Hyundai HW65AH User manual

HW65AH
WHEELED EXCAVATOR
SERVICE MANUAL

TABLE OF CONTENT
CONTENTS 2
FOREWORD 4
1. Structure 4
2. How To Read The Service Manual 5
3. Conversion Table 6
SECTION 1 GENERAL 13
Group 1 Safety 13
Group 2 Specifications 21
1. Major Component 21
2. Specifications 22
3. Working Range 24
4. Weight 25
5. Lifting Capacities 26
6. Bucket Selection Guide 42
7. Specifications For Major Components 43
8. Recommended Lubricants 46
SECTION 2 STRUCTURE AND FUNCTION 48
Group 1 Hydraulic Pump 48
1. General 48
2. Principal Components And Functions 49
Group 2 Main Control Valve 53
1. Outline 53
2. Structure (1/4) 55
3. Hydraulic Circuit (boom Swing) 59
4. Function 60
Group 3 Swing Device 75
1. Structure 75
2. Function 78
Group 4 Travel Device 85
1. Construction 85
2. Function 88
Group 5 Rcv Lever 91
1. Structure 91
2. Functions 94
Group 6 Rcv Pedal 98
1. Structure 98
Group 7 Brake Pedal (valve) 99
1. Structure 99
2. Function 100
Group 8 Gear Box 101
1. Structure 101
2. Gear Box Function 102
3. Technical Data 103
Group 9 Axle 104
1. Operation 104
2. Section Of Differential 105
3. Differential 106
4. Final Drive 107
5. Tire And Wheel 109
SECTION 3 HYDRAULIC SYSTEM 110
Group 1 Hydraulic Circuit 111
1. Hydraulic Circuit (1/3) 111
2. Hydraulic Circuit (2/3) 112
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3. Hydraulic Circuit (3/3) 113
Group 2 Main Circuit 114
1. Suction And Delivery Circuit 114
2. Return Circuit 115
3. Drain Circuit 116
Group 3 Pilot Circuit 117
1. Suction, Delivery And Return Circuit 118
2. Safety Valve (safety Lever) 119
3. Travel Speed Control System 120
4. Swing Parking Brake Release 121
Group 4 Single Operation 122
1. Boom Up Operation 122
2. Boom Down Operation 123
3. Arm Roll In Operation 124
4. Arm Roll Out Operation 125
5. Bucket Roll In Operation 126
6. Bucket Roll Out Operation 127
7. Swing Operation 128
8. Travel Forward And Reverse Operation 130
9. Dozer Up Operation 132
10. Dozer Down Operation 133
11. Front And Rear Axle Brake System (service Brake) 134
12. Steering Circuit Operation 135
13. Ram Lock Circuit Operation 136
Group 5 Combined Operation 137
1. Outline 137
2. Combined Swing And Boom Operation 138
3. Combined Swing And Arm Operation 139
4. Combined Swing And Bucket Operation 140
5. Combined Swing, Boom, Arm And Bucket Operation 141
SECTION 4 ELECTRICAL SYSTEM 142
Group 1 Component Location 143
1. Location 1 143
2. Location 2 144
Group 2 Monitoring System 145
Hest Pilot Lamp Dpf Regeneration Inhibit Pilot Lamp Maintenance Pilot Lamp Smart Key Pilot
Lamp (opt) Seat Belt Reminder Warning 155
N/min 156
A) Rotary Setting 167
B) Grapple Setting 168
C) Confifi Fifi Rmation 169
Switch To Activate Rear / Rh View Camera From The Beginning Screen. While In That Mode,
Select The Esc Switch To Return To The H 178
Select 178
Cam Image Control (cic) Mode 178
Rh) Button On Screen To Set Single-view Camera Mode. Touch 178
Touch 178
Rear), 178
(2ch-split-view) Button To Set Split-view Camera Mode. 178
Split-view Camera Order Setting 178
(camera Setting) Button To Set Split-view Camera Order. 178
Touch 178
You Can Change Spilt-view Camera Order On Display Order Menu. 178
Group 3 Electrical Circuit 189
·electrical Circuit (1/3) 189
·electrical Circuit (2/3) 190
Memorandum 192
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1. Power Circuit 193
2. Starting Circuit 195
3. Charging Circuit 197
4. Head Lamp And Work Lamp Circuit 199
5. Beacon Lamp And Cab Lamp Circuit 201
6. Wiper And Washer Circuit 203
Monitoring Circuit 205
Illumination Circuit 206
Combination Lamp Circuit 207
Electric Circuit For Hydraulic 208
Group 4 Electrical Component Specification 209
Group 5 Connectors 218
1. Connector Destination 218
- 220
2 222
2. Connection Table For Connectors 223
Group 6 Fault Codes 237
1. Machine Fault Code 237
SECTION 5 TROUBLESHOOTING 249
Group 1 Before Troubleshooting 250
1. Introduction 250
2. Diagnosing Procedure 251
Group 2 Hydraulic And Mechanical System 253
1. Introduction 253
2. Drive System 254
3. Hydraulic System 256
4. Swing System 258
5. Travel System 262
6. Attachment System 266
Group 3 Electrical System 272
1. When Starting Switch Is Turned On, Monitor Panel Display Does Not Appear 272
2. Battery Charging Warning Lamp Lights Up (starting Switch : On) 273
3. When Coolant Overheat Warning Lamp Lights Up (engine Is Started) 274
4. When Air Cleaner Warning Lamp Lights Up (engine Is Started) 275
5. When Engine Oil Pressure Warning Lamp Lights Up (engine Is Started) 276
