Furukawa HCR 910

HCR910-DS-F101

Serial No. 2114548-

WARNING Neither the operator nor the person in charge of maintenance should operate, or inspect, or maintain or adjust the machine after reading this manual carefully thoroughly.

and

understanding

the

contents

IMPORTANT INFORM ATION

Model:

Serial Number:

Year of Ma nufacture :

CE Mark:

After the delivery of the machine, please fill in Warranty Registration Information and send it to the local Caterpillar dealer. If the Warranty Registration Information is not correctly registered, you cannot have the warranty of Caterpillar Corporation concerning the engine.

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IMPORTANT INFORMATION

Name of the distributor, authorized agent and service agent

Address: 5-3, 1-CHOME, NIHONBASHI, CHUO-KU, TOKYO 103-0027, JAPAN Phone: +81-3-3231-6982 Fax: +81-3-3231-6994

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Foreword This manual contains operation, lubrication and maintenance information. Read this manual and safety manual carefully to learn how to operate and service your machine correctly. Failure to do so could result in personal injury or equipment damage. As the specifications, contents and illustrations in this manual are based on information available when this manual is prepared, they might be slightly different from the actual product which you have purchased because of a specification change in product or other alternation. All equipment described may not pertain to your machine, as some equipment mentioned is optional or exclusive for some countries. If you have any questions or comments about the handling and maintenance of your machine, please contact your nearest distributor.

WARNING Incorrect operation, or inspection or maintenance may cause serious danger. If this machine is used carelessly, an accident may cause serious injury or death. Do not use the machine before understanding the descriptions in this manual. The person in charge of operating or managing the machine should keep this manual close to the machine to be used and carefully read until fully understood. If this manual is lost, damaged or another needed, please place an order for it at your nearest distributor. When the machine is transferred to the next owner, please always attach this manual with the machine. Since the product has been improved constantly, this manual may not cover the entire machine. Please contact the distributor. Use this manual according to the regulations and provisions of the country where the customer uses the machine.

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Safety Information WARNING When this machine is used properly, the working efficiency will be increased safety and without failures. On the contrary, when machine is used improperly, unexpected accidents and failures will be caused. Operate machine correctly following the Labor Safety and other similar acts and, further, operates safety according to machine performance.

Most of accidents, which occur during operation, are due to neglect of precautionary measure and safety rules. So sufficient care should be taken to avoid these accidents. Erroneous driving operation, lubrication or maintenance services are very dangerous and may cause injury or death personnel. Thus precautionary measures or notes written in this manual should be read and understood well by personnel before starting each task. Moreover safety signs, on which warnings are written, are affixed to

machine.

Read them carefully to prevent injury or accidents involving personnel at

the site.

It is very difficult for us to forecast every danger that may occur during operation. However, operating machine according to methods recommended by Furukawa can ensure safety. Besides, while operating machine, be sure to perform work with greatest care so, as not is damage machine or let accidents occur . Be sure to check machine before operation and periodically to use machine safety and prevent possible failures. Especially, be sure to check water and oil levels. Replace oil and filter elements periodically . Use genuine Furukawa parts.

The specification values and numerical values in this manual are described in Le Système International d’Unités (SI Units), the units commonly use with SI Units and the units available to use with SI Units.

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Safety Information

Safety signs and messages are classified as follows so that the users can understand the

warnings

on the machine or in this manual.

DANGER Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. This signal word is to be limited to the most extreme situations.

WARNING Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices.

NOTICE Signs used to indicate a statement of company policy directly or indirectly related to the safety of personnel or protection of property.

DANGER or WARNING should not be considered for property damage accidents unless personal injury risk appropriate to these levels is also involved. ★ CAUTION (and NOTICE) is permitted for property-damage-only accidents.

We can't totally anticipate in detail where and what dangers

exists.

The safety signs and messages include “prevention measures which should be taken to avoid danger”. When operating the machine and performing checks and maintenance, which are not specified in manual, please consider the “safety measures for working” in accordance with your responsibility .

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this

Safety Information

Machine Direction In this manual, the positions and lateral and longitudinal directions of the machine are described as viewed toward the front from the operator ’s seat.

Front

Left

Right

Rear

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Safety Information

Running-in Operation This machine is adjusted and inspected sufficiently before delivery, but its function will be deteriorated to shorten the service life if it is used forcedly from the first. Carry out “Running-in operation” for initial 100 hours (indicated by the engine hour meter) as being careful about the following. After the engine start, warm-up the engine for about three minutes of idling. Sufficiently warm the hydraulic oil until automatic heating is completed. Before any drilling work, perform the warm-up operation of the drifter. Avoid sudden starting, sudden acceleration, sudden stopping or sudden turning.

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Machine Serial Number

When ordering spare parts or in case of repair, inform us Machine Model and Serial Number. The serial number nameplate (1) is located on the frame at the lower right of the cab.

1

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Safety Signs WARNING Carefully read all safety messages in this manual and on your machine safety signs. Keep safety signs in good condition. Replace damaged or discolored safety signs.

On the safety signs affixed on the machine there are descriptions of the precautions and handling methods needed to prevent accident caused by malfunction in operation or carelessness in inspections and maintenance. Operate, inspect, and maintain as directed by the safety signs as well as by this instruction manual. ★ For the part numbers of the safety signs, English safety sign numbers are indicated.

Order the safety signs at your nearest distributor , referring to the Parts List.

In the Cab 1. 090200-04346

1

2. 090200-04352 3. 090200-04668 2

3

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Safety Signs

4. 090200-04354 5. 090200-04392

5

4

6. 090200-06566 7. 090200-04353 6

7

8. 090200-04798 9. 090200-04270 10. 090200-04852

8 10

9

Outside of the Cab 1. 090200-04378 2. 090200-04381 3. 090200-04391 4. 090200-04741

1

★ They are affixed on the left side of the cab.

2 3 4

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Safety Signs

5. 090200-04380 ★ It is affixed on the right side of the cab.

4

5

Working Equipment 1. 090200-04381 2. 090200-04378

2 1

3. 090200-04747 4. 090200-04749

4

3

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Safety Signs

Left Side of the Machine 1. 090200-04849 2. 090200-04350

1

3. 090200-04798

2

4. 090200-04380

4

5. 090200-04386

3

6. 090200-04387

5 6

Right Side of the Machine 1. 090200-04849 2. 090200-04850 3. 090200-04366 1

4. 090200-04798 5. 090200-04380

2 4 3 5

6. 090200-04392

6

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Safety Signs

In the Engine Room 1. 090200-04388 ★ It is affixed on the battery box.

1

2. 090200-04668 ★ It is affixed on the control box.

2

3. 090200-04271 4. 090200-04268 5. 090200-04269 ★ They are affixed on the receiver tank.

3 4 5

Rear of the Machine 1. 090200-04389 2. 090200-04380 1

3. 090200-04391 4. 090200-04798

2

5. 090200-04850 3

4 5

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Safety Signs

Travel Device 1. 090200-04371 ★ It is affixed on the each side of the track frame.

1

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Contents IMPORTANT INFORMATION Foreword

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Safety Information

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Machine Serial Number Safety Signs Contents

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･･･････････････････････････････････････････････････････････････････････

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Safety 1. Safety Precautions

1-1-1

･･････････････････････････････････････････････････････････

1.1 Safety Management 1.2 Precautions before

････････････････････････････････････････････････････････

Engine Start

1.3 Precautions after Engine Start 1.4 Precautions for Safe

･････････････････････････････････････････････

･･････････････････････････････････････････････

Operation

･･････････････････････････････････････････････

1.5 Precautions with Machine Parking 1.6 Precautions for Towing

･･･････････････････････････････････････････

･･････････････････････････････････････････････････････

1.7 Precautions for Transporti ng

････････････････････････････････････････････････

1.8 Precautions before Maintenance 1.9 Precautions during Maintenance 1.10 Precautions after Maintenance

･････････････････････････････････････････････

･････････････････････････････････････････････

････････････････････････････････････････････

1-1-1 1-2-1 1-3-1 1-4-1 1-5-1 1-6-1 1-7-1 1-8-1 1-9-1 1-10-1

Operation 2. Specifications

2-1-1

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2.1 Component Names 2.2 Specifications

3. Operator’s Station 3.1 Meter Panel 3.2 Gauges

･････････････････････････････････････････････････････････

･････････････････････････････････････････････････････････････

2-2-1

3-1

･････････････････････････････････････････････････････････････

･･･････････････････････････････････････････････････････････････

･･･････････････････････････････････････････････････････････････････

3.3 Travel Levers

2-1-1

･･････････････････････････････････････････････････････････････

3.3.1 Travel Levers

･･････････････････････････････････････････････････････

3.3.2 Oscillating Lock Mechanism 3.4 Hydraulic Cylinder Control

3-3-1 3-3-1 3-3-2

･･････････････････････････････････････････････････

3-4-1

3.4.2 Rod Changer Control Levers

･････････････････････････････････････

･････････････････････････････････････････

･････････････････････････････････････････････････････････

3.5.1 Drilling Control Panel

3-2-1

･･････････････････････････････････････････

3.4.1 Hydraulic Cylinder Control Levers 3.5 Drilling Control Box

3-1-1

････････････････････････････････････････････････

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3-4-1 3-4-3 3-5-1 3-5-1

3.5.2 Drilling Switch Panel 3.6 Operator’s Cab

････････････････････････････････････････････････

････････････････････････････････････････････････････････････

3.6.1 Operator’s Seat Adjustment 3.6.2 Operator’s Cab 3.6.3 Switches

･･････････････････････････････････････････

･････････････････････････････････････････････････････

･･･････････････････････････････････････････････････････････

3.6.4 Accessories in Cab

･････････････････････････････････････････････････

3.7 Operation of Cooler/Heater

･･････････････････････････････････････････････････

3-5-3 3-6-1 3-6-1 3-6-3 3-6-5 3-6-7 3-7-1

3.7.1 Cooler

･････････････････････････････････････････････････････････････

3-7-1

3.7.2 Heater

･････････････････････････････････････････････････････････････

3-7-3

3.8 Handling of Fire Extinguisher

4. Running Operation

････････････････････････････････････････････････

4-1-1

･･････････････････････････････････････････････････････････

4.1 Daily Inspection

････････････････････････････････････････････････････････････

4.1.1 Before Starting the Engine 4.2 Operation of Engine

4.2.2 Starting the Engine 4.2.4 Stopping the Engine 4.3 Traveling the Machine

･･･････････････････････････････････････････

･･････････････････････････････････････････････････

4.2.3 After Starting the Engine

･････････････････････････････････････････････

････････････････････････････････････････････････

･･････････････････････････････････････････････････････

4.3.1 Traveling Posture 4.3.2 Starting

･･･････････････････････････････････････････

････････････････････････････････････････････････････････

4.2.1 Before Starting the Engine

･･･････････････････････････････････････････････････

････････････････････････････････････････････････････････････

4.3.3 Direction Control 4.3.4 Stopping the Machine

････････････････････････････････････････････････････

4.4 Parking the Machine 4.4.1 Locking 4.5 Drilling Work

････････････････････････････････････････････････････････

･･････････････････････････････････････････････････････････････

4.5.2 Collaring

･････････････････････････････････････････････････････

4.5.4 End of Drilling Work 4.6 Rod Changer Operation 4.6.1 Loading of Rods 4.6.2 Adding of Rod 4.6.3 Drawing of Rods

･････････････････････････････････････････････････

･････････････････････････････････････････････････････

････････････････････････････････････････････････････

･･････････････････････････････････････････････････････

･･･････････････････････････････････････････････････

･･････････････････････････････････････････････････････････････

4-1-1 4-1-2 4-2-1 4-2-1 4-2-3 4-2-5 4-2-16 4-3-1 4-3-2 4-3-3 4-3-4 4-3-6 4-4-1 4-4-2 4-5-1 4-5-1 4-5-4 4-5-6 4-5-8 4-6-1 4-6-2 4-6-8 4-6-15 4-7-1

5-1-1

････････････････････････････････････････････････････････････････

5.1 Loading Machine on 5.2 Towing

･･････････････････････････････････････････････

･･･････････････････････････････････････････････････････････

4.5.3 Regular Drilling

5. Transporting

･･･････････････････････････････････････････････

････････････････････････････････････････････････････････････

4.5.1 Preparation for Drilling

4.7 Auto Greaser

3-8-1

a Trailer

････････････････････････････････････････････････

････････････････････････････････････････････････････････････････････

5.3 Lifting Procedure

6. Electrical Equipment 6.1 Control Panel

･･･････････････････････････････････････････････････････････

5-1-1 5-2-1 5-3-1

6-1-1

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･･････････････････････････････････････････････････････････････

