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CONST RUCTION

SERVICE MANUAL

E265C

E305C

Crawler Excavators

Print no. 47357333A

1

st

Edition

English 03/12

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Summary of Contents for E265C

Page 1: ...SERVICE MANUAL E265C E305C Crawler Excavators Print No 47357333A Print No 47357333A SERVICE MANUAL E305C E265C Crawler Excavators ...

Page 2: ...CONSTRUCTION SERVICE MANUAL E265C E305C Crawler Excavators Print no 47357333A 1st Edition English 03 12 Find manuals at https best manuals com ...

Page 3: ...o the ground before repairing adjusting or servicing machines fitted with hydraulically mechanically or cable controlled attachments such as excavators loaders dozers scrapers etc Should it be necessary to partially or fully raise the hydraulically mechanically or cable controlled attachment to gain access to certain items make sure the attachment is adequately retained in the raised position by m...

Page 4: ...as stated below The Service Manual Crawler Excavators consists of five parts General Safety Information Operational Principle Operational Performance Test Troubleshouting Repair Instructions The General Safety Information part includes the recommended procedures that if followed can avoid the risk of accident for operator and for staff related to the work and maintenance machine operations The Ope...

Page 5: ...eights To avoid injury and damage be sure to use appropriate lifting techniques and equipment when lifting heavy parts UNITS USED SI Units International System of Units are used in this manual MKSA system units and English units are also indicated in parentheses just behinds SI units Example 24 5 MPa 250 kgf cm2 A table for conversion from SI units to other system units is shown below for referenc...

Page 6: ...c Pump Assy T3 1 Group 2 Pilot Valve T3 2 Group 3 Control Valve T3 3 Group 4 Swing Device T3 4 Group 5 Travel Device T3 5 Group 6 Swivel Joint T3 6 Group 7 Cylinders T3 7 Group 8 Air Conditioner system T3 8 Group 9 Electrical Equipment T3 9 OPERATIONAL PERFORMANCE TEST Section 4 OPERATIONAL PERFORMANCE TEST Group 1 Introduction T4 1 Group 2 Standard Performances T4 2 Group 3 Test Procedures T4 3 G...

Page 7: ...oup 2 Pump Device W2 2 Group 3 Control Valve W2 3 Group 4 Swing Device W2 4 Group 5 Pilot Valve W2 5 Section 3 UNDERCARRIAGE Group 1 Swing Bearing W3 1 Group 2 Travel Device W3 2 Group 3 Swivel Joint W3 3 Group 4 Track Adjuster W3 4 Group 5 Front Idler W3 5 Group 6 Upper and Lower Roller W3 6 Group 7 Tracks W3 7 Section 4 FRONT ATTACHMENT Group 1 Front attachment W4 1 Find manuals at https best ma...

Page 8: ...GENERAL SAFETY INFORMATION Find manuals at https best manuals com ...

Page 9: ...Find manuals at https best manuals com ...

Page 10: ...GENERAL SAFETY INFORMATION E265C E305C INDEX Section 1 SAFETY INFORMATION Section 2 SAFETY PRECAUTIONS Section 3 SAFETY DECALS Find manuals at https best manuals com ...

Page 11: ......

Page 12: ...ul of possible slippery conditions of the steps and hand rails as well as of the ground around the machine Wear protective boots or shoes with the soles made of highly no slip rubber Do not leave the machine until it has come to a complete stop Always check height width and weight limitations which may be encountered in the working site and ensure the machine does not exceed them Assess exact path...

Page 13: ... load or at idle immediately report this problem to the maintenance managers for proper action Do not operate the machine until this condition is corrected Regularly check all exhaust system components as exhaust fumes are toxic for the operator Operators must know the performance of the machine they are driving When working on slopes or near sudden level drops in the terrain pay attention not to ...

Page 14: ...e should be exclusively hooked to the hitch specially provided The excavator is no lifting and transportation means therefore it should not be used to position loads accurately Should it be exceptionally used to lift and lay building components special caution must be taken as follows The machine must be equipped compulsorily with the appropriate variant provided upon request Secure the loads to b...

Page 15: ...the machine and or load at all times If the load has to be guided down for laying consult the Electric Power Company to know which precautions should be taken Appoint a person in charge of signalling duties This person will have the responsibility of observing the machine any part of it and or the load approaching the electric lines from a standpoint more favorable than the Operator This signal ma...