6. When Hydraulic Oil Temperature Warning Lamp Lights Up (engine Is Started) 277
7. When Coolant Temperature Gauge Does Not Operate 278
8. When Fuel Gauge Does Not Operate (check Warning Lamp On/off) 279
9. When Safety Solenoid Does Not Operate 280
10. When Starting Switch Is Turned On, Work Lamp Does Not Lights Up 281
11. When Engine Does Not Start 282
12. When Starting Switch On Does Not Operate 283
13. When Starting Switch Is Turned On, Wiper Motor Does Not Operate 284
14. When Starting Switch Is Turned On, Head Lamp Does Not Lights Up 285
Group 4 Axle 286
1. Trouble Shooting 286
Group 5 Air Conditioner And Heater System 289
1. Air Conditioner Does Not Operate 289
SECTION 6 MAINTENANCE STANDARD 293
Group 1 Operational Performance Test 293
1. Purpose 293
2. Terminology 294
3. Operation For Performance Tests 295
Group 2 Major Component 311
1. Main Pump 311
2. Main Control Valve 313
3. Swing Device 314
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4. Travel Motor 315
5. Rcv Lever 317
6. Accelerator Pedal 318
7. Turning Joint 319
8. Cylinder 320
9. Work Equipment 321
SECTION 7 DISASSEMBLY AND ASSEMBLY 323
Group 1 Precautions 323
1. Removal Work 323
323
2. Install Work 324
3. Completing Work 325
Group 2 Tightening Torque 326
1. Major Components 326
2. Torque Chart 327
5. 347
6. 349
Group 4 Main Control Valve 363
1. Removal And Install Of Motor 363
363
2. Structure (1/4) 364
Structure (2/4) 365
Structure (3/4) 366
Structure 367
3. Disassembly And Assembly 368
Group 5 Swing Device 378
1. Removal And Install Of Motor 378
378
2. Disassembly And Assembly Of Swing Motor 379
3. Removal And Install Of Reduction Gear 392
Friction 392
4. Disassembly And Assembly Of Reduction Gear 393
Group 6 Travel Motor 399
1. Removal And Install 399
2. Structure 400
3. Tightening Torque 403
4. Disassembly And Assembly 404
Group 7 Gear Box 423
1. Removal And Install 423
2. Instructions 424
3. Counter Revolution Sensor 425
4. Hydraulic Gear Control 426
5. Integrated Reduction Gear 434
Group 8 Steering Valve 458
1. Removal And Install 458
2. Steering Valve 459
Group 9 Axle 479
1. General Introductions Introduction 479
1) 2) 3) 479
Introductory Statement 479
Maintenance And Repair 479
2. Front Axle 480
4. Rear Axle 563
Group 10 Rcv Lever 623
1. Removal And Install 623
2. Disassembly And Assembly 624
Group 11 Turning Joint 637
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1. Removal And Install 637
2. Disassembly And Assembly 638
Group 12 Boom, Arm And Bucket Cylinders 642
1. Removal And Install 642
2. Disassembly And Assembly 648
Group 13 Work Equipment 668
1. Structure 668
2. Removal And Install 669
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CONTENTS
CONTENTS
SECTION 1 GENERAL
SECTION 1 GENERAL
Group 1 Safety Hints ---------------------------------------------------------------------------------------------------- 1-1
Group 2 Specifications
------------------------------------------------------------------------------------------------- 1-9
SECTION 2 STRUCTURE AND FUNCTION
SECTION 2 STRUCTURE AND FUNCTION
Group 1 Pump Device -------------------------------------------------------------------------------------------------- 2-1
Group 2 Main Control Valve
----------------------------------------------------------------------------------------- 2-6
Group 3 Swing Device ------------------------------------------------------------------------------------------------- 2-28
Group 4 Travel Device -------------------------------------------------------------------------------------------------- 2-38
Group 5 RCV Lever ------------------------------------------------------------------------------------------------------ 2-44
Group 6 RCV pedal ------------------------------------------------------------------------------------------------------ 2-51
Group 7 Brake pedal (valve) ---------------------------------------------------------------------------------------- 2-52
Group 8 Gear box --------------------------------------------------------------------------------------------------------- 2-54
Group 9 Axle ------------------------------------------------------------------------------------------------------------------ 2-57
SECTION 3 HYDRAULIC SYSTEM
SECTION 3 HYDRAULIC SYSTEM
Group 1 Hydraulic Circuit --------------------------------------------------------------------------------------------- 3-1
Group 2 Main Circuit
----------------------------------------------------------------------------------------------------- 3-4