0-16

6-1-1

6.1.1 Fuses

6.2 Battery Servicing

6-1-5

･･･････････････････････････････････････････････

6-2-1

･･･････････････････････････････････････････････････････････

6.2.1 Replace Batteries

6.3 Battery Cut Switch (If Equipped) 6.4 Emergency Stop Devices

･････････････････････････････････････････････

6-2-6

･････････････････････････････････････････････

6-3-1 6-4-1

･･･････････････････････････････････････････････････

6.4.1 Emergency Stop Switch (If

Equipped)

6-4-1

････････････････････････････････

6.4.2 Emergency Stop Wire System (If Equipped)

7. Operation in Cold Weather

6-2-4

･･･････････････････････････････････････････････････

6.2.2 Using Booster Batteries

8. Storage

6-1-3

･････････････････････････････････････････････････････････････

6.1.2 Energy Saving Switch

6-4-2

･･･････････････････････････

7-1

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8-1

･･････････････････････････････････････････････････････････････････････

9. Troubleshooting

9-1

･･･････････････････････････････････････････････････････････････

Maintenance Section 10. General Safety Instructions 11. Fuels and Lubricants

11-1-1

･･････････････････････････････････････････････････････

11.1 Emergency Measures 11.2 Fuel

････････････････････････････････････････････････････

････････････････････････････････････････････････････････････････････

11.3 Lubricants

･･･････････････････････････････････････････････････････････････

11.4 Oil Supply Pump

12. Coolant

10-1

･････････････････････････････････････････････････

･････････････････････････････････････････････････････････

11-1-1 11-2-1 11-3-1 11-4-1

12-1

･･･････････････････････････････････････････････････････････････････

13. Refill Capacities

13-1

･･･････････････････････････････････････････････････････････

14. Maintenance Interval Schedule 14.1 When Required 14.2 First Maintenance

14-1

･･････････････････････････････････････････････

･･････････････････････････････････････････････････････････

････････････････････････････････････････････････････････

14.3 Periodic Maintenance / 50 Hours

･･･････････････････････････････････････････

14-1-1 14-2-1 14-3-1

14.4 Periodic Maintenance / 250

Hours

･････････････････････････････････････････

14-4-1


Hours

･････････････････････････････････････････

14-5-1


Hours

････････････････････････････････････････

14-6-1


Hours

････････････････････････････････････････

14-7-1

15. Periodical Replacement of Maintenance Parts

0-17

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15-1

Safety Section

1. Safety Precautions 1.1 Safety Management Importance of Personal Self-Management If your physical condition is not sound you might make the wrong decision at a dangerous moment. Never operate the machine if you have not had enough sleep or if your physical condition is not satisfactory.

Follow the Rules on Site Only trained and qualified person can operate the machine. A designated operator should only operate the machine. The operator of the machine should be thoroughly instructed in its operation before work begins. Create a work plan for the job: prepare daily and monthly work reports to record work progress. Make very sure of the blasting time and place and of the escape zone. When another relieve s the machine operator the latter should be inform ed orally or in writing of the machine condition. When guiding personnel is arranged, decide on the signs. The operator should follow the signs of the guide.

Wear Safe and Protective Clothing Wear working clothing of the right size, so that it is not snagged or rolled by the operation levers or projecting sections. Never wear oily work clothes: they are highly flammable. When operating, wear protective clothing such as helmet, protective glasses, earplugs, and dust-proof mask and safety shoes. According to the nature of the operation, wear the required protective clothing, such as insulated clothes, protective gloves, and safety belt. SS-002

1-1-1

Safety Management

Prepare First Aid Kit Decide a storage location for a fire extinguisher and first aid kit and know how to administer first aid. Read the instruction manual for the fire extinguisher in advance. Be sure to understand its type and use. Decide a contact address and method of communication in case of emergency: keep a telephone No. list at hand.

SS-003

Keep the “Safety Signs” Clean The safety signs and nameplates affixed to the machine describe the precautions in handling. Follow instructions whenever the machine is operated, inspected, or maintained. If the safety sign has damaged or discolored, affix a new safety sign.

SS-004

No Modifications If a trouble occurred or if the machine is disassembled and repaired, or modification is required, contact your nearest distributor. We are not responsible for indemnity of any accident or breakdown (directly or indirectly) caused by unap proved modification (including disassembly and repair).

Use Furukawa Genuine Parts No irregularity caused by unapproved components is covered by warranty. Our company takes no responsibility for any irregularity, breakdown, or accident, caused by the use of an unapproved component. When a component is changed, use only “Furukawa Genuine Parts” as listed on the parts list.

1-1-2

Safety Management

Beware of Fire All oils including fuel are flammable. If near to fire, they in turn will catch fire. When supplying the fuel or lubricants, stop the engine beforehand. Do not smoke or put fire in the place where oil is supplied. Store fuel and lubr icants in well-ve ntilated place and let nobody exc ept design ated personnel go there. Do not check fuel or oil leakage with naked flame of match or lighter. When degradation of hydraulic piping or oil hoses and any non-conformity such as oil leakage or hose is found, repair or replace immediately ．

SS-034

SS-005

Use Safety Equipment Correctly Do not remove or modify safety equipment. If safety equipment is used incorrectly, it might cause a dangerous accident resulting in injury or death.

Escape in Emergency The machine where the ROPS/FOPS cab is mounted is equipped with a safety hammer for escape in emergency. If the door cannot be opened, the operator can escape from the cab by breaking the front or rear glass with the safety hammer. When the glass is broken with the safety hammer, wear protective glasses.

SS-008

1-1-3

SS-009

Precautions before Engine Start

1.2 Precautions before Engine Start Secure Onsite Safety Before operation, check the topography, geographical features and road conditions in the operation site and record them. For a dangerous zone in which the mount might collapse, take measures such as “KEEP OUT” or arrange for guiding personnel. Do not allow anybody except associated personnel to enter the operation site. If the ground becomes soft after rain a landslide might occur due to the mass or vibration of the machine. Approach the soft or weakened ground only with great care. When drilling close to a soil wall there is a danger that falling stones or collapse may cause serious injury or death. Remove fragmented rocks carefully before the ＥＲ

ＤＡＮＧ

operation. On sites near power lines or high-tension cables, contact the Power Company in advance and keep sufficient distance between the machine and lines or cables.

Level the Ground With an inclined ground or mount, great stability change might cause the machine to fall. Arrange and level the ground before bringing in the machine. Launch the machine on solid and level ground.

Beware of Underground Utilities If drilling in urban districts make sure of the positions of such underground utilities as gas pipes, water pipes, sewage pipes and cables. If underground utilities are damaged get advises from the managing company. If a gas pipe is damaged warn the workers around and instruct not to use naked flames. If you look at the cross section of a cut optical fiber cable, you might be blinded or your eyes damaged. Do not look at the cross section of an optical fiber cable.

SS-055

1-2-1


Prevention of Fire If inflammables such as dry leaves and waste paper are allowed to accumulate, they might cause a fire. Clear any such inflammables from around engine and compressor. Oil leakage might cause fire. Inspect the piping and hoses in the fuel and hydraulic oil lines and immediately repair or replace any non-conformity such as oil leakage or hose degradation. SS-006

No smoking while filling fuel or oil.

Inspection before Operation Performing the daily inspection before starting daily work can prevent troubles or failures prevented in advance. Inspect the surrounding and lower p art of the machine for oil leakage, missing bol ts and nuts, conditions of the working equipment and hydraulic system. If any non-conformity is found in the daily inspection, always repair and adjust it before the engine start.

Get On/Off Machine Carefully Before getting on the machine, check around and behind the machine and make sure that there are no workers or obstacles. If any worker is standing in the way of the mach ine, move them out of the way to a safe place. Completely wipe any dirt or oil on the handrails, steps, or floor; if slippery you might fall. Wipe any dirt or oil from the soles of your shoes before getting on the machine. When getting on or off the machine, constantly face the machine and support yourself by three or more points, using handrails and steps. Do not jump off or on the machine. Get on or off the machine only when it is stopped completely.

SS-012

1-2-2


Clean Around Operator’s Seat Do not leave tools or component sin the cab because they might hinder operation. Wipe dirt or oil from floor, levers, or seat, because it might cause mistakes in operation or other malfunction. Wipe dirt from the surfaces of windows and mirrors and always keep them clean.

SS-011

Safety Check before Engine Start Adjust the operator’s seat to a proper position. Make sure the light turns on normally. Make sure the horn sounds normally. Perform the lamp test so that there is no burnout monitor lamp on the electric monitor.

Start from the Operator’s Station Only the operator can get on the machine. It is very dangerous for another person to get on the machine, because it might disturb operation or cause an overturn. Do not take any other person on the machine or in the cab. Start the engine after sitting in the operator’s seat. When the engine is started, warning horn to draw attention of the workers around.

SS-013

1-2-3


Use the Seat Belt Use the seat belt if the operator’s seat is equipped with it. Make sure that the fixture of the seat belt is not loosened before using it. Replace the seat belt if there is a feathery place or damage on the appearance or if the fixture is deformed.

SS-060

Dangerous Exhaust Gas Start the engine in the place ventilated as well as possible. Fully ventilate the room for preventing gas poisoning when starting the engine indoors.

SS-015

1-2-4

Precautions after Engine Start

1.3 Precautions after Engine Start Performance Check of Emergency Stopping The emergency system immediately stops the en gine in an emergency. After the engine is started, press the emergency stop button to make sure that the engine is stopped immediately. In the machine equi pped with an emergen cy stop system; make sure that the engine is stopped immediately by activating the emergency stop system after the

engine is started.

After Starting the Engine Immediately after the engine is started, do not operate the traveling levers or working equipment, but make sure of the condition of the machine. Make sure that no monitor lamp on the meter panel is turned ON Make sure there is no abnormal vibration, revolution or en gine noise.

Warming-up The engine warm-up gradually raises the temperature of the water and oil to optimal levels, and distributes lubricating oil to all parts of the engine. Warm up the engine and hydraulic system before operation.

1-3-1

Precautions for Safe Operation

1.4 Precautions for Safe Operation Care in Levers/Switches Operation Do not operation l evers and switches abruptly when the engine speed is high, otherwise the machine may fall down or the boom, guide shell and other working equipment may be broken. Operate the hydraulic cylinder control levers carefully, while confirming the motion of the boom and guide shell. Be careful not to contact the guide shell with the cabin. Move the travel levers slowly checking all conditions.

Travel the Machine Safely When the machine is to travel set it to the “Traveling Posture”. For switching over from the forward or backward, stop traveling the machine once, and make sure in advance that n either workers nor obstacles exist in the running direction. Arrange for a guide in place when visibility is bad: the operator must follow the guide's signals.

Traveling Posture

1-4-1


Backing Precautions The rear of the machine is a particularly hard for the operator to see. Careless backing may cause an accident resulting in injury or death from “catching”, “crushing” or “flattening”. Do not back the machine w ithout having made sure that no w orkers or obstacle s are in the way.

Traveling on Unleveled Ground Do not manipulate the travel levers too much when on soft or frozen ground, and take the greatest precautions against sticking or slipping. When the machine is moved over unleveled ground, do so at a low speed and avoid sudden direction changes. Move the machine so as to avoid such obstacles as rolling rocks, as much as possible. If you ride across an obstacle during traveling due to unavoidable circumstances, lower the traveling speed, and ride across it at the center of the track shoes. After rain, take care of unstable rises in or shoulders of roads: only approach such places with extreme care.

1-4-2


Going Up and Down Slopes Stop running once before the slope when ascending a slope, and adjust the traveling speed by the engine throttle dial. Don’t adjust the engine throttle dial halfway in the course of the slope. When the machine is to go down a slope, adjust the speed using the travel levers and sufficiently reduce speed. If the machine is to go diagonal ly across a slope or parallel to a slope, there could be “overturn” or “side slide”. On inclined ground, always move the machine at an angle of 90 degree to the slope.

Conform to the Appropriate Water Depth First pump out any water hole or spring coming from underground source. When the machine is moved through water, check the depth of the water and the condition of the bottom and do not splash water on the lower end of the track frame. After the machine has traveled through water, completely dry out the lower section of the machine.

1-4-3


Protection from Drill Noise Drilling without wearing the noise-proof protective gear might damage hearing. Wear noise-proof protection gear such as earplugs and earmuffs. Close the cab door.

SS-016

Take Dust Preventive Measures Inhalation of dust for a long time might affect health and lead to pneumoconiosis. Wear a specified dust-proof mask when drilling. Operate the machine from the windward if possible in order to avoid inhaling dust. Pay closest attention to the wind direction and also to the position and direction of the machine in order not to inhale engine exhaust gas.

SS-017

Set Up Track Shoes to the Ground The base where the machine is landed should be as level as possible. Set the oscillating lock lever to OFF position before moving the boom, guide shell and other working equipment. Make sure that both track shoes touch the ground.

SS-018

1-4-4


Loading Rods safely The rods are large and heavy. When the rods are attached or removed, lift the rods by using the machine as a crane. When the rods are attached or removed, lift the rods using the machine such as crane. For loading the rods, decide upon signals between the operator of the machine and the worker who connects the rods and maintain a good communication during the work. Do not touch the rod, while the working equipment is moving.

