...

Page 290: ... 272 MEMO ...

Page 291: ...orques for hydraulic and pneumatic related joints 274 2 Dimensions and weight 280 3 Consumable parts guide 284 3 1 Genuine lubricants table 284 3 2 Replacement parts 286 4 Hydraulic circuit diagram 295 5 Electrical circuit diagram 296 6 Inspection sheet 299 6 1 Hydraulic excavator preoperational check sheet 299 6 2 Hydraulic excavator monthly voluntary inspection sheet 300 ...

Page 292: ...5 85 8 7 M10 17 1 25 38 3 9 54 5 5 M12 19 1 75 31 3 2 67 6 8 87 8 9 127 13 0 149 15 2 M12 19 1 25 74 7 5 96 9 8 M14 22 2 00 52 5 3 106 10 9 139 14 2 204 20 8 238 24 3 M14 22 1 50 116 11 8 151 15 4 M16 24 2 00 81 8 3 166 16 9 217 22 1 318 32 5 371 37 9 M16 24 1 50 179 18 2 233 23 8 M18 27 2 50 112 11 4 228 23 3 298 30 4 438 44 7 512 52 2 M18 27 1 50 260 26 5 339 34 6 M20 30 2 50 159 16 2 324 33 0 4...

Page 293: ...9 1 75 28 87 8 9 T308741 047 0E 1 3 Tightening torques for hydraulic and pneumatic related joints T218081 104 0E 1 The tolerance for the torque values is 10 2 The unit for the torque values is N m kgf m 3 Never allow oil to adhere on the threads or the rotating section of the nut 4 When tightening secure the socket with a spanner so that it does not rotate along with the joint with the female thre...

Page 294: ...4 3 8 1 2 3 4 1 1 1 4 1 1 2 2 Width across faces H mm 14 19 22 27 36 41 50 55 60 70 Tightening torque Seating surface material Steel Note 1 34 5MPa 27 5MPa 20 5MPa 17 0MPa 10 5MPa Note 2 15 1 5 25 2 5 34 3 5 64 6 5 132 13 5 196 20 225 23 255 26 316 32 49 5 157 16 412 42 Brass Note 3 10 5MPa 9 0 9 13 1 3 21 2 1 33 3 4 Note 1 Indicates the application pressure based on the maximum pressure to be use...

Page 295: ...faces H mm 19 22 27 30 32 36 41 50 60 Recommendable pressure to be used 34 5MPa 27 5MPa 20 5MPa Tightening torque 25 34 64 118 132 196 225 255 01E0 0598 1E 9 Adapterless piping rolled screw type Units N m kgf m Screw size G 1 4 3 8 1 2 3 4 1 Width across faces H mm 12 15 19 24 30 Tightening torque Schedule 80 25 2 5 49 5 59 6 118 12 137 14 Schedule 40 23 2 3 44 4 5 54 5 5 108 11 137 14 01E0 0517 1...

Page 296: ...4 3 5 44 4 5 69 7 Brass 9 0 9 12 1 2 25 2 5 33 3 4 52 5 3 01E0 0518 1E 11 Split ﬂange ﬂange head joint 1 SAE standard Type I Units N m kgf m Inner diameter indication 08 12 16 20 24 32 Hose size 1 2 3 4 1 1 1 4 1 1 2 2 Inner diameter of hose mm 12 7 19 0 25 4 31 8 38 1 50 8 Recommendable pressure to be used MPa kgf cm2 Type I 34 5 350 24 0 245 20 5 210 Tightening torque N m kgf m 24 2 5 48 4 9 48 ...

Page 297: ...kgf cm2 Type Ⅱ 34 5 350 Type Ⅲ 34 5 350 Tightening torque N m kgf m 24 2 5 48 4 9 48 4 9 87 8 9 217 22 1 298 30 4 Bolt to be used M8 1 25 M10 1 5 M10 1 5 M12 1 75 M16 2 0 M18 2 5 01E0 0520 2E 12 Piping ﬂange Units N m kgf m Bolt to be used 001 105 M8 1 25 M10 1 5 M12 1 75 M16 2 0 Tightening torque Seating surface material Steel 23 2 3 59 6 88 9 167 17 Aluminum Note 1 3 4 3 5 Note 1 Refers to the a...