Page 16: ...nger of slipping or stumbling Clean mud or grease from your shoes before climbing on the machine or driving it Never attempt to operate the machine or its attachments from any position other than sitting in the operator s seat Keep the driver s seat free from foreign objects especially if these are not secured Should it be necessary to move the attachment for maintenance purposes do not raise or l...

Page 17: ...er to the lock position before starting adjusting or repairing an assembly Do not carry out any work on the attachment without prior authorisation Observe maintenance and repair procedures In case of field service move the machine to level ground and block it If work on an incline cannot be avoided securely block the machine and its attachments Move the machine to level ground as soon as possible ...

Page 18: ... to inform that you are about to move off It is necessary to know load limits of bridges and dimensional limits of tunnels Such limits must never be exceeded You should also know machine height width and weight Have a signal man help you when clearances are limited Check distance between boom arm and dimensional limits during transfer or transportation Rough terrain may cause the machine to sway a...

Page 19: ...ld up of explosive gas released during charging Disconnect batteries before working on the electrical system or carrying out any other type of work HYDRAULIC SYSTEM Pressure fluid escaping from a very small hole can be almost invisible and still have sufficient force to penetrate the skin Always check any suspected pressure leaks using a piece of cardboard or wood Do not use hands If injured by es...

Page 20: ...R indicates an imminent hazardous situation which if not avoided will result in death or serious injury WARNING indicated a potential hazardous situation which if not avoided could result in death or serious injury CAUTION indicates a potential hazardous situation which if not avoided may result in minor or moderate injury ATTENTION indicates a situation which if not avoided may cause damage to th...

Page 21: ...king conditions Unauthorised changes to the machine may impair function and or safety and affect machine life Safety messages in this Chapter are intended to il lustrate basic safety procedures of the machine However it is impossible for these safety messages to cover every hazardous situation you may en counter If you have any doubts consult your direct supervisor prior to operating or servicing ...

Page 22: ... not wear headphones while operating the ma chine Work clothing that has come in contact with oil could catch fire Change clothes immediately PROTECT AGAINST NOISE Prolonged exposure to loud noise can cause impair ment or loss of hearing Wear a suitable hearing protection such as earmuffs or earplugs to protect objectionable or uncomfortably loud noise INSPECT THE MACHINE Inspect the machine caref...

Page 23: ...Be careful of slippery conditions on platforms steps and handrails when leaving the machine ADJUST THE OPERATOR S SEAT A seat poorly adjusted for operator or work require ments may quickly fatigue the operator leading to improper operations The seat should be adjusted whenever machine operator changes The operator should be able to fully press the pedals and correctly move the control levers with ...

Page 24: ...though they do not look damaged OPERATE ONLY FROM THE DRIVER S SEAT Inappropriate engine starting procedures may cause the machine unexpected movement possibly resulting in serious injury and even death Start the engine only from the operator s seat Never start the engine while standing on the track or on the ground Do not start the engine by shorting across starter motor terminals Before starting...

Page 25: ...ossibility of serious bodily harm or death due to accidental falls from the machine CONFIRM TRAVEL DIRECTION Incorrect travel controls operation may result in se rious injury and even death Before driving the machine be aware of the undercarriage position relative to the operator s position If travel motors M are located at the front of the cab the machine will move reverse when travel controls ar...

Page 26: ...the work area Sound the horn or other signal to warn bystanders before moving machine If your view is obstructed use a signal person when traveling or swinging Always keep the signal person in view No machine motions shall be made unless signals are clearly understood by both signalman and operator Learn the meanings of all flags signs and markings used on the job and confirm with the person in ch...

Page 27: ...ximately 20 30 cm above the ground A If machine starts to skid or becomes unstable lower the bucket immediately Traveling across the face of a slope may cause the machine to skid or to overturn When travelling ascending descending on a slope be sure to point the tracks uphill downhill Turning on an incline may cause the machine to tip over If turning on an incline is absolutely unavoidable do so a...

Page 28: ... dangerous spots Actuate the controls slowly and carefully to prevent the machine from making unwanted slippery manoeuvres or movements Even on minor slopes when snow is present and on frozen ground unwanted slippery manoeuvres or movements of the machine could occur INVESTIGATE JOB SITE BEFORE OPERATING THE MACHINE Explore the working area to identify potential risks before starting and operating...