Attach and Remove the Bit and Sleeve Safely Do not touch any rotation section such as the rod or shank rod during drifter operation; otherwise your finger or other part of your body might be caught. Screw the bit and the sleeve, after drifter has stopped. When the sleeves are attached or removed with the centralizer closed or opened, take the greatest care not to be caught by the centralizer. The sleeve and shank rod becomes very hot during, and immediately after drilling. Do not touch the sleeve or shank rod until their temperatures are down to the normal temperature.

SS-022

1-4-5


Beware of Drilling Operation When drilling, make sure no workers are around before starting. Do not travel or move the equipment with the rod inserted while drilling. Do not touch rotating parts, such as rod and sleeve, during drifter operation: it might cause a “rolled-on” or “snagged” accident. If drifter or guide shell is carelessly touched during drilling, otherwise you may be “rolled-on” or “cut” by feed chain to cause a dangerous accident. During drilling, or when the drifter is moving forward or backward, do not touch the guide shell or put your hand between guide shell and rod. Do not put your hand around foot pad or place your hand or foot under the bit.

SS-019

SS-021

SS-020

Beware of Moving Rod Changer When rod changing, do not go near moving parts such as the clamp, clamp shaft and magazine: it might cause a “roll-on” or “crush” accident.

SS-058

Good Visibility Wipe all oil or dust from the cab windows. When visibility is bad, due to dust, rain or wind, stop the operation and wait until visibility is restored. In dark places, where good visibility cannot be secured even with the machine lighting lamp on, provide an adequate external lighting facility.

1-4-6


Don’t Use the Machine Except for Specified Work If the machine is wrongly used for other than specified work, it might cause an accident with injury or breakdown. Never use the machine in that way. If the crane operation (lifting a load) is performed with the chain or wire suspended from the working equipment, it might cause an accident resulting in injury or

death.

When the load is lifted, use the lifting machine such as a crane.

Avoid Power Lines If the power line or high-tension cable is approached or touched, it might cau se an accident resulting in injury or death. If operating is close to a high-tension cable, contact the Power Company in advance and keep sufficient distance between the machine and cable. On sites with power lines nearby, make the workers and guides wear properly insulated protection wear, such as shoes with rubber or leather soles. When drilling or when the machine is moved, arrange the supervisor and guides so that the operator can see clearly. The operation should follow the signals of the supervisor and guides. Conform to all regulations of local and national governments on safe distances from power lines.

SS-024

1-4-7


Dealing with Electric Shock If you get an electric shock, do not panic but do as follows: The operator should warn nearby workers: “Don't touch the machine” and do not move. When the operator is to escape from the machine, he must not touch the handrails or steps, but jump away from the machine as far as possible, while following the instructions of the supervisor or guides. The supervisor and guides shoul d contact the Power or Management Company to ask them to stop the power and give some guidance on emergency reaction. After the operator who got an electric shock has been attended, remove the cause of the charging of the machine and make sure that it is no longer charged. To prevent secondary disaster, make the workers around the machine evacuate and make sure that no worker approaches the machine.

Beware of Thunder Strike If the machine is stuck by lightning, not only the operator, but also the guides and supervisor might be affected and be injured or killed. While lightening strike threatens, stop work and set the machine to the traveling posture. Until the lightening threat passes, keep away from the machine and take refuge in a safe place.

SS-070

Contact the Distributor for Maintenance If a trouble occurred or if disassembly and repairs are needed, contact your nearest distributor. When the monitor lamp lights up, move the machine to a safe place immediately and inspect/repair it. If there is any abnormality in the machine, report it to the manager and do not operate until repaired.

1-4-8

Precautions with Machine Parking

1.5 Precautions with Machine Parking Park Safely When the machine is to be parked, select a solid and flat place and set it to the “traveling posture” or set the guide shell to down and press the end of the foot pad against the ground. If the machine has to be parked on an inclined plane, apply the stopper to the

track shoes.

Do not park the machine in any such place as soft ground, a shoulder of the road, or anywhere there may be rock fall or any collapse.

Leave the Machine Safely When leaving from the operator’s station, move the l safety lock to fix the travel levers. Stop the engine and pull out the starter switch key. Store the key in the specified place. Lock the cab door, control panel cover and engine covers.

1-5-1

Precautions for Towing

1.6 Precautions for Towing Incorrect towing is very dangerous and might cause accidents resulting in injury or death. When the towing vehicle is connected to the machine, follow the guide's signals and make sure there are no workers around. Use a tow wire rope of 1.5 times or more of the strength needed to tow a vehicle of the mass of the machine to be towed. Do not use a twisted or kinked wire rope. Do not use a chain to tow the machine because a link might break. Move and set the wire rope so that the coupling section of the tractor is aligned with the hitch on the machine. Before towing, make sure there is nobody between the tractor and the machine. If the tractor moves suddenly the wire rope might break. Operate the tractor slowly and at a steady speed. Do not tow the machine on sloping ground because the machine might run away under its own mass.

Hitch SS-025

1-6-1

Precautions for Transporting

1.7 Precautions for Transportin g Check Conditions at Travel Route When the machine is to be transported, use a trailer or truck dedicated to transporting construction machinery. Investigate travel route for road width and overpass. Check any bridges for

weight limits.

Obey local laws governing weight, width and length of a load. Observe all regulations governing wide loads.

Load Machine Safely on a Trailer Loading and unloading have their own d angers. Take the greatest care. Stop the trailer on a level and firm place on the road. Chock the trailer wheels before you load the machine. Use a ramp of sufficient length, width, and strength and also with claws so that it does not come off the trailer bed. Fix the ramps on the trailer bed so that the slope is 15 degrees or less. Wipe off any dirt or oil on the ramps and trailer bed. Set the machine in the traveling posture and move it according to the instructions of the guides. Load the machine on the trailer, taking the greatest care that it’s placing on the trailer bed is not skewed. If the placing should alter, go down to the machine and change its direction. Then load the machine onto the trailer bed. After the loading, use chocks at the front and rear tracks so that it cannot move during transport and fix it onto the trailer with wire ropes.

1-7-1

Precautions before Maintenance

1.8 Precautions before Maintenance Practice Safety Maintenance Do not let anybody except for associated personnel enter the inspection and maintenance area. Always keep the work place orderly, and clean and dry. Before operation, the operator should be trained in safety work procedures. During operation, two or more workers should always be present and one of them should direct and secure the workers' safety. When maintenance of the machine is done at the same time as attachment installation and removal, then follow the instructions of the supervisor and decide upon the specific signals with all the workers. All this needs a sound mutual understanding. If oil or grease is not cleaned off, or tools are spread on the floor or on the machine, it might cause accidents such as falling or d ropping. Always check the tools to be used. Do not use tools such as dull-edge spanners, folded-edge hammers or chipped drivers. Dropping the tools or parts onto the machine can cause machine breakage or lead to accidents. Do not anything, which is not necessary for inspections in a pocket. When a component is changed, use only Furukawa Genuine Parts as listed on the parts list.

SS-061

SS-028

Observe Safety Signs The safety signs give important precautions. Follow instructions whenever the machine is operated, inspected, or maintained.

SS-065

1-8-1


Perform Inspection at Flat Place Stop the machine on a solid and flat place such as the service shop floor and prepare the operation equipment. Use chocks at the front and rear tracks. Stop the engine and pull out the starter switch key. Move the l safety lock to fix the travel levers.

Wear Protective Clothing Before performing inspections and maintenance, wear the appropriate protective clothing. Wear the right sized working clothes so that they're not snagged or caught in the operation levers or projecting sections. As oily clothing catches fire, never wear it. When working, wear protective gear such as helmet, protective glasses, earplugs, and dust-proof mask and safety shoes. When a pin is inserted or withdrawn by hammering, metal and coating fragments are spread. Wear protective glasses. Depending on the nature of the work, wear proper protective gear, such as insulated protective gear, protective gloves and safety belt.

SS-002

SS-030

Clean the Machine before Inspection Wash the machine before performing inspections and maintenance, to find what needs attention the more easily. Clean off any oil or grease and level gauges carefully. Keep dust out. Take extreme care not to wet the control panel, battery, or electrical equipment: it might cause a short circuit or malfunction.

SS-031

1-8-2


Hang “WARNING Tags” If anybody other than the operator actuates the engine or moves operation levers by mistake, it could result in accident, injury or death. When performing and maintenance, hang a “WARNING Tags” on the operator's seat and instructions about prohibiting starting the engine and operating the levers. If required, hang “WARNING Tags” around the machine with thorough instructions about how to avoid any wrong operation. SS-062

Stop the Engine Before performing inspections and maintenance stop the engine and set the starter switch key to the OFF position. If any part of your body or any tool touches such a rotating section as fan or fan belt, it might cause a “caught in” or “cut” accident. Do not bring anything easily caught close to any rotating section. Do not open the engine covers and top cover until the engine has completely stopped. SS-033

Fire Prevention When flammables such as fuel, oil, and battery electrolyte are handled do not let any flame or fire come near them. Wash

the

components

and

hydraulic

tank

with

non-flammable solvent. Use explosion-proof type lighting. Prepare such fire extinguishing equipment as a fire extinguisher. SS-006

1-8-3


Handle Fuel and Lubricants Safely Before supplying fuel and lubricants, stop the engine. Supply fuel and lubricants in a well-ventilated place. Do not put fire near the machine while supplying fuel and lubricants. Wipe away the spilt fuel and lubricants carefully.

SS-034

1-8-4

Precautions during Maintenance

1.9 Precautions during Maintenance Safe Maintenance with the Engine Running Do not perform inspections and maintenance while the engine is running. When

maintenance

with

running

the

engine

is

unavoidable, more than two person are needed to safely complete the maintenance One person should sit in the operator’s seat to be ready to stop the engine at any time. In particular, take the greatest care that no finger or other part of your body is caught in rotating parts. SS-035

Beware of Internal Pressure The hydraulic tank is pressurized. When the hydraulic oil is supplied or drained away or when the hoses/parts are disconnected/removed from the hydraulic tank, open the handle on the top of the hydraulic tank to release the pressure from the hydraulic tank. When the engine has stopped, the air in the receiver tank is released from outside at the automatic relief valve. When inspecting, and during maintenance on, the pneumatic equipment, wait for 5 minutes or more until the air in the receiver tank is all released.

SS-036

1-9-1


Beware of the Radiator If the cap of the reservoir tank is opened when the engine is hot, hot steam and water burst out and might cause scalding. Check the coolant in the reservoir tank before starting the engine and after it has dropped to normal temperature. Only check the cooling system after the engine has stopped and you are sure that the radiator has completely cooled to a normal temperature. When the cap of the reservoir tank is to be opened, place a cloth over the cap a nd only gradually release the inside pressure.

SS-037

Secure Drop-Prevention Measures Maintenance under the machine can cause crushing injury or death. Do

not

service,

perform

maintenance

or

make

adjustments under the machine without secure supports. Do not stand under the boom or guide shell. Put down the guide shell on the ground or hold it with safely props or wooden blocks.

SS-038

Clean the Machine Safely If the operator inhales dust over a long time, it might affect his health and he might contract pneumoconiosis. When the dust collector is cleaned wear a dust-proof mask. If using compressed air wear protective glasses and clothing that will withstand the pressure.

SS-015

1-9-2


Don’t Climb on the Working Equipment Do not climb on the equipment such as the guide shell, boom or drifter. Falling from equipment may cause injury or death. Place the guide shell to be horizontal and lower it down to the ground.

SS-039

Secure the Drifter Accumulator Safely If any gas except for nitrogen is put in the drifter accumulator, it might explode. Always use nitrogen in the drifter accumulator. Do not hit the accumulator cover with a hammer or loosen the cover without releasing nitrogen gas, because it might cause the accumulator cover to blow off.

SS-040

Adjust Track Shoes Tension Safely The pressure inside the track shoes adjusting cylinder is very high. If the relief valve is loosened carelessly, high-pressure grease bursts out. Do not loosen relief valve more than three turns. Do not peer into the grease discharge outlet to check grease discharge: because it might burst forth from the outlet.

SS-041

1-9-3


Beware of Pressurized Oil If exhausted or degraded hosing is used, pressurized oil might burst out. Pressurized oil invades into your skin. When pinhole oil leakage is checked, do not touch it directly with your hand, but check it with cardboard or wooden sheeting. If you are touched by pressurized oil, immediately get medical treatment. If oil invades your skin, you might get gangrene unless it is removed within some hou rs.

SS-042

Beware of Burn Hazards Immediately after the engine is stopped, all temperatures are high. If a section is touched with a bare hand, it might cause burn or a further accident. Before performing inspections and maintenance after all parts become cool down.

