Kobelco ED160-3 Operators Manual

OPERATOR’S MANUAL Hydraulic Excavator ED160-3 Blade Runner ™ Tier 4 S2LH00006ZE01 Issued October 2012 APPLICABLE: ED160-3 . . . . . . . . . . . . . LH02-01501~

Contents 1 GENERAL INFORMATION Note to the owner........................................................................... 1-1 Intended use ................................................................................ 1-2 Electro-Magnetic Compatibility (EMC) ..................................................... 1-4 Right, left, front and rear of the machine ................................................... 1-5 Diesel particulate ﬁlter (DPF) ............................................................... 1-9 2 SAFETY INFORMATION Safety rules ................................................................................. 2-1 Proposition 65 .............................................................................. 2-2 Safety rules ................................................................................. 2-3 Safety signs ............................................................................... 2-17 Safety signs ............................................................................... 2-18 Hand signals ............................................................................... 2-34 3 CONTROLS/INSTRUMENTS ACCESS TO OPERATOR'S PLATFORM Cab ..................................................................................... 3-1 OPERATOR'S SEAT Operator's seat ......................................................................... 3-4 FORWARD CONTROLS Front console ........................................................................... 3-6 Instrument cluster ...................................................................... 3-9 Rear view camera ..................................................................... 3-23 RIGHT-HAND SIDE CONTROLS Right-hand console - operating ........................................................ 3-24 Radio .................................................................................. 3-29 Climate control panel .................................................................. 3-33 REARWARD CONTROLS Rearward controls ..................................................................... 3-36 4 OPERATING INSTRUCTIONS COMMISSIONING THE UNIT Hydraulic oil level ....................................................................... 4-1 Fuel level ............................................................................... 4-2 Engine oil level ......................................................................... 4-3 Engine coolant level .................................................................... 4-4 Windshield washer ﬂuid level ........................................................... 4-5

Draining the fuel ﬁlter water separator ................................................. 4-6 STARTING THE UNIT Starting the engine ..................................................................... 4-7 Inspection after starting the engine .................................................... 4-10 STOPPING THE UNIT Stopping the engine ................................................................... 4-11 PARKING THE UNIT Parking the machine ................................................................... 4-12 5 TRANSPORT OPERATIONS ROAD TRANSPORT Preparing for road transport ............................................................ 5-1 SHIPPING TRANSPORT Lifting the machine ..................................................................... 5-4 6 WORKING OPERATIONS GENERAL INFORMATION Operating the controls .................................................................. 6-1 Machine travel .......................................................................... 6-2 Attachment controls .................................................................... 6-3 Swing control ........................................................................... 6-4 Dozer blade control ..................................................................... 6-5 Practices to improve efﬁciency ......................................................... 6-6 Emergency boom lowering ............................................................. 6-8 Machine operation in adverse weather conditions ..................................... 6-9 7 MAINTENANCE GENERAL INFORMATION Preparing machine for maintenance ................................................... 7-1 Biodiesel fuel - Biodiesel fuels ......................................................... 7-2 Break-in period ......................................................................... 7-4 MAINTENANCE CHART Maintenance Chart ..................................................................... 7-5 Every 50 hours of operation or weekly Battery .................................................................................. 7-7

Fuel tank ................................................................................ 7-9 Track tension .......................................................................... 7-10 Dozer blade lubrication ................................................................ 7-12 Every 120 hours Swing reduction unit oil ................................................................ 7-13 Travel reduction unit oil ................................................................ 7-14 Every 250 hours Engine air filter: outer element ........................................................ 7-15 Checking the radiator hoses ........................................................... 7-17 Hydraulic return filter (Breaker use only) .............................................. 7-18 Hydraulic oil tank ...................................................................... 7-19 Bucket grease fittings.................................................................. 7-20 Outside fresh air filter .................................................................. 7-21 Fan, alternator, and air conditioner belts .............................................. 7-22 Every 500 hours Cab air recirculation filter .............................................................. 7-24 Engine oil and filter .................................................................... 7-25 Fuel filter ............................................................................... 7-27 Fuel pre-filter .......................................................................... 7-29 Fuel tank filter ......................................................................... 7-31 Swing bearing ......................................................................... 7-32 Control lever lubrication ............................................................... 7-33 Boom lift - Lubricate ................................................................... 7-34 Every 1000 hours Engine air filters ....................................................................... 7-35 Hydraulic oil return filters .............................................................. 7-36 Hydraulic reservoir breather ........................................................... 7-37 Every 2000 hours Pilot line filter .......................................................................... 7-38 Swing reduction unit oil ................................................................ 7-39 Travel reduction unit oil ................................................................ 7-40 Engine coolant ......................................................................... 7-41 Every 5000 hours Hydraulic oil ........................................................................... 7-43 As required Fuses and relays ...................................................................... 7-46 Removing and installing the bucket ................................................... 7-48 Removing and installing the dozer blade in the field .................................. 7-50 Bucket teeth and side cutters.......................................................... 7-52

Moving a disabled machine ........................................................... 7-54 Lowering bucket attachment on a disabled machine .................................. 7-55 Preparing for storage .................................................................. 7-56 Every 30 days ......................................................................... 7-57 Starting up after storage ............................................................... 7-58 Fluids and lubricants Fluids and lubricants ED160-3 ........................................................ 7-59 8 SPECIFICATIONS General speciﬁcations ED160–3 ........................................................... 8-1 Dozer speciﬁcations ........................................................................ 8-2 Dimensions and weights ED160–3 ........................................................ 8-3 Digging data ED160–3 ..................................................................... 8-4 Buckets application as a function of the arm ED160–3 .................................... 8-6 Lift capacities - Model ED160–3 ........................................................... 8-7 9 ACCESSORIES Nibbler ...................................................................................... 9-1 Breaker ..................................................................................... 9-5 Hydraulic oil - breaker/nibbler ............................................................. 9-10 Hammer and rotating bucket hydraulic system - Operating ............................... 9-11 Biodegradable hydraulic oil ................................................................ 9-12