Group 3 Pilot Circuit ------------------------------------------------------------------------------------------------------ 3-7
Group 4 Single Operation -------------------------------------------------------------------------------------------- 3-12
Group 5 Combined Operation ------------------------------------------------------------------------------------- 3-27
SECTION 4 ELECTRICAL SYSTEM
SECTION 4 ELECTRICAL SYSTEM
Group 1 Component Location ------------------------------------------------------------------------------------- 4-1
Group 2 Monitoring system
------------------------------------------------------------------------------------------ 4-3
Group 3 Electrical Circuit
---------------------------------------------------------------------------------------------- 4-47
Group 4 Electrical Component Specification ------------------------------------------------------------- 4-67
Group 5 Connectors ----------------------------------------------------------------------------------------------------- 4-76
Group 6 Fault codes ----------------------------------------------------------------------------------------------------- 4-95
SECTION 5 TROUBLESHOOTING
SECTION 5 TROUBLESHOOTING
Group 1 Before Troubleshooting ---------------------------------------------------------------------------------- 5-1
Group 2 Hydraulic and Mechanical System
--------------------------------------------------------------- 5-4
Group 3 Electrical System ------------------------------------------------------------------------------------------- 5-23
Group 4 Axle ----------------------------------------------------------------------------------------------------------------- 5-37
Group 5 Air Conditioner and Heater system --------------------------------------------------------------- 5-40
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SECTION 6 MAINTENANCE STANDARD
SECTION 6 MAINTENANCE STANDARD
Group 1 Operational Performance Test ---------------------------------------------------------------------- 6-1
Group 2 Major Components
---------------------------------------------------------------------------------------- 6-19
SECTION 7 DISASSEMBLY AND ASSEMBLY
SECTION 7 DISASSEMBLY AND ASSEMBLY
Group 1 Precaution ------------------------------------------------------------------------------------------------------ 7-1
Group 2 Tightening Torque
------------------------------------------------------------------------------------------ 7-4
Group 3 Pump Device -------------------------------------------------------------------------------------------------- 7-7
Group 4 Main Control Valve ----------------------------------------------------------------------------------------- 7-41
Group 5 Swing Device ------------------------------------------------------------------------------------------------- 7-56
Group 6 Travel Device -------------------------------------------------------------------------------------------------- 7-76
Group 7 Gear box -------------------------------------------------------------------------------------------------------- 7-100
Group 8 Steering valve ------------------------------------------------------------------------------------------------ 7-135
Group 9 Axle ----------------------------------------------------------------------------------------------------------------- 7-156
Group 10 RCV Lever ------------------------------------------------------------------------------------------------------ 7-301
Group 11 Turning Joint --------------------------------------------------------------------------------------------------- 7-315
Group 12 Boom, Arm and Bucket Cylinder ------------------------------------------------------------------ 7-320
Group 13 Work Equipment -------------------------------------------------------------------------------------------- 7-335
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0-1
FOREWORD
FOREWORD
1. STRUCTURE
1. STRUCTURE
This service manual has been prepared as an aid to improve the quality of repairs by giving the
serviceman an accurate understanding of the product and by showing him the correct way to
perform repairs and make judgements. Make sure you understand the contents of this manual and
use it to full effect at every opportunity.
This service manual mainly contains the necessary technical information for operations performed in
a service workshop.
For ease of understanding, the manual is divided into the following sections.
SECTION 1 GENERAL
SECTION 1 GENERAL