Page 29: ...ten or repair protective structures Contact a Dealer to verify the functionality to repair or to completely or partially replace the protective structures DIG WITH CAUTION Accidental severing of underground cables or gas lines may cause an explosion and or fire possibly resulting in serious injury or death Before digging check the location of cables gas lines and water lines Keep the minimum dista...

Page 30: ...move any part of the machine or load closer than 5 m plus twice the line insulator length L Check and comply with any local regulations that may apply Wet ground will expand the area that could cause any person on it to be affected by electric shock Keep all bystanders or co workers away from the site KEEP PERSONNEL CLEAR FROM WORKING AREA A person may be hit severely by the swinging front attachm...

Page 31: ...with the bucket DO NOT OPERATE IN TUNNELS Do not operate the machine in enclosed spaces or in any case without appropriate ventilation Opera tions in tunnels or underground sites where poten tial explosive conditions exist are not allowed There is a danger for explosions and potentially deadly in juries NEVER UNDERCUT A HIGH BANK The edges could collapse or a land slide could occur causing serious...

Page 32: ...o remain under the raised load or within the excavator operating range for any reason whatever Never exceed specified loading capacity Incorrect fastening of slings or chains may cause boom arm failure or failure of the lifting means with consequent bodily injuries and even death Always ensure that slings and chains used for lifting are adequate to the load and in good condition All loading capaci...

Page 33: ...ess on the front attachment could results in damages to the structure Use the undercarriage for travelling only DO NOT USE THE TURRET SWING FOR DIGGING Do not use the turret swing for digging or moving rocks An excessive stress on the front attachment could results in damages to the structure reducing the operating life of the swing system Also this in appropriate use of the machine could cause se...

Page 34: ... a level surface Lower bucket to the ground Pull the safety lever pilot control shut off lever to the LOCK position Turn auto idle switch off Run engine at slow idle speed without load for 5 minutes Turn key start switch to OFF to stop engine Remove the ignition key from the key switch Prior to leaving the machine close the windows the cab door and all panels TRANSPORTING THE MACHINE UNDER SAFE CO...

Page 35: ... spray water or steam inside the cab Do not lubricate or service the machine when it is in motion Keep hands feet and clothes far from moving parts Do not leave the machine unattended if servicing requires the engine running If the machine is to be raised place boom and arm at an angle 90 to 110 Lock machine components which should be raised for maintenance or repair using suitable supporting mean...

Page 36: ...st work on a lifted machine or attachment securely support the machine or attachment Do not support the machine on cinder blocks hollow tires or props that may crumble under continuous load Do not work under a machine that is supported solely by a jack STOP THE ENGINE PRIOR TO PERFORMING Do not perform any maintenance operation with the engine running Trapping by moving parts could cause serious i...

Page 37: ... containers for food or beverages which may induce drinking Do not spill waste over the ground into drains or water beds Obtain information about the correct methods to recycle or dispose of waste from local Authorities collection centres or your Dealer PROPERLY LIGHT THE WORKING AREA Properly and safely light the working area Use safe portable lamps in order to work inside and under the machine M...

Page 38: ...der to quicken the engine cooling process and clean the compart ment PREVENT ACID SCALDS The sulfuric acid contained in the battery is poison ous It is strong enough to scald the skin corrode clothes and cause blindness if it is sprayed into the eyes To avoid dangers Fill the batteries in airy areas Wear eye protections and rubber gloves Avoid breathing the electrolyte vapours when topping up Avoi...

Page 39: ...for starting the engine with slave batteries may cause the batteries to explode or machine to move unexpectedly PREVENT BATTERY EXPLOSIONS Battery gas can explode Keep sparks lighted matches and flames away from the top of battery Never check battery charge by placing a metal object across the posts Use a voltmeter or hydrometer Do not charge a frozen battery it may explode Warm battery to 16 C Ba...

Page 40: ...ressure to be released before removing the cap The hydraulic oil tank is pressurized Again be sure to release all pressure before removing the cap Engine oil reduction gear oil and hydraulic oil also become hot during operation The engine hoses lines and other parts become hot as well Wait for the oil and components to cool down before starting any maintenance or inspection work STORE ATTACHMENTS ...

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