Page 298: ...ipments Units N m kgf m Screw size M6 M8 M10 M12 M14 M20 Tightening torque 10 1 23 2 3 59 6 78 8 167 17 275 28 01E0 0522 0E After the first 50 hours of use of a new machine and every month thereafter inspect and retighten the bolts When tightening clean oﬀ any corrosion earth and debris 01E0 0523 0E ...

Page 299: ...90 7550 2820 2490 Operating weight kg 14100 14500 T218601 026 0E 2 Upper structure lower structure Standard speciﬁcation LC speciﬁcation Overall length L overall height H overall width W mm 3570 2820 2490 3740 2820 2490 Base machine weight kg 11700 12100 T218601 038 0E 3 Upper structure Overall length L overall height H overall width W mm 3140 1950 2480 Weight kg 7400 T218601 027 0E ...

Page 300: ...0 2490 Weight kg 4300 4700 T218601 039 0E 5 Arm bucket dimensions and weight Combination 2 50m arm 0 50m3 bucket 3 00m arm 0 40m3 bucket Overall length L overall height H overall width W mm 4380 860 980 4930 860 830 Weight kg 1030 1070 T218601 029 0E 6 Boom dimensions and weight 4 65m boom Overall length L overall height H overall width W mm 4820 1360 580 Weight kg 1050 02E0 0071 1E ...

Page 301: ...rall width W mm 1260 990 630 1260 990 790 1220 1020 840 Weight kg 290 360 380 Bucket capacity m3 0 25 0 35 0 40 Type Backhoe bucket Overall length L overall height H overall width W mm 1260 990 970 1220 1020 980 1220 1020 1050 Weight kg 400 450 430 490 450 520 Bucket capacity m3 0 45 0 50 0 55 Type Backhoe bucket Skeleton bucket Skeleton bucket cross pin Overall length L overall height H overall w...

Page 302: ...gf cm2 32 9MPa 335kgf cm2 high power Maximum output ﬂow 126L min Bucket cylinder Bore diameter φ95mm Rod diameter φ70mm Full retraction length 1470mm Stroke 995mm Rod pin diameter φ65mm Rod boss width 98mm Rod boss outside diameter φ120mm Side link length 553mm Tipping link length 460mm Dimensions for each location ...

Page 303: ... 0 4kg Grease cartridge Li 999 00200070 0 4kg 20 01E0 0588 0E 2 Oil Classiﬁcation Name Part number Quantity Standard Reduction gear oil GO Gear oil 779 70831010 20L API GL 4 SAE 90 Hydraulic oil HO Hydraulic oil KV32 779 70511010 200L Hydraulic oil KV46 779 70521010 779 70521020 200L 20L Hydraulic oil KV68 779 70531010 200L 01E0 0589 1E 3 Long Life Coolant Name Part number Quantity KATO Diesel Lon...

Page 304: ... 285 3 Consumable parts guide Consumable parts guide 4 DEF AdBlue Name Part number Quantity KATO recommended DEF AdBlue 779 71100400 10L 2 T218371 027 1E ...

Page 305: ...umable parts guide 3 2 Replacement parts 01E0 0591 0E Inspection and servicing section 4 1 3 Consumable part name Oil ﬁlter Inspection and servicing section 4 1 5 Consumable part name DEF pump ﬁlter T218341 118 0E ...

Page 306: ...mable parts guide Consumable parts guide Inspection and servicing section 4 1 6 Consumable part name DEF tank suction ﬁlter Inspection and servicing section 4 1 8 Consumable part name Fuel pre ﬁlter T218341 119 0E ...

Page 307: ... 288 3 Consumable parts guide Inspection and servicing section 4 1 9 Consumable part name Main fuel ﬁlter Inspection and servicing section 4 1 13 Consumable part name Air cleaner element T218341 120 0E ...

Page 308: ...ble parts guide Consumable parts guide Inspection and servicing section 4 2 4 Consumable part name Return ﬁlter element Inspection and servicing section 4 2 6 Consumable part name Air breather element T218341 121 0E ...