This section explains the safety hints and gives the specification of the machine and major
components.
SECTION 2 STRUCTURE AND FUNCTION
SECTION 2 STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an
understanding of the structure, but also serves as reference material for troubleshooting.
SECTION 3 HYDRAULIC SYSTEM
SECTION 3 HYDRAULIC SYSTEM
This section explains the hydraulic circuit, single and combined operation.
SECTION 4 ELECTRICAL SYSTEM
SECTION 4 ELECTRICAL SYSTEM
This section explains the electrical circuit, monitoring system and each component. It serves not
only to give an understanding electrical system, but also serves as reference material for trouble
shooting.
SECTION 5 MECHATRONICS SYSTEM
SECTION 5 MECHATRONICS SYSTEM
This section explains the computer aided power optimization system and each component.
SECTION 6 TROUBLESHOOTING
SECTION 6 TROUBLESHOOTING
This section explains the troubleshooting charts correlating
problems
problems to
causes
causes.
SECTION 7 MAINTENANCE STANDARD
SECTION 7 MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
SECTION 8 DISASSEMBLY AND ASSEMBLY
SECTION 8 DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or
assembling each component, as well as precautions to be taken for these operations.
SECTION 9 COMPONENT MOUNTING TORQUE
SECTION 9 COMPONENT MOUNTING TORQUE
This section shows bolt specifications and standard torque values needed when mounting
components to the machine.
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Contact your HD Hyundai Construction Equipment distributor for the latest
information.
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0-2
Revised edition mark
Revised edition mark (①②③…)
When a manual is revised, an edition mark is
recorded on the bottom outside corner of the
pages.
Revisions
Revisions
Revised pages are shown at the list of revised
pages on the between the contents page and
section 1 page.
Symbols
Symbols
So that the shop manual can be of ample
practical use, important places for safety and
quality are marked with the following symbols.
2. HOW TO READ THE SERVICE MANUAL
2. HOW TO READ THE SERVICE MANUAL
Distribution and updating
Distribution and updating
Any additions, amendments or other changes will
be sent to HD Hyundai Construction Equipment
distributors.
Get the most up-to-date information before you
start any work.
Filing method
Filing method
See the page number on the bottom of the
page.
File the pages in correct order.
Following examples shows how to read the
page number.
Example 1
2 - 3
Item number (2. Structure and
Function)
Consecutive page number for
each item.
Additional pages : Additional pages are
indicated by a hyphen(-) and number after the
page number. File as in the example.
1.
2.
3.
※
10 - 4
10 - 4 - 1
10 - 4 - 2
10 - 5
Added pages
Symbol Item Remarks
Safety
Special safety precautions are
necessary when performing the
work.
Extra special safety precautions
are necessary when
performing the work because it
is under internal pressure.
Caution
Special technical precautions
or other precautions for
preserving standards are
necessary when performing the
work.
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0-3
3. CONVERSION TABLE
Method of using the Conversion Table
The Conversion Table in this section is provided to enable simple conversion of figures. For details of
the method of using the Conversion Table, see the example given below.
Example
Method of using the Conversion Table to convert from millimeters to inches
Convert 55 mm into inches.
Locate the number 50 in the vertical column at the left side, take this as ͽ , then draw a
horizontal line from ͽ .
Locate the number 5 in the row across the top, take this as ; , then draw a perpendicular line
down from ; .
Take the point where the two lines cross as Ϳ . This point Ϳ gives the value when converting
from millimeters to inches. Therefore, 55 mm = 2.165 inches.
Convert 550 mm into inches.
The number 550 does not appear in the table, so divide by 10(Move the decimal point one place
to the left) to convert it to 55 mm .
Carry out the same procedure as above to convert 55 mm to 2.165 inches.
The original value (550 mm ) was divided by 10, so multiply 2.165 inches by 10 (Move the decimal
point one place to the right) to return to the original value.
This gives 550 mm = 21.65 inches.
1.
2.
(1)
(2)
(3)
(1)
(2)
(3)
Millimeters to inches 1
mm = 0.03937 in
;
ͽ
0 1 2 3 4 5 6 7 8 9
0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Ϳ