SS-022

Service Batteries Carefully Battery gas can explode. Do not smoke near a battery, keep flame and sparks away. Battery electrolyte is a dilute sulfuric acid solution, so avoid contact with eyes, skin, clothing or other metallic surfaces. If it contacts anything, wash it off quickly with water. Always wear protective glasses when working with batteries. Keep children away from battery. SS-046

1-9-4


Don’t Use a Flame as a Light If flame of match or lighter is used as a light, there may be fire or explosion. When flammables, which easily generate combustible gas, such as fuel and battery fluid are checked, do not use a naked flame, but such safe light as an electric torch.

SS-005

Weld Safely Only qualified persons should weld. Only qualified personnel should weld. Welding to be in a well-equipped place. When welding indoors, ventilate by opening windows and doors. Stop the engine and pull out the starter switch key. When welding, ground the grounding wire 1m or less from the welding site. Do not allow any seal or bearing between the welding site and the grounding. Lower the battery from the machine to the ground to prevent explosion. Remove electric components to prevent error or damage. Prepare a first aid kit and fire extinguisher to provide against unexpected accident or fire.

1-9-5

Precautions after Maintenance

1.10 Precautions after Maintenance Check the Machine after Maintenance Check that the machine operates correctly after maintenance. After maintenance, run the engine at low idle and check for oil and water leakage areas where the maintenance was performed. Activate the compressor to check oil or air leakage. Move the operation levers and switches slowly to check their functions. Increase the engine speed and check again for oil and water leakage.

Store Accessories Safely Store such accessories as the bit, rod, and sleeve, in a safe place so that they do not fall down. Take safety measures against unauthorized entry by locking the storage place so that children or others cannot enter.

SS-044

Disposal of Wastes Do not pour waste fluid such as engine or hydraulic oils into a river or sewage system. Always collect waste fluids from the machine in a container and do not pour it away on the ground. Do not carelessly burn or throw away oiled or greasy rags. Do not dispose of refuse oils, fuels, cooling water, coolants, solvents, filters or batteries and other potentially harmful waste along with normal incombustible garbage. Illegal disposal of wastes is environmentally destructive. Comply with applicable regulations and rules for disposal of waste.

SS-045

1-10-1

Handling Section

2. Specifications 2.1 Component Names 2 1

5

4 3

1 10 12 17113001

6

7 13

11

8 9

15 14

1. Drifter

7. Guide Shell

13. Under Mirror

2. Pre-Cleaner

8. Guide Mounting

14. Track Frames

3. Rod Changer: Carrier (F)

9. Boom

15. Drive Motors

4. Rod Changer: Carrier (B)

10. Operator’s Cab

5. Hydraulic Tank

11. Radiator/Air cooler

6. Foot Pad

12. Dust Collector

2-1-1

Specifications

2.2 Specification s

NOTICE For the values other than specified in the specifications, ask your nearest distributor.

Performances Mass

10,450 kg (∗1) / 10,490 kg (∗2)

Travel speed

0 - 3.8 km/h

Maximum traction force

74.0 kN

Maximum grade of hill climb

57.7 % (30°)

Oscillating angle

±10°

Ground pressure

79.2 kPa (∗1) / 79.5 kPa ( ∗2)

Drifter Model

HD709

Mass

185 kg

Overall length

1,103 mm

Overall width

352 mm

Overall height

263 mm

Number of blows

2,250 - 2,500 min

Number of revolutions

0 - 250 min

-1

-1

Engine Make & model

Caterpillar, C7

Type

Water-cooled direct fuel injection turbo charged diesel engine

Rated output

168 kW/2,200 min

-1

Hydraulic Equipment Variable displacement pump

Axial piston pump

Fix displacement pump

Gear pump

Drive motor

∗1:

The standard cab is installed

∗2:

The ROPS/FOPS cab is installed

Hydraulic motor with reduction gear

2-2-1

Specifications

Boom Model

JF200

Type

Fix boom

Boom lifting angle: up/down

43°/30°

Boom swing angle: right/left

45°/10°

Guide Shell Model

GH831

Overall length

7,015 mm

Feed length

4,089 mm

Feed length (with reverse percussion)

3,904 mm

Guide slide length

1,500 mm

Guide swing angle: right/left

50°/50°

Guide tilt angle

180°

Maximum pulling force

24.5 kN

Feed system

Hydraulic motor drive

Compressor Make & model

Hokuetsu (AIR MAN), PDS265-S35A

Type

Screw 3

Discharge airflow

5.4 m /min

Discharge pressure

1.03 MPa

Unload type

Suction throttle type

Dust Collector Model

A884-221

Airflow

20 m /min

3

Number of elements

4

Dust removal system

Automatic pulse air jet

Suction cap

Slide type

2-2-2

Specifications

Rod Changer Model

GR180

Number of rods

4

Rod length

3,050 mm

Electrical Equipment Battery

12 V-108 Ah/5 Hr

Voltage

×

4

DC24V

Oil Capacity Fuel tank

320 L

Hydraulic tank

170 L

Bit and Rod Bit diameter

ø65 - ø90 mm

Bit profile

Button, cross and spike

Rod size

32H, 38R, 45R, (38H)

Rod length

3,050 mm

First rod length

4,000 mm

Working Temperature Working environment temperature

- 15 ~ + 45°C

2-2-3

Specifications

Dimensions Unit: mm 2500 (輸送時／SHIPPING）（*1） 2400 (輸送時／SHIPPING）

0 5 5

300 2390 3200 （*2） 3300 （*3）

7015

) G IN P P I H S ／時送 (輸 0 3 8 2

2155 2785 8465 (輸送時／SHIPPING) 8635

∗1)

The folding step is installed

∗2)

The short type step and pre-cleaner are installed

∗3)

The wide type step and pre-cleaner are installed

2-2-4

0 9 8 2

3. Operator’s Station

1. Switch Panel

1

2. Meter Panel

2

3. Travel Levers

3

4. Hydraulic Cylinder Control Levers

4

5

5. Drilling Control Box 6. Pressure Gauges

6

3-1

Meter Panel

3.1 Switch Panel

CAUTION When the emergency relay is activated and the engine is stopped, do not re-start until check and maintenance is complete. When the engine is started or the machine moved sound the horn to draw other worker’s attention.

9

1. Starter Switch 8

7

2. Engine Throttle Switch 3. Compressor Switch

6 5

2 4

4. Front Floodlight Switch 5. Rear Floodlight Switch 6. Front Wiper and Washer Switch 7. Roof Wiper and Washer Switch 8. Radio

3

9. Air-Conditioner Control Panel

1

1. Starter Switch This switch starts and stops the engine. O: Stop (Off) The starter switch key can be pulled out or pushed in, and engine electric circuit is turned off. When the engine is stopped, the switch is set t o this position. If the engine does not stop when the key is set to O position, check the engine stop switch or electrical system. R: Running To activate the electric circuits in the cab, turn the engine starter switch key clockwise to the R position. HS: Start To start the engine, turn the engine starter switch key clockwise to the HS position. When the engine starter switch key is released, the engine starter switch key will return to the R p osition.

3-1-1

Meter Panel

H: Lamp Test Set the starter switch key at H position. If the engine diagnosis monitor lamps (1) and the alternator (charge) lamp (2) light up, they are normal. Then, five seconds later, the engine diagnostic lamps (1) turn off. 2 1

2. Engine Throttle Switch This switch adjusts the engine speed. Use the engine throttle switch to adjust the engine speed. Position [I] When the engine starts and stops, set the switch to [I] position. -1

After the engine has started, the idling speed is kept at 1250 min . Position [II] The engine speed is kept at 1600 min

-1

.

Position [III] When operating the boom and rod changer, set the switch to [III]. -1

Set the switch to [III], and the engine speed is kept at 1800 min . Position [IV] -１

Set the switch to [IV], and the engine speed is kept at 2000 min Position [V]

.

Set the switch to [V], and the engine speed is set at the maximum 2200 min

-1

.

3. Compressor Switch The compressor discharges compressed air when the engine is started. The compressor switch controls the air discharged from the compressor in two stages; low pressure and

high.

ON Tilt the switch forward in order to gush the pulsejet. The pulsejet will gush in about 30 seconds, and the pressure

ＯＮ

of the receiver tank is kept 1.05 - 1.1MPa. Tilt the compressor switch forward when carrying out drilling. ★ Controlling the compressor switch when the engine is

idling. OFF

ＯＦＦ

Tilt the switch backward, the amount of air intakes by the compressor decreases. The compressor enters the state of unloading, and the pressure of the receiver tank is kept at 0.38 - 0.40MPa. ★ When the engine is started or stopped, set the switch to

OFF position.

3-1-2

17410027

Meter Panel

4. Front Floodlight Switch Tilt the switch forward in order to turn on the front floodlights.

5. Rear Floodlight Switch Tilt the switch forward in order to turn on the rear floodlight.

6. Front Wiper and Washer Switch Turn the switch clockwise in order to turn on the front wiper. Windshield washer gushes while being pushing the switch.

3-1-3

Meter Panel

7. Roof Wiper and Washer Switch Turn the switch clockwise in order to turn on the front wiper. Windshield washer gushes while being pushing the switch.

8. Radio Listen to the radio with appropriate sound volume so that the operation of the machine is not disturbed. ★ For the handling of the radio, refer to instruction manual being packed in the machine together.

9. Air-Conditioner Control Panel This panel control the air-conditioner installed in the machine as standard equipment. Refer to 3.8 “Handling of Air-Conditioner” .

3-1-4

Meter Panel

3.2 Meter Panel

CAUTION When the alert indicator on the electric monitor is lit, then stop the machine immediately. Stop the engine and investigate the cause. When the emergency relay is activated and the engine is stopped, do not re-start until check and maintenance is complete. Before starting engine, check the electric monitor. If the alert indicator does not turn on, ask your nearest distributor to check it.

1

2

1. Electric Monitor

3

2. Compressor Discharge Air Temperature Gauge 4

3. Hydraulic Oil Temperature Gauge 4. PowerView Display

1. Electric Monitor The electric monitor consists of six alert indicators. The alert indicators show any abnormal condition of the machine. ★ Refer to the next section “Electric Monitor” .

3-2-1

Meter Panel

2. Compressor Discharge Air Temperature Gauge This gauge indicates the temperature of the compressor discharge air . If the needle of this gauge is in the red area, stop full

１０３℃

operation immediately and continue with engine at low idle. Wait until the needle of the gauge returns to white range, and

１００℃

H

then stop the compressor. After the engine is stopped, check the amount and quality of compressor oil and, if low, add more. ★ When the compressor discharge air temperature rises to

８０℃

５０℃

C

110°C or more, the engine is stopped in emergency. 17314024

3. Hydraulic Oil Temperature Gauge This gauge indicates the temperature of the hydraulic oil. Before full operation, operate the drill with light load until the hydraulic oil temperature rises to about 30°C. If the needle of this gauge is in the red area, stop full operation immediately and continue with engine at low idle. Wait until the hand returns to white range, and then stop the engine. After the engine is stopped, check the amount and quality of hydraulic oil and, if low, add more.

８０℃

３０℃

Check that there is no clog in the oil cooler.

H

５０℃

C

★ The engine stopped automatically if the hydraulic oil level

is beneath the specified level.

17314025

4. PowerView Display PowerView Display is a multi-display unit. The PowerView Display provides information on operating condition of machine and p of the engine systems. ★ For the handling of the PowerView Display, refer to user’s guide.

3-2-2

roblem with any

Monitor Panel

Electric Monitor

1

5

6

1. Alternator (Charge) 2. Air Cleaner 3. Compressor Oil Filter 4. Hydraulic Oil Filter

2

3

4

Engine Diagnostic Lamps

5. Engine Fault 6. Engine Diagnosis

The electric monitor consists of six alert indicators. The alert indicators show any abnormal condition of the machine.

1. Alternator (Charge) There is a malfunction in the electrical system. The system voltage is too low for normal machine operation. If this alert indicator lights during operation, then stop the work immediately and move the machine to a safe place. Check alternator and battery and that there is no looseness or cut in the fan belt.

2. Air Cleaner The warning light notifies the operator that the engine air cleaner element or compressor air cleaner element is plugged. If this alert indicator lights during operation, then stop the work immediately and move the machine to a safe place. Stop the engine. Investigate the cause.

3. Compressor Oil Filter The warning light notifies the operator that the compressor oil filter is plugged. If this alert indicator lights during operation, then stop the work immediately and move the machine to a safe place. Stop the engine. Investigate the cause.

4. Hydraulic Oil Filter The warning light notifies the operator that the hydraulic oil filter is plugged. If this alert indicator lights during operation, then stop the work immediately and move the machine to a safe place. Stop the engine. Investigate the cause.

5. Engine Fault The warning light indicates a serious malfunction in the engine. If this alert indicator lights during operation, then stop the work immediately and move the machine to a safe place. Stop the engine. Investigate the cause.

3-2-3

Monitor Panel

6. Engine Diagnosis This alert indicator is used to indicate the existence of an active fault by flashing codes. When the starter switch key is turned on, the alert indicator light

and the alert indicator remains on five seconds.