Page 309: ...290 3 Consumable parts guide Inspection and servicing section 4 2 7 Consumable part name Suction strainer Inspection and servicing section 4 2 8 Consumable part name Drain ﬁlter cartridge T218341 122 0E ...

Page 310: ...e parts guide Consumable parts guide Inspection and servicing section 4 2 9 Consumable part name Pilot line ﬁlter cartridge Inspection and servicing section 4 6 3 Consumable part name Bulb and LED light T218341 123 0E ...

Page 311: ... 292 3 Consumable parts guide Inspection and servicing section 4 6 4 Consumable part name Fuse Inspection and servicing section 4 6 5 Consumable part name High current fuse T218341 124 0E ...

Page 312: ...arts guide Consumable parts guide Inspection and servicing section 4 6 6 Consumable part name Wiper blade Inspection and servicing section 4 7 2 Consumable part name Internal air ﬁlter and outside air ﬁlter T218341 125 0E ...

Page 313: ... 294 3 Consumable parts guide Inspection and servicing section 4 7 3 Consumable part name V belt Inspection and servicing section 4 7 6 Consumable part name Receiver drier T218341 126 0E ...

Page 314: ... 295 295 4 Hydraulic circuit diagram Hydraulic circuit diagram 4 Hydraulic circuit diagram 01EE 0608 0E ...

Page 315: ... 296 296 5 Electrical circuit diagram 5 Electrical circuit diagram 01EE 0609 0E ...

Page 316: ... 297 297 5 Electrical circuit diagram Electrical circuit diagram ...

Page 317: ... 298 298 MEMO ...

Page 318: ... 299 Inspection sheet 6 Inspection sheet 6 Inspection sheet 01E0 0543 0E 6 1 Hydraulic excavator preoperational check sheet 01E0 0544 0E ...

Page 319: ... 300 6 Inspection sheet 6 2 Hydraulic excavator monthly voluntary inspection sheet 01E0 0545 0E ...

Page 320: ...Backup switch 63 Backup switch panel 63 Battery disconnect switch 77 Boom 39 Bucket 39 138 C Cab 39 Console lock lever 55 Control levers 55 Control panel 60 Control valve 39 Cooling system 207 Counterweight 39 Cover hood 74 D Date Time 108 DEF indicator 108 DEF level meter 108 DEF pump ﬁlter 192 DEF tank 39 DEF tank suction ﬁlter 193 Door 43 Door window 48 Dozer lever optional 59 Drink holder 54 ...

Page 321: ... 47 Front window 45 Fuel consumption gauge Leaf indicator 109 Fuel gauge 107 Fuel pre ﬁlter 195 Fuel pump optional 79 Fuel system 194 Fuel tank 39 Fuse box 236 G Grease pump 75 H High power switch 56 Horn selection switch optional 62 Horn switch 56 Hot cool box 52 Hour meter 52 Hour meter Monitor 109 Hydraulic devices 213 Hydraulic oil temperature gauge 108 Hydraulic pump 39 I Interior lamp 53 K K...

Page 322: ...6 R Radio 65 Rain visor optional 80 Rear view camera 79 246 Right control lever 58 Roof window 48 S Safety lock lever 55 SCR system 191 Seatbelt 52 Slow down mode switch 106 Starter switch 60 Sun visor optional 49 Sunshade optional or included standard on models with a polycarbonate hatch 48 Supply pump strainer 203 Swing gear 39 Swing lock release switch 64 Swing motor reduction gear 229 Swing ta...

Page 323: ...8 Touch panel display 103 Track shoe 39 Travel link alarm switch optional 62 Traveling control levers 57 Traveling mode switch 104 Traveling motor 39 W Washer switch 111 Washer tank 76 Wiper switch 111 Working lamp 78 ...

Page 324: ...shi ohi 1 chome Shinagawa ku Tokyo 140 0011 Japan Tel Head Office Tokyo 03 3458 1111 Overseas Marketing Department Tokyo 03 3458 1115 Fax Tokyo 03 3458 1163 URL http www kato works co jp 180213TI 8 2018 50 GD 1 ...

Page 325: ...899 92186210 ...

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