0-4
Millimeters to inches 1
mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound 1
kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.5. 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26

0-5
Liter to U.S. Gallon 1˶= 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.6076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.631 25.625 25.889 26.153
Liter to U.K. Gallon 1˶= 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777

0-6
kgfÂm to lbfÂft
1 kgfÂm = 7.233 lbfÂft
0 1 2 3 4 5 6 7 8 9
7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 396.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 10005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4

0-7
kgf/cm2 to lbf/in2
1 kgf / cm2 = 14.2233 lbf / in
2
0 1 2 3 4 5 6 7 8 9
14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 2863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 5603 2617 2631 2646 2660 2674 2688
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542

0-8
TEMPERATURE
Fahrenheit-Centigrade Conversion.
A simple way to convert a fahrenheit temperature reading into a centigrade temperature reading or vice verse
is to enter the accompanying table in the center or boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
˚ C ˚ F ˚ C ˚ F ˚ C ˚ F ˚ C ˚ F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8
-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8
-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8
-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8
-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 35 95.0 21.1 70 158.0 51.7 125 257.0
-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0
-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0
-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0
-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 172 347.0

SECTION 1 GENERAL
SECTION 1 GENERAL
Group 1 Safety Hints ----------------------------------------------------------------------------------------------------- 1-1
Group 2 Specifications
-------------------------------------------------------------------------------------------------- 1-9

1-1
FOLLOW SAFE PROCEDURE
FOLLOW SAFE PROCEDURE
Unsafe work practices are dangerous. Understand
service procedure before doing work; do not
attempt shortcuts.
WEAR PROTECTIVE CLOTHING
WEAR PROTECTIVE CLOTHING
Wear close fitting clothing and safety equipment
appropriate to the job.
WARN OTHERS OF SERVICE WORK
WARN OTHERS OF SERVICE WORK
Unexpected machine movement can cause
serious injury.
Before performing any work on the excavator,
attach a Ö
Do Not Operate
Do Not Operate ×tag on the right
side control lever.
USE HANDHOLDS AND STEPS
USE HANDHOLDS AND STEPS
Falling is one of the major causes of personal
injury.
When you get on and off the machine, always
maintain a three point contact with the steps and
handrails and face the machine. Do not use any
controls as handholds.
Never jump on or off the machine. Never mount or
dismount a moving machine.
Be careful of slippery conditions on platforms,
steps, and handrails when leaving the machine.
SECTION 1 GENERAL
SECTION 1 GENERAL
GROUP 1 SAFETY
GROUP 1 SAFETY
13031GE01
13031GE02
13031GE03

1-2
PREPARE FOR EMERGENCIES
PREPARE FOR EMERGENCIES
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance
service, hospital, and fire department near your
telephone.
PROTECT AGAINST FLYING DEBRIS
PROTECT AGAINST FLYING DEBRIS
Guard against injury from flying pieces of metal
or debris; wear goggles or safety glasses.
PROTECT AGAINST NOISE
PROTECT AGAINST NOISE
Prolonged exposure to loud noise can cause
impairment or loss of hearing.
Wear a suitable hearing protective device such as
ear-
muffs or earplugs to protect against objectionable
or uncomfortable loud noises.
AVOID POWER LINES
AVOID POWER LINES
Serious injury or death can result from contact with
electric lines.
Never move any part of the machine or load closer
to electric line than 3 m (10 ft ) plus twice the line
insulator length.
13031GE04
13031GE05
13031GE06
14W7A1GE07

1-3
KEEP RIDERS OFF EXCAVATOR
KEEP RIDERS OFF EXCAVATOR
Only allow the operator on the excavator. Keep
riders off.
Riders on excavator are subject to injury such as
being struck by foreign objects and being thrown
off the excavator. Riders also obstruct the
operator's view resulting in the excavator being
operated in an unsafe manner.
MOVE AND OPERATE MACHINE SAFELY
MOVE AND OPERATE MACHINE SAFELY
Bystanders can be run over. Know the location of
bystanders before moving, swinging, or operating
the machine.
Always keep the travel alarm in working condition.
It warns people when the excavator starts to move.
Use a signal person when moving, swinging, or
operating the machine in congested areas.
Coordinate hand signals before starting the
excavator.
OPERATE ONLY FORM OPERATOR'S SEAT
OPERATE ONLY FORM OPERATOR'S SEAT
Avoid possible injury machine damage. Do not
start engine by shorting across starter terminals.
NEVER start engine while standing on ground.
Start engine only from operator's seat.
PARK MACHINE SAFELY
PARK MACHINE SAFELY
Before working on the machine:
ÂPark machine on a level surface.
ÂLower bucket to the ground.
ÂTurn auto idle switch off.
ÂRun engine at 1/2 speed without load for 2 minutes.
ÂTurn key switch to OFF to stop engine.
Remove key from switch.
ÂMove pilot control shutoff lever to locked position.
ÂAllow engine to cool.
14W7A1GE08
13031GE26
14W7A1GE09