This checks the operation of the alert indicator. If the code is active, the alert indicator will flash the flash code at five-second intervals. A fault diagnostic code remains active until the problem is repaired. For engine diagnostic codes, refer to Operation and Maintenance Manual of Caterpillar C7 Engine.

3-2-4

Travel Levers

3.3 Travel Levers 3.3.1 Travel Levers

WARNING Move the safety lock (1) to fix the travel levers (2), except for traveling.

2 1

The travel levers can run the right/left drive motors respectively . By manipulating the right and left travel levers, the forward and backward move of the machine, traveling speed and lateral turning degree can be controlled.

Moving Forward (

)

Push the travel levers forward. The machine will move in a forward direction.

Moving Backward (

)

Pull the travel levers backward. The machine will move in a reverse direction. The alarm will sound when the travel levers are pulled to the backward side. The backup alarm is used to alert people behind the machine that the machine is backing up. The backup alarm is mounted at the rear of the machine behind the grill.

Neutral When you release the travel levers, the travel levers will return the neutral position, so that th e machine stops traveling.

3-3-1

Travel Levers

3.3.2 Oscillating Lock Mechanism

WARNING When operating such equipment as the boom or guide shell, make sure that the right and left track shoes are both touching the ground otherwise it might tip the machine over. If the right and left track frames are not oscillating during the machine traveling, stop moving and ask your nearest distributor to check and restore it.

The oscillating lock lever is used to cut off the connecting circuit between the right and left cylinders.

OFF

ON

LOCK When the oscillating lock lever is at [OFF], the right and left track frames cannot oscillate. Move the safety lock to fix the travel levers during drilling work or when the running operation is

not done.

17305002

3-3-2

Travel Levers

OPEN When the oscillating lock lever is at [ON], the hydraulic connecting circuit is released during traveling or oscillating operation to set the oscillation of the right and left track frames to be possible. Because the right and left oscillating cylinders work together as a hydraulic connecting circuit, the

right and left

track frames oscillate in reverse directions and against each other, according to the unevenness of the ground. That increases stability when moving over unleveled ground.

17305003

3-3-3

Hydraulic Cylinder Control

3.4 Hydraulic Cylinder Control

WARNING When equipment such as boom and guide shell is moved, set the body parallels to the track frame and holds both crawler track shoes on the ground, otherwise the machine might fall. Operate the hydraulic cylinder control levers only after making sure that there is no worker around the machine.

CAUTION When the machine moved sound the horn to draw other worker’s attention.

1

2

1

1. Hydraulic Cylinder Control Levers 3

2. Rod Changer Control Levers 3. Horn Switch

1. Hydraulic Cylinder Control Levers Hydraulic cylinder control levers are used to operate work equipment such as boom and guide shell or oscillation of machine body.

2. Rod Changer Control Levers Hydraulic cylinder control levers are used to operate rod changer. A series of composite operation is automated from the [Adding] to the [Drawing] of the rod by the rod changer.

3. Horn Switch Push the horn switch in order to sound the horn.

3-4-1


3.4.1 Hydraulic Cylinder Control Levers

2

3 1

1. Boom Lift/Boom Swing Lever 2. Guide Tilt/Guide Swing Lever 3. Oscillating/Guide Slide Lever

1. Boom Lift/Boom Swing Lever A: Boom (Up)

Ｃ

Pull the lever backward, and the boom moves upward. B: Boom (Down) Push the lever forward, and the boom moves downward. C. Boom (Right Swing) Move the lever toward the right, and the boom swings rightward.

Ｂ

Ａ

D. Boom (Left Swing) Move the lever toward the left, and the boom swings leftward.

Ｄ

2. Guide Tilt/Guide Swing Lever Ｃ

A: Guide Tilt (Tilt) Pull the lever backward, and the guide shell (end) moves upward. B: Guide Tilt (Dump) Push the lever forward, and the guide shell (end) moves Ｂ

downward.

Ａ

C. Guide Swing (Turning Right) Move the lever toward the right, and the guide shell (end) swings rightward. D. Guide Swing (Turning Left) Move the lever toward the left, and the guide shell (end) swings leftward.

3-4-2

Ｄ


3. Oscillating/Guide Slide Lever A: Oscillating (Up)

Ｃ

Pull the lever backward, and the body front moves upward and the rear moves downward. B: Oscillating (Down) Push the lever forward, and the body front moves downward and the rear moves upward.

Ｂ

Ａ

C: Guide Slide (Backward) Move the lever toward the right, and the guide shell moves backward. D: Guide Slide (Forward) Move the lever toward the left, and the guide shell moves Ｄ

forward.

3-4-3


3.4.2 Rod Changer Control Levers

2

1. Carrier Swing/ Rod Adding - Drawing Lever

1

2. Roller Rotation / Roller Slide Lever

★ For operating the rod changer, refer to 4.7 “Rod Changer

Operation”.

1. Carrier Swing / Rod Adding - Drawing Lever

Ｃ

A. Carrier (Swing In) Pull the lever backward. The rotator opens the roller and the rotator and sleeve clamp swings out. And now, the front and rear carrier moves to the rod drawing position. By resetting the lever to the neutral position, the rotator and sleeve clamp

Ｂ

Ａ

swings in to close the rotator roller. B. Carrier (Swing Out) Push the lever forward. The rotator opens the roller and the rotator and sleeve clamp swings out. The front and rear carrier moves to the refuge position. By resetting the lever to the neutral position, the rotator and sleeve clamp swings in to close the rotator roller. C. Rod (Drawing) Move the lever toward the right. The rod is drawn into the carrier. D. Rod (Adding) Move the lever toward the left. The rod is sent to the drilling center.

3-4-4

Ｄ


2. Roller Rotation / Roller Slide Lever

Ｃ

A. Roller (Rotation) Push the lever forward. The roller rotates reversely and the rotating rod is pulled out. The sleeve clamp open operation functions only when the roller rotation operation is done in the

Ａ

recovery mode B. Slide (Forward) Move the lever toward the left. The rod caught by the roller moves forward.

Ｂ

C. Slide (Backward) Move the lever toward the right. The rod caught by the roller moves backward.

3-4-5

Drilling Control Box

3.5 Drilling Control Box

WARNING When the engine is started or re-started, set all operating levers and switches to “neutral” or “stop”, otherwise the machine might be accidentally operated.

CAUTION When the engine is started or the machine moved sound the horn to draw other worker’s attention.

3.5.1 Drilling Control Panel

4 3

2 1

1. Impact Lever 2. Feed Lever 3. Rotation Lever 4. Flushing Lever

1. Impact Lever This lever is used for impacting for the drifter and heating the hydraulic oil. Impact Operation Pull the impact lever more backward than neutral positions, and the drifter performs impact operation. The impact pressure can be adjusted by the lever-tilting angle. The impact lever can be stopped at an arbitrary position. Heat Operation Push the impact lever forward fully in order to heating the hydraulic oil. After warm-up of engine, push the impact lever forward fully to heat the hydraulic oil. Before the machine travels or drilling starts, heat the hydraulic oil to warm the hydraulic devices. ★ For heating of the hydraulic oil, refer to 4.2.3 “After Starting the Engine”.

2. Feed Lever This is the lever to move the drifter forward or backward. 2-step change can be carried out for each work.

3-5-1


(1) Feed Forward (Normal Feed) Pull the feed lever backward from the neutral position into the detent. The drifter is moved slowly forward. The feed lever remains in the NORMAL FEED position until the feed lever is pushed out of the detent. (2) Feed Forward (Fast Forward) Pull the feed lever backward side fully, and the drifter is moved fast forward. The

feed lever returns to

the NORMAL FEED position when the feed lever is released. (3) Feed Backward (Normal Feed) Push the feed lever forward from the neutral position into the detent. The drifter is moved slowly backward. The feed lever remains in the NORMAL FEED position until the feed lever is pulled out of the detent. (4) Feed Backward (Fast Backward) Push the feed lever forward fully, the drifter is moved fast backward. The feed lever returns to the NORMAL FEED position when the feed lever is released.

3. Rotation Lever The rotation lever is used to tu rn the shank rod normally (counterclockwise) or reversely (clockwise) . The shank rod stops rotating when resetting this lever to the neutral position. Normal Rotation Pull the rotation lever from a neutral position to one step backward, and the shank rod is turned normally. Reverse Rotation Push the rotation lever from a neutral position to one step forward, and the shank rod is turned reversely.

4. Flushing lever This lever is used to adjust the amount of the discharge of the

flushing air. The flushing airflow can be

adjusted by the lever-tilting angle. Push the lever forward fully , and the discharge of air stops.

3-5-2


Tilt Lock Pedal This pedal is used to fix the drilling control box (1) to an optional angle. By setting on the tilt pedal (2), the tilt pedal (2) is unlocked to be able to tilt the drilling control box (1) forward or backward.

1

2

3-5-3


3.5.2 Drilling Switch Panel

1. Feed Pressure Control Dial 2. Dust Collector Switch 1

3. Hood & Centralizer Switch

2 3

4. Pilot Lamp 4

5

6

7

5. Anti-Jamming Switch 6. Mode Selector Switch 7. Grease Lubrication Switch

1. Feed Pressure Control Dial This dial is used to adjust the feed pressure force during drilling. By adjusting the feed pressure force, such irregularities as hole bend and rod damage are prevented. Pull the dial, and release the lock. Turn the dial clockwise to increase the feed pressure force. Turn the dial counterclockwise to decrease the feed pressure force. After adjusting, push the dial. Generally, when the rock drilled is hard or large diameter drilling performed, the feed pressure force is increased, and

LOCK

when soft rock is drilled or small diameter drilling is performed, the feed pressure force is decreased.

CANCEL

2. Dust Collector Switch This switch is used for the dust collector ON/OFF operation. ON Tilt the dust collector switch forward in order to operate the dust collector. OFF

ON

Tilt the dust collector switch backward when stopping the dust collector because of spring water. When the engine is started or stopped, set the switch to OFF. OFF

3-5-4


3. Hood & Centralizer Switch This switch opens and closes the centralizer and moves the

sliding hood up and down.

When the finger is released from the lever switch, the lever switch automatically returns to neutral. 

The centralizer opens when tilting the switch leftward and the centralizer is closed when titling the switch rightward.



The sliding hood moves downward when tilting this switch to the operator side or the sliding hood moves upward when titling this switch forward. UP

DOWN

OPEN

CLOSE

4. Pilot Lamp This lamp lights up when the flushing air pressure or airflow drops or when feedback occurs because the rod rotation pressure increases.

5. Anti-Jamming Switch The anti-jamming switch has two functions; one is to prevent jamming

where the bit and rod cannot

be pulled out during the drilling. And the other is RP (Reverse Per cussion), which is to pull out the rod by using the drifter impact force when the rod cannot be pulled out during drilling. Anti-Jamming Position Tilt the anti-Jamming switch forward, and the safety device (ant i-jamming) operates. It automatically moves backward, if an abnormal condition is detected during drilling.

3-5-5


If the following troubles are detected while the anti-jamming works, the drifter moves backward automatically. The flushing air pressure has dropped due to a trouble of the compressor . Flushing airflow has dropped due to stuffing of bit tip, etc. Rod rotation pressure has increased abnormally due to thrust up to the fracture zone or a solid zone. Position RP (If Equipped) RP (Reverse Percussion) uses drifter impact force to pull out the rod when the rod cannot be pulled out during drilling. RP (Reverse Percussion) is installed as an option when the machine is delivered from the factory. The RP (Reverse Percussion) is activated by the following procedure.

1. Tilt the anti-jamming switch (1) backward.

1

2. Push the feed lever (2) one step forward and set the feed lever (2) to normal feed position.

3. Pull the impact lever (3) backward fully. The drifter

2

activates strong impact and the rod is pulled out. The RP (Reverse Percussion) is automatically stopped after 20 seconds.

4. When the RP (Reverse Percussion) needs repeated use, temporarily stop impact and then pull the impact lever (3) again.

NOTICE

Continuous operation of the RP function not only leads to increased oil temperature and degradation of

the

drifter

function,

but

also

to

machine

breakdown. Avoid the continuous use of the RP function, as much as possible.

3-5-6

3


6. Mode Selector Switch Select the drilling mode according to the rock quality to be drilled.

NOTICE Too much high speed drilling in H mode greatly increases damage and wears to the drifter rotary components, rod, and bit. Use the N mode for normal drilling. Do not drill for more than 5 minutes in the H mode

Tilt the mode selector switch backward; the “N” mode is selected for normal drilling. Tilt the mode selector switch forward to select “H” mode for drilling the fracture zone or clay layer, soft rocks, etc.

H

N

7. Grease Lubrication Switch This switch is used to apply a coat of grease to the threaded portions of the rod and shank rod. Grease is applied only when the switch is pressed.

3-5-7

Pressure Gauges

3.6 Pressure Gauges

1 2

3

1. Impact Pressure Gauge 4

2. Feed Pressure Gauge 3. Rotation Pressure Gauge 4. Flushing Air Pressure Gauge

The four drilling pressure gauges consist of impact pressure gauge, feed pressure gauge, rotation pressure gauge and flushing pressure gauge.