1 - GENERAL INFORMATION 1 - GENERAL INFORMATION Note to the owner This manual contains information concerning the adjustment and maintenance of your new equipment. You have purchased a dependable machine, but only by proper care and operation can you expect to receive the performance and long service built into this equipment. Please have all operators read this manual carefully and keep it available for ready reference. Your KOBELCO dealer will instruct you in the general operation of your new equipment. Your dealer's staff of fac- tory-trained service technicians will be glad to answer any questions that may arise regarding the operation of your machine. KOBELCO Construction Customer Service is also available. Call 1-866-KOB-LC01 (1-866-562-5201) or email customerservicekobelco.na@cnh.com. Your KOBELCO dealer carries a complete line of genuine KOBELCO service parts. These parts are manufactured and carefully inspected to insure high quality and accurate fitting of any necessary replacement parts. Be prepared to give your dealer the model and product identification number of your new equipment when ordering parts. Locate these numbers now and record them below. Refer to the 'General Information' section of this manual for the location of the model and product identification numbers of your machine. PLEASE RECORD THE FOLLOWING INFORMATION Model Product Identification Number (PIN) Date Purchased Engine Model Engine PIN This is the safety alert symbol. It is used with and without signal words to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible death or injury. WARNING Illustrations in this manual may show protective shielding open or removed to better illustrate a par- ticular feature or adjustment. Replace all shields before operating the machine. Failure to comply could result in death or serious injury. W0012A IMPROVEMENTS CNH America LLC is continually striving to improve its products. We reserve the right to make improvements or changes when it becomes practical and possible to do so, without incurring any obligation to make changes or addi- tions to the equipment sold previously. 1-1

1 - GENERAL INFORMATION Intended use The machine has been designed and constructed in accordance with the most rigorous standards of quality and in compliance with current safety regulations. Never use the machine for applications not included in the manual. If the machine needs to be used for work that involves the use of special equipment, accessories or instruments, consult the dealer to make sure that any adaptations or modifications carried out comply with the technical specifications of the machine and with the safety standards. Any modification or adaptation that is not approved by the manufacturer may invalidate the original conformity of the machine to the safety requirements and the persons that carry out these unapproved modifications will be held responsible for the consequences. Before handing the machine over to an operator, check that: • The operator has been properly trained in the correct and safe use of the machine. • The operator has read the instructions in this manual and that they understand them fully. Always keep this manual in the cab. Make sure that it is always intact and in good condition. Contact the dealer for further copies or a translation into a different language from the country of use. ATTENTION: The engine and fuel system on your machine is designed and built to government emissions standards. Tampering by dealers, customers, operators and users is strictly prohibited by law. Failure to comply could result in government fines, rework charges, invalid warranty, legal action and possible confiscation of the machine until rework to original condition is completed. Engine service and/or repairs must be done by a certified technician only. NOTE: Each machine is supplied complete with a copy of this Manual. Descriptions and illustrations herein are not binding. The manufacturer, provided that the basic characteristics of machine types described and shown in this Manual remain the same, reserves the right to change components, parts and accessories supplied without any com- mitment to timely update this publication; and this any time it deems it convenient for improvement purposes or due to commercial or manufacturing requirements. For exact information, please consult your dealer or contact the manufacturer’s branch offices. 1-2

1 - GENERAL INFORMATION Introduction The excavator is a hydraulically operated machine. It consists of an undercarriage fitted with tracks and a swing bearing which supports the upper frame. The upper frame supports the attachment, the engine, the hydraulic components, the cab, the fuel tank and the counterweight. When the operator activates the controls (pedals/levers), the hydraulic pumps, operated by the engine, pumps the oil from the tank, sending it to the control valve which sends the oil to perform the requested operation. A cooling system maintains the hydraulic oil at normal operating temperature. RAPH12CEX1197EA 1 NOTICE: Do not use the excavator for operations which are foreign to its specifications and not included in this manual in order to prevent serious injury to persons or damage to the machine. The manufacturer/dealer is not responsible for damage caused by improper use. The excavator has been designed to carry out digging and earth moving operations through the use of a bucket. Operations that involve the use of hydraulic hammers or crushers are also possible. Other operations, such as moving suspended loads, are only possible if the specific variant approved by the manufacturer is present. Using the excavator and its equipment for different operations, such as, for example, towing, transporting and lifting people, is considered inappropriate and is prohibited. 1-3

1 - GENERAL INFORMATION Electro-Magnetic Compatibility (EMC) Interference may arise as a result of add‐on equipment which may not necessarily meet the required standards. As such interference can result in serious malfunction of the unit and/or create unsafe situations, you must observe the following: • The maximum power of emission equipment (radio, telephones, etc.) must not exceed the limits imposed by the national authorities of the country where you use the machine. • The electro‐magnetic ﬁeld generated by the add‐on system should not exceed 24 V/m at any time and at any location in the proximity of electronic components. • The add‐on equipment must not interfere with the functioning of the on board electronics. Failure to comply with these rules will render the KOBELCO warranty null and void. 1-4

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Kobelco ED160-3 Operators Manual

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