1. Impact Pressure Gauge This gauge indicates the drifter impact pressure.

2. Feed Pressure Gauge This indicates the feed pressure in drilling. The feed pressure is the pressure of the bit on the rock.

3. Rotation Pressure Gauge This gauge indicates the drifter normal rotation pressure.

4. Flushing Air Pressure Gauge This shows the pressure of the flushing air discharge.

3-6-1

Operator’s Cab

3.7 Operator’s Cab 3.7.1 Operator’s Seat Ad justment

CAUTION Adjust the seat at the beginning of each shift. Adjust the seat when operators are changed. Adjust the seat in order to allow full travel of the pedals. The operator should be seated against the back cushion of the seat.

1. Seat Forward/Backward Adjustment Pull up the slide lever (1), and slide seat to forward and backwards. Set to desired position and release hand from slide lever (1).

1

2. Reclining Adjustment Pull up the reclining lever (2), and set the back seat to the 2

desired position. Then release the hand from the reclining lever (2).

3. Armrest adjustment The armrest (3) can be pulled up.

4

4. Headrest adjustment The headrest (4) can be pulled up for two steps.

3

3-7-1

Operator’s Cab

Seat Belt Adjustment (If Equipped)

WARNING When the machine is equipped with seat belt, always wear the belt. Inspect the seat belt for webbing that is worn or frayed. Check the buckle (2) for wear or for damage. If the seat belt is worn or if the buckle (2) is damaged, replace the seat belt and/or the buckle (2). Regardless of the appearance, the seat belt should be replaced after every three years.

If the seat belt is not worn correctly , half might reduce its efficiency or it might cause other danger.

1. When the seat belt is to be worn, adjust the seat position and sit deeply in it with your upper body upright. 1

2. Holding the plate (1) and insert in buckle (2) until “click” sound is heard.

3

3. Adjust the belt so that it closely contacts your hips as low

2

as possible. 17414062

4. When the seat belt is to be released, press the button (3) on the buckle (2) and remove the plate (1).

3-7-2

Operator’s Cab

3.7.2 Operator’s Cab

CAUTION When the machine is moved or when drilling, close the cab door.

Opening Cab Door Pull out on the door latch lever (1) to open the cab door.

1

Locking Open Cab Door

The door can be locked both open and closed. When the door is to be locked open, fix it by pressing the door against the catcher section (1). When opening a door, the button (2) inside a door is pushed.

2 1

3-7-3

Operator’s Cab

Room Lamp Move the switch (1) to turn the room lamp (2) on or off.

1

2

Cup Holder For cup holder (1) use, open the cover.

1

3-7-4

Handling of Air-Conditioner

3.8 Handling of Air-Condition er By operating the air-conditioner, outside air is sent into the cab through the filter and raises the atmospheric pressure in the cab. It prevents dust from entering the cab even in a dusty site and maintains a comfortable condition in the drilling operation.

Control Panel

4

1

3

A/C

1. Air Conditioning Switch 2. Temperature Control Switch OFF

LO

HI

3. Mode Selector Switch 4. Internal/External Air Selector Switch

2

6

5. Fan Switch

5

6. OFF Switch 17414049

1. Air-Conditione r Switch When this switch is pressed during fan operation, the air conditioner is activated and the indicator turned on. When this switch is pressed once more, the air-conditioning is stopped and the indicator turned off.

A/C

17314007

2. Temperature Control Switch This switch adjusts the temperature of the discharged air. When the engine is started, eight indicators are all turned on. When the switch is pressed and the temperature is set to lowest, the indicators are all green. When the temperature is set to highest, the indicators are all red. When the discharged air temperature is set to lowest and temperature is increased, the indicator color is sequentially changed to red from the left side.

17314002

3-8-1


3. Mode Selector Switch By changing the air blow outlet, the air blow is available for use. ★ In the front and rear air blow outlets, operating the louvers

changes the blow direction.

17314003

: Front Blow This switch is pressed when air is to be blown from the front air blow outlet (A). When this switch is pressed, the indicator is turned on. A

: Front/Rear Blow This switch is pressed when air-blow is wanted from the front

B

air blow outlet (A) and rear air blow outlet (B). When this switch is pressed, the indicator is turned on.

: Foot Blow Press this switch to blow air from the foot air-blow outlet (C). When this switch is pressed, the indicator is turned on.

C

3-8-2


4. Internal/External Air Selector Switch This switch changes over the intake. Internal air circulation Press this switch for fast cooling or heating. When this switch is pressed, the indicator is turned on and external air is stopped.

Internal Air Circulation

External air Introduction When this switch is pressed, the fresh external air is filtered

External Air Introduction 17314004

into the cab. The air in the cab can be pressurized to prevent dust from entering.

5. Fan Switch When cooling or heating, this switch adjusts the flow rate in four steps. When this switch is pressed, the indicator is turned on. ★ When the indicator for the air conditioning switch is turned

off and this switch is pressed, the fan is operated independently.

17314076

6. OFF Switch When this switch is pressed, the air-conditioning (or fan) is stopped and the fan switch indicator turned off.

17314075

3-8-3


Cooling Operation

CAUTION It is said that the healthiest cab temperature is about 5 - 6 C different from the open air temperature. It is not healthy to lower the temperature excessively or blow cold air on your body for a long time. Take the greatest care of temperature adjustment. Inside the cab may become dry because of the dehumidifying effect of the air-conditioner. When the air-conditioner is operated, open the door about once an hour for ventilation. If inside the cab is dry, you might get pain in your eyes with cigarette smoke. If you smoke, open the window slightly for ventilation.

The air-conditioner cools the cabin by circulating the outside in the

cab and dehumidifying.

1. Set the internal/external air selector switch (1) to “External Air Introduction”. 5

2

Make sure the indicator is turned on.

1

★ For quick cooling, temporarily set to “Internal Air

Circulation”. A/C

2. Change the mode selector switch (2) and select the OFF

desired air-blow outlet.

LO

HI

3. Press the temperature control switch (3) and set the blown 3

air temperature to the lowest.

6

4

Make sure that all eight indicators are turned on in green.

4. Press the fan switch (4) to a djust the flow rate. Press the air-conditioning switch (5) to activate the air-conditioner. Make sure the indicator is turned on. When operation of the air-conditioner is to be stopped, press the OFF switch (6).

5. The air temperature in the cab is adjusted by using the temperature control switch (3) and fan switch (4).

3-8-4

17314099


Heating Operation Introduce outside air into the cab to heat. 1.

Set the internal/external air selector switch (1) to “External 1

5

2

Air Introduction”. Make sure the indicator is turned on. ★ For quick heating, temporarily set to “Internal Air

A/C

Circulation”. OFF

2.

LO

HI

Set the mode selector switch (2) to “Foot Blow”. Make sure the indicator is turned on. 3

3.

Press the temperature control switch to the highest (3) to set the blown air temperature. Make sure all eight indicators are turned on in red.

4.

Press the fan switch (4) to adjust the flow rate.

5.

To adjust air temperature in the cab use the temperature control switch (3) and the fan switch (4).

NOTICE With

dehumidifying

heating,

press

the

air-conditione r switch (5). The indicator is turned on and the air-conditioner activat ed.

3-8-5

4

17314099


Handling during the Season

NOTICE For the supply of cooling refrigerant (gas) and checking and maintenance of the air-conditioner, ask your nearest distributor.

In order to optimize the air-conditioning in the season, supply the cooling refrigerant: do check and maintenance. ★ To check the cooling refrigerant (gas), refer to 14.1 “When Required”.

Handling in the Off-Season If the air-conditioner is left for a long time with cooling refrigerant (gas) leaking, it might cause corrosion in the system. During the off-season, operate the air-conditioner for 5 - 6 minutes twice of three times a month will prevent the leakage of cooling refrigerant (gas) from the compressor sealing section.

3-8-6

Handling of Fire Extinguisher

3.9 Handling of Fire Extinguisher

WARNING Do not disassemble the fire extinguisher: the container might burst. If the fire extinguishing liquid gets into your eyes or on your skin, wash it well off with clean running water and consult your doctor.

CAUTION The life period of the fire extinguisher is about 8 years. Replace if the following are found: 

Container rusts or damages.



Loosening of cap



Loosening of cap

When machine is delivered, install fire extinguisher (1) on its bracket and secure it Fire extinguisher (1) must be fastened properly and ready

1

The fire extinguisher in the machine is effective for the following: General Fire: fiber, paper and wood fires. 

Oil Fire: Diesel and other such oil fires.



Electric Fire: Fire in electrical equipment with a risk of shock.

3-9-1

with the band (2).

to be used.

2

Handling of Fire Extinguisher

Precautions in Extinguishing Fire The forcible use might increase the fire. It may not be possible to use the extinguisher to deal with a large fire or to use the extinguisher fast enough. The fire extinguishing should be from the windward so that gases are not inhaled. Tilting the extinguisher reduces its efficiency . Keep it as straight upright as possible. 

The fire extinguishing liquid is electric conductive. In order to prevent a short circuit or electric shock; turn off the power when fighting fire electrical equipment.



In fire fighting, approach the fire gradually keeping back 3 m after the fire is reduced.



When fighting fire always keep open an escape route.

How to Use 1. Pull out the safety stopper on the top of the lever.

2. Remove the nozzle from its holder and aim it at the srcin of a fire.

3. Grasp the upper and lower levers strongly and discharge the liquid, as though sweeping the srcin of a fire. When the hand is released from the levers, the discharge of the liquid is stopped.

3-9-2

4. Running Operation 4.1 Daily Inspection Daily inspection is the inspection before the work of the day is started. Make the inspection before operation results in using the

machine safely or prevents failures.

Open/Close of the Cover

The engine cover and rear cover are opened and closed as follows.

1. Insert the key and turn it clockwise to release the lock. Pull up the handle (1). Use the key dedicated to the cover open/close.

1

2. Turn the handle (1) counterclockwis e.

1

3. Open the cover; fix it with the stopper (2) not to be closed. 4. When you wish to close the cover, remove the stopper (2), it inserts in a stopper receptacle, and a cover is closed.

5. Turn the handle (1) counterclockwise and house it. Insert the key into the lock and turn it counterclockwise and lock it so that the cover cannot open. Validate the lock not to open the cover.

4-1-1

2

Daily Inspection

4.1.1 Before Starting the Engine Walk-Around Inspection Check the surrounding and lower part of the machine by visual inspection for leakage of fuel or oil, missing bolts and nuts, and conditions of working equipment and

hydraulic system.

Check Drifter and Working Equipment Make sure there is no galling or damage to the hydraulic cylinder and no oil leakage at the junctions of high-pressure hoses.

2 5

2

1

4 3 6

(1) Check the drifter for excessive wear , damage, and deformation. Check the rod changer for excessive wear, damage, and deformation. (2) Check the rotator and rotator rollers for exce ssive damage and wear . (3) Check the boom and boom pedestal for excessive deformation, wear , and damage. (4) Check the guide shell and guide mounting for excessive wear , cracking, and deformation. (5) Check the foot pad and centralizer for excessive wear , cracking, and deformation. (6) Check the hose reel for excessive deformation, damage, and crac king.

4-1-2

Daily Inspection

Check Chassis

3

6

2 1

7 4

5

(1) Check the engine compartment loose or missing parts and for any evidence of damage or leakage. (2) Check the control panel interior and remove dust parti cles. (3) Check the battery box and remove du st particles. (4) Open the rear cover, and check the compress or and oil lines for leakage. (5) Check the oil cooler and cool er condenser for clogging . (6) Check the cooling system for coolant leaks and also check the radiator and air cooler for clogging. (7) Check the dust collector for excessive damage and deformation. Check the oil motor for oil leak.

4-1-3

Daily Inspection

Check Cab/Traveling Device

3

1

3 2

4

5

3

7

6 5

8

(1) Wipe off any dirt on the fron t and side glasses and clean them. Check the cab interior and remove dust particles. (2) Check the steps or handrail s for oil and mud, and clean them . (3) Check the lights and mirror for damage, and clean them. (4) Check the oscillating cylinders for galling and damage, and also check the high-pressure joints for oil leakage. (5) Check the front idlers and track rollers for oil leakage, excessi ve wear, damage, and crack ing. (6) Check the track frames for excessive wear , damage, and cracking. (7) Check the carrier rollers for excessi ve wear, damage, and cracking. (8) Check the drive motors for oil leakage and also check the sprockets for excessive wear , damage, and cracking.

4-1-4

Daily Inspection

Check Engine Oil Level

NOTICE Allow 5 to 6 minutes between addition of the engine oil and checking of the oil level. To check it immediately after adding the engine oil will not show the true oil level.

1. Open the engine cover that is located on the left side of the machine.

2. Pull out the oil level dipstick (1) and wipe oil off with a clean cloth. Reinsert the oil level dipstick (1) and pull the oil level 1

dipstick (1) out again.

3. Maintain the oil level between the upper and lower marks in the oil level dipstick (1).

Upper Limit

If the oil level is low, add oil. Lower Limit

FULL

D AD

4. Remove the oil filler cap (2) to add oil to the specified level. ★ For the engine oil, refer to 11. “Fuels and Lubricants”.

5. Clean the oil filler cap (2) and install the oil filler cap (2). 2

6. Close the engine cover.

4-1-5

Daily Inspection

Check Radiator Coolant Level

WARNING Check the coolant level in the reservoir tank (1) when the engine is stopped and cool. Do not open the radiator cap (2), when the radiator cap (2) is not necessary and when the water is hot.


2. Maintain the coolant level between [FULL - LOW] lines on the reservoir tank (1). If the coolant level is on below LOW

1

line, add coolant. Bring level up to FULL line. If the coolant level is low, add coolant as follows.

NOTICE If the coolant level drops within a short time, check for coolant leaks from radiator, radiator hoses and other parts of the cooling system. FULL

LOW

17203001

3. Remove the radiator cap (2) and add coolant until it reaches proper level.

4. Clean the radiator cap (2) with a clean cloth. Inspect the radiator cap (2) and the cap seal for damage, deposits or foreign material. Replace the radiator cap (2) if the radiator cap (2) is damaged. 2

5. Install the radiator cap (2). 6. Close the engine cover.

4-1-6

Daily Inspection

Drain Water and Sediment from Primary Fuel Filter

WARNING Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. Clean up all leaked or spilled fuel. Do not smoke while working on the fuel system.

CAUTION Dispose of all fluids according to local regulations and mandates.

The primary fuel filter (1) separates water mixed with fuel to prevent

trouble due to water.

1. Open the rear cover. 2. Place a suitable container under the drain valve (2) 1

3. Open the drain valve (2) in order to drain any fuel from the fuel filter bowl (3).

4. Close the drain valve (2).

3


3

2

4-1-7

Daily Inspection

Check Fuel Tank Level

WARNING Personal injury or death can result from a fire. Clean up all leaked or spilled fuel. Do not smoke while working on the fuel system.

★ Fill the fuel tank at the end of operation.

The rear cover is opened, and the amount of the fuel is checked with the fuel gauge (1). Remove the fuel cap (2). 1

When fueling, attach a strainer (3) on the fuel tank. Wash the strainer (3) in a clean nonflammable solvent, if necessary, to remove any foreign materials. Replace the strainer (3), if the strainer (3) is damaged. After fueling, install the fuel cap (2) securely.

3

4-1-8

2

Daily Inspection

Drain Water and Sediment from Fuel Tank

WARNING Personal injury or death can result from a fire. Clean up all leaked or spilled fuel. Do not smoke while working on the fuel system.


Open the engine cover that is located on the rear of the machine. Open the drain cock (1) and allow the water and sediment to drain into a suitable container. When clean fuel comes out, close the drain cock (1).

1

4-1-9

Daily Inspection

Check Hydraulic Oil Level

WARNING Spilt oil must be cleaned up as it may cause fire.

★ The level gauge (1) is located on the front of the hydraulic tank.

Maintain the hydraulic oil level between the upper and lower marks in the level gauge (1). If the oil level is low, add oil by using the oil supply pump. ★ For supplying hydraulic oil, refer to 11.4 “Oil Supply

1

Pump”. ★ For the hydraulic oil, refer to 11. “Fuels and Lubricants”.

Upper Limit

Lower Limit 17305001

4-1-10

Daily Inspection

Drain Water and Sediment from Receiver Tank



★ The drain cock (1) is located on the right side of the machine.

Open the drain cock (1) and allow the water and sediment to drain into a suitable container. When clean oil comes out, close the drain cock (1).

1

4-1-11

Daily Inspection

Check Receiver Tank Oil Level


NOTICE Check the compressor oil level before engine start and during compressor operation.

★ For the compressor oil level check during compressor operation, refer to 4.2.3 “After Starting the

Engine”.

1. Open the engine cover that is located on the right side of the machine.

2. Before the engine is stared, the level of the compressor oil should be within the STOP mark of the level gauge (1).

3. Remove the receiver tank filler cap (2) and add oil, if necessary.

2 1

★ For the compressor oil, refer to 11. “Fuels and

Lubricants”.

4. Clean the receiver tank filler cap (2) and install the receiver tank filler cap (2). 停止


P O T S

運転

ＮＵＲ

17304001

4-1-12

Daily Inspection

Check Battery Electrolyte Level and Terminal

DANGER Battery electrolyte is a dilute sulfuric acid solution, so avoid contact with eyes, skin clothing or other metallic surfaces. If it should get onto anything, wash it off quickly with water. Get medical attention immediately. Battery gas can explode. Do not smoke when observing the battery electrolyte levels.

★ For handling the battery (1), refer to 6.3 “Battery Servicing”.

1. Open the engine cover that is located on the left side of the machine. 1

2. Remove the cover. Clean the battery surface with a clean cloth. Keep the terminals clean and keep the terminals coated with petroleum jelly.

3. Inspect the electrolyte level in each battery cell.

176S210005

Maintain the electrolyte level between the UPPER and LOWER lines or 10 to 15mm above battery plate. UPPER LEVEL

4. If the electrolyte level is low, remove the cap and add distilled water. UPPER LEVEL LOWER LEVEL

5. Tighten cable clamps and ground connection. 6. Install the cover.

LOWER LEVEL 26110071


4-1-13

Daily Inspection

Drain Water and Sediment from Air Filter

WARNING When the bowl (2) is removed, make sure that the pointer of the pressure gauge (3) shows “0” and the inside pressure is released, otherwise air might blow off.

The air filter is separate and removes moisture and dust from the air circuit. Any separated moisture and dust accumulates at the bottom of the bowl (2) of the air filter. ★ The air filter is located on the dust collector at the rear of machine.

1. Press clamp ring (1) and turn the bowl (2) to remove the bowl (2).

2. Drain the water and dust from the bowl (2) into a suitable container.

3. Clean the inside of the bowl (2) with a clean cloth. Install the bowl (2).

4-1-14

2

1

3

Operation of Engine

4.2 Operation of Engine This section describes the engine operations from start to stop.

4.2.1 Before Starting the Engine 1. Before boarding the machine and starting the engine, perform a start-up inspection. ★ For the check items, refer to 4.1 “Daily Inspection".

2 1

2. Tilt the safety lock (1) to fix the travel levers (2). Set all operation levers and switches to “Neutral” or “OFF”. In a machine with an emergency stop system, reset the stop condition.

3. Set the engine throttle switch (3) to the [I] position.

3

4. Adjust the operator seat position so that your back is firmly against the seat. ★ For the adjustment of the operator seat, refer to 3.7.1 “Operator’s Seat Adjustment”.

5. Fasten the seat belt.

4-2-1

Operation of Engine

Engine Throttle Control This switch (1) adjusts the engine speed. Use the engine throttle switch (1) to adjust the engine speed. By changing the switch (1), the engine speed can be adjusted. The following energy saving function is provided: operating the impact switch or flushing lever during drilling automatically increases the engine speed.

1

Automatic Operation This is an energy-saving mechanism, which controls the engine speed automatically . Set the engine throttle switch to the [III] position. During drilling, when the impact lever (1) or the flushing lever (2) is operated, the engine speed is increased automatically (❋)

from middle to high speed

.

2 1

❋ For the highest engine speed during drilling, the selector switch can access the normal mode or economy mode. In the normal mode, the highest engine speed is 2200min¯¹. In the economy mode, it is controlled to 2000min¯¹. ★ For selector switch, refer to 6.1.2 ” Energy Saving Switch “.

4-2-2

Operation of Engine

4.2.2 Starting the Engine

WARNING When the engine is started, sound a warning horn to draw attention of the workers around.

NOTICE Do not keep turning the starter for more than 30 seconds. If the engine starting fails, re-start after an interval of more than 2 minutes.

1. Turn the starter switch key to the “R” position. Make sure that the engine diagnosis monitor lamps (1) and the alternator (charge) lamp (2) turn on. ★ The engine diagnosis monitor lamp (1) will be turned off in about five seconds.

2 1

2. Turn the starter switch key to the “HS” position to start the engine. When the engine starts, the air relief valve opens for about 15 seconds to discharge the air from the receiver tank.

4-2-3

Operation of Engine

3. Release the starter switch key. The key is automatically returned to the “R” position.

4. When the machine is normal, all the monitor lamps turn off. ★ For the monitor lamp displays of the electric monitor,

refer to 3.2 “Meter Panel”.

Re-starting the Engine

CAUTION If the engine is re-starte d with air stored in the receiver tank, it might damage not only to the engine, but also pump, coupling and compressor. Before the engine is re-started, wait for more than 5 minutes until the air is completely bled from the receiver tank.

Make sure the hand of the pressure gauge on the receiver tank shows “0” and the inside pressure released when the engine is re-started.

1

4-2-4

Operation of Engine

4.2.3 After Starting the Engine Do not operate the machine immediately after engine starts, but perform the following operation and check.

1. Make sure that the engine is stopped when the emergency stop system is operated. Return the starter switch key to the “O” position and reset the stop condition.

2. After making sure that the inside pressure of the receiver tank has been released, re-start the engine.

3. Make sure the monitor lamp (1) is n ot turned on. 4. Make sure that no warning indications are shown on the

1

PowerView display (2).

2

5. Idle the engine for five minutes and warm up. 6. Make sure there is no abnormal vibration, noise, smell or exhaust from the engine.

7. Make sure there is no oil leakage in the engine or hydraulic components.

NOTICE Do not operate the engine at high speed or perform any fast lever operation until warm-up is complete.

4-2-5

Operation of Engine

Heating of Hydraulic Oil Heat the hydraulic oil and warm up the hydraulic system before starting the running operation of the machine.

1. Set the engine throttle switch (1) to the [III] position. ★ Set the compressor switch (2) at [OFF] position.

2 1

2. Push the impact lever (3) forward fully in order to heat the hydraulic oil.

3

3. Heat the hydraulic oil until the hydraulic oil temperature rises to about 30°C.

4. Set the impact lever (3) to neutral position.

4-2-6

Operation of Engine

Check Receiver Tank Pressure (For JIS Specification)

WARNING Compressed air might blow off. When pulling the lever (3), wear the protective glasses. Don’t put your face or hand near the exhaust port (4).

The safety valve discharges the air in the receiver tank to outside so that the inside pressure of the receiver tank is not increased beyond the specified level. The air blowout pressure from the safety valve has been set to 1.18MPa.

1. Warm up the engine and heat the hydraulic oil. 2. Tilt the compressor switch (1) forward.

1


4. Check that the pressure inside the receiver tank becomes stable within the rage of 1.05 - 1.1MPa, using the pressure gauge (2). 3

5. Pull the lever (3) of the safety valve mounted at the upper part of the receiver tank and makes sure that air exhausts

2

through exhaust port (4).

3 4

4-2-7

Operation of Engine

Check Receiver Tank Pressure (For ASME Specification)

WARNING Compressed air might blow off. When pulling the ring (3), wear the protective glasses. Don’t put your face or hand near the exhaust port (4).

The safety valve discharges the air in the receiver tank to outside so that the inside pressure of the receiver tank is not increased beyond the specified level. The air blowout pressure from the safety valve (3) has been set to 1.18MPa.

1. Warm up the engine and heat the hydraulic oil. 2. Tilt the compressor switch (1) forward.

1


4. Check that the pressure inside the receiver tank becomes stable within the rage of 1.05 - 1.1MPa, using the pressure gauge (2).

3

5. Pull the test ring (3) of the safety valve mounted at the upper part of the receiver tank and makes sure that air exhausts through exhaust port (4).

4 2

4-2-8

Operation of Engine

Check Receiver Tank Oil Level

WARNING Spilled oil might cause fire. If any compress or oil is spilled, wipe it off carefully.

NOTICE Perform a compressor oil level check while keeping the vehicle body horizontal.

When the receiver tank pressure check is completed, proceed with the

oil level check.

1. Make sure the pressure inside the receiver tank becomes stable within the rage of 1.05 - 1.1MPa, using the pressure gauge (1).

1

2. Check the oil level at the level gauge (2) located on the side of the receiver tank is in the arrow mark showing the RUN.

3. If the oil is low, stop the engine and wait for 10 - 20 3

minutes. Then remove the oil filler port (3) to replenish the 2

compressor oil. ★ For the compressor oil, refer to 11. “Fuels and Lubricants”.

4-2-9

Operation of Engine

Adjust Drifter Lubricating Oil This machine is equipped with an automatic oiling type lubricator (2) for lubricating drifter front section. Start the compressor after the engine is started and check and adjust the

hydraulic oil level.

★ The lubricator (2) is located on the right side of the cab.

NOTICE If lubricant is not available from the lubricator and the drifter is operated for long, it might cause seizure of the chuck and chuck driver bush. Make sure that the hydraulic oil is delivered to the site dome (3) of the lubricator (2) during drilling.

1. Start the compressor and pull the flushing lever (1) backward in order to discharge the flushing air. 1

2. When drilling, about 60 - 120 droplets of hydraulic oil per minutes on the site dome (3) of the lubricator (2) are appropriate.

3. If the drop rate is too low or high turn the adjuster. When the adjusting screw (4) is turned clockwise, the drop rate is decreased. When the adjusting screw (4) is turned

2

counterclockwise, the drop rate is increased.

3

4

4-2-10

Operation of Engine

Inspect and Adjust Feed Chain Tension The chain, which moves the drifter and hose reel forward and backward, always needs an appropriate tension. If the chain is sag, irregularities such as gearing error into carriage, or damage or uneven wear, might occur. After the chain is used for some time it must sag. Therefore, check and adjust the tension before work. When the machine is new and immediately after the delivery, the chain may sag. Therefore, take great care to check the tension.

Inspection Lower the guide shell in parallel to the ground. Move the drifter to the rear end of the guide shell. Insert bar into the middle section of the chain and lift it. If the play in the chain is within 50 - 60mm, it is right. If the sag is more than that, adjust tension.

50 ~ 60 mm 17307002

Adjustment 1. Loosen the chain adjuster fixing nuts (1) on both right and left.

2. Tighten the right and left adjusting nuts (3) in turn so that

3

2

the front shaft (2) is at a right angle to the guide shell. 1

3. Check the tension of the chain is appropriate. 4. After checking the tension of the chain, tighten the fixing nuts (1) on the right and left.

2

1 3

4-2-11

Operation of Engine

Lubrication For supplying grease, attach the guide shell to the ground and stop the engine. Supply grease by using the grease pump. If grease contains dust or sand, it causes early wear of rotary parts. After supplying grease, wipe off protruded old grease carefully.

Foot Pad (1) Rod holder pin (2 p oints)

1

(2) Clamp cylinder arm pin (1 point) (3) Clamp cylinder plate pin (2 points)

4

(4) Arm plate pin (2 points) (5) Slide cylinder slider (2 points)

5 3

2

Guide Shell (1) Sprocket shaft (1 point)

1

4-2-12

Operation of Engine

Greaser Nozzle (1) Swing arm plate pin (1 point)

1

Carrier (F) (1) Feed shaft (1 point) (2) Swing pin bush (1 po int) (3) Swing cylinder plate pin (2 points) (4) Swing arm pin (1 point)

2

1

(5) Swing pin (1 point)

3

4 5

3

Slide Body (1) Slide body plate pin (2 points) (2) Rotator cylinder plate pin (1 point)

1

(3) Rotator pin (1 point)

3 2

4-2-13

Operation of Engine

(4) Slide shifter (2 po ints)

4

Rotator (1) Rotator case (4 points) (2) Rotator gear box (1 point) 2

1 2

Carrier (B) (1) Swing pin bush (1 po int) (2) Swing cylinder plate pin (2 points) (3) Ratchet wheel (1 point) 1

(4) Swing arm pin (1 point) (5) Swing pin (1 point)

2

3 4 5 2

4-2-14

Operation of Engine

(6) Ratchet (1 point)

6

Sleeve Clamp (1) Clamp arm base (1 point)

1

4-2-15

Operation of Engine

4.2.4 Stopping the Engine The engine is heated if it has been operated under load. When the engine is stopped suddenly, abnormality such as seizure of the turbo charger may be caused. Stop the engine by cooling gradually.

NOTICE Before stopping the engine, set the compressor switch to OFF side so that the compressor is unloaded.

1. Set the machine to traveling posture or guide shell downward, and press the end of the foot pad against the ground.

2 1

2. Tilt the safety lock (1) to fix the travel levers (2). 3. Set all the operation levers and switches to “Neutral” or “OFF”.

4. Set the engine throttle switch (3) to the [I] position and gently idle the engine for 2 - 3 minutes in.

3

5. Return the starter switch key to “O” position and stop the engine.

4-2-16

Traveling the Machine

4.3 Traveling the Machine

WARNING If any abnormality is found do not operate the machine until checking and maintenance is completed.

Test operation in a safe place to check on proper operations and traveling condition. After engine start the engine warm-up operation is performed. After heating the hydraulic oil, make sure that the hydraulic control levers corresponds to the operation of the machine. Carry out traveling at a low speed and check it the machine goes straight and if the travel lever operates normally.

4-3-1


4.3.1 Traveling Posture For traveling the machine, set it to “Traveling Posture” without fail.

1 2

1. Place the machine to be horizontal to the ground by oscillating operation. 2. Shift the drifter backward until it stops at the rear end of the guide shell. 3. Move the guide shell to be horizontal to the machine. 4. Move the guide shell to be horizontal to the machine by boom lift and guide tilt operation, and put the guide shell bracket (1) on the pedestal (2) while contracting the guide shell.

4-3-2


4.3.2 Starting

WARNING When the machine is started sound the horn to draw attentions of workers around. In particular, the rear of the machine is a blind spot for the operator. When the machine is moved backwards, make sure there is no worker or obstacle, using the under mirror.

1. Set the engine throttle switch (1) to the [II] position. 2. Set the machine to “Traveling Posture”. Refer to 4.3.1 “Traveling Posture”.

1

3. Set the oscillating lock lever (2) “ON” position.

2

4. Unlock safety lock (3) of travel levers (4). 4

5. Push the travel levers (4) forward or pull them to this side 3

(backward) to move the machine. The travel speed is adjusted by operating the travel levers (4).

4-3-3


4.3.3 Direction Control

WARNING Do not change the direction of movement on sloping ground, if possible; otherwise turnover or slide might occur.

CAUTION Do not perform spin-turn at high speed or quick turn on rocky or clay bed: the track shoes may come off or udder carriage is worn earlier than usual. For switching over from the forward or backward, stop traveling the machine once.

Change the travel direction using the travel levers (1). Operate the travel levers (1) as follows.

1

When the machine is stopped and the right travel lever is pushed forwards, the machine turns to the left in its forward movement. When the right travel lever is pulled this side, the machine turns to the left its backward movement. ★ When the left travel lever is pushed forwards, the machine

turns to the right in its forward movement. When the left travel lever is pulled to this side, the machine turns to the right in its backward movement. Forward Left Turning Reverse Left Turning

4-3-4


When the machine is moving forward and is to be turned left, gradually return the left travel lever to neutral. The machine will be slowly turned to the left. When the machine is moving backward and is to be turned left, gradually return the left travel lever to neutral. The machine will be slowly turned to the left. ★ When the machine is moving backward and is to be turned

right, gradually return the right travel lever to neutral. The machine will be slowly turned to the right. Forward Left Turning Reverse Left Turning

For a left spin-turn, pull the left travel lever this way and at the same time push the right travel lever forwards. ★ For a right spin-turn, pull the right travel lever this way and

at the same time push the left travel lever forwards.

NOTICE For a spin-turn, select solid and flat ground and temporarily stop the drill.

4-3-5


4.3.4 Stopping the Machine

WARNING When a machine is stopped on an inclination background, press the end of the foot pad against the ground. Place a block to each track shoe.

CAUTION When the machine is to be stopped, reduce the engine speed and slowly return the travel levers to neutral and then stop it with calm and composure.

1. Select solid and flat ground and slowly return the right and left travel levers to neutral to stop the machine. The travel levers are returned automatically to neutral when hands are released from levers.

2. Set the safety lock (1) to the travel levers (2). 2

1 1

3. Set the machine to traveling posture or guide shell downward, and press the end of the foot pad against the ground. For the traveling posture, refer to 4.3.1 “Traveling Posture”.

4. Set the engine throttle switch (3) to the [I] position.

3

4-3-6

Parking the Machine

4.4 Parking the Machine

WARNING Do not park the machine anywhere they may be landslide or lower place where collapse of scaffold might occur. Park the machine on the flat and solid ground.

When a machine is stopped on an inclination background, press the end of the foot pad against the ground. Place a block to each track shoe.

1. Select solid and flat ground and slowly return the right and left travel levers to neutral to stop the machine.

2

★ The travel levers are returned automatically to neutral

1

when hands are released from levers.

1

2. Set the safety lock (1) to the travel levers (2). 3. Set the machine to traveling posture or guide shell downward, and press the end of the foot pad against the ground.

4. Set the engine throttle switch (3) to [I] position.

3

5. Set the oscillating lock lever (4) “OFF” position. 4

6. Stop the engine. Pull out the starter switch key . The starter switch key should be stored in the specified place.

4-4-1

Parking the Machine

4.4.1 Locking

CAUTION When you leave the machine, lock it to prevent theft or tampering.

4 1 2

3

(1) Cab Door ★ Always close the windows. (2) Engine Side Cover (2 locati ons on the right and left)

(3) Rear Cover (4) Fuel Cap (If Equipped)

4-4-2

2

Drilling Work

4.5 Drilling Work

WARNING Do not allow the workers to approach within the danger zone when drilling; otherwise accident might lead to injury or death. Wear earplugs, earmuffs, or other sound preventive protectors during the work, otherwise the drilling work without these protectors may damage hearing. If the operator inhales dust over a long time, it might affect his health and he contracts pneumoconios is. Wear dust-proof mask during drilling work.

NOTICE Operate the emergency stop system before drilling work is started, and confirm the engine stops.

4.5.1 Preparation for Drilling After shifting the machine to a desired place by traveling it, prepare for drilling.

1. Set the oscillating lock lever (1) “OFF” position. 1

2. Set the engine throttle switch (2) to [I] position.

2

4-5-1

Drilling Work

3. Tilt the compressor switch (3) forward in order to go to a compressor full load condition.

4. Make sure the injection sound of pulse jet air for shaking down dust particles is heard from dust collector.

3

5. Set the engine throttle switch (2) to [III] position.

2

6. Tilt the dust collector switch (4) forward in order to start the dust collector. 5

7. Pull the flushing lever (5) backward. Make sure that the air is discharged from bit tip and oil motor of dust collector rotates.

4

8. Make sure the lubricating oil drops into sight dome of the lubricator (6).

6

9. Make sure the exhaust air with hydraulic oil is discharged from the exhaust port and front section of the drifter. ★ For lubrication of drifter, refer to “Hydraulic Drifter

Maintenance Manual” (separate volume).

4-5-2

Drilling Work

Drifter Warm-up

CAUTION Warm up the drifter before drilling, otherwise galling is generate d on drifter piston and valve.

For drifter warm-up, pull the impact lever (1) backward fully, and perform strong impacting for 2 - 3 seconds, then stop. The impact operation is repeated until the drifter impact pressure is raised and stabilized.

1

4-5-3

Drilling Work

4.5.2 Collaring

WARNING Stop the drilling operation before cleaning the drilling hole and filling the hole with clay.

Perform collaring before regular drilling for reducing the damage or wear of drilling tools and carrying out drilling work efficiently. Perform collaring to a depth of 20 - 30 cm until the drilling position and drilling direction are stabilized. If the hole is not stable, reinforce with clay. ★ In the case of limestone mine, 1 - 2 m of collaring might be required until the surface layer

becomes stable.

1. Set the engine throttle switch (1) to the [III] position.

1

2. Operate the hydraulic cylinder control levers so that the tilt angle of the guide shell equals the bench set angle. Position the guide shell on the drilling point and press down the foot pad. ★ The guide shell tilt angle can be checked using the

angle meter installed on the boom.

3. Move the guide shell forward until the front of the track shoe is 5 - 10cm off the ground, and then stop it.

5 - 10cm

4-5-4

Drilling Work

4. Pull the rotation lever (2) backward and turn the shank rod normally.

5. Pull the flushing lever (3) backward. Set the flushing lever (3) at half open.

3

2

6. Pull the impact lever (4) backward. 7. Pull the feed lever (5) backward into the detent in order to move the drifter forward and start collaring. The drifter is moved forward and collaring is started with a light

5

impacting. 4

8. Pull the feed pressure control dial (6) to unlock. Turn the dial (6) to drilling with low thrust.

6

4-5-5

Drilling Work

4.5.3 Regular Drilling The drilling position and direction become stable after collaring, and when the drifter has passed through the surface layer then start the regular drilling.

1. Tilt the hood & centralizer switch (1) backward and press the hood so that the hole to be drilled is totally covered. 1

Return the hood & centralizer switch (1) to neutral.

2. Pull the flushing lever (2) backward furthermore. 3 2

3. Pull the impact lever (3) backward fully. The drifter starts a strong impacting and regular drilling. ★ The feed lever (4) starts drilling by normal feed at the

4

same position as in collaring.

4. Tilt the anti-jamming switch (5) forward. 5. Turn the feed pressure control dial (6) to adjust the feed force. 5

6

4-5-6

Drilling Work

Drilling Precautions Beware with Blow Up of Cuttings Check if cuttings are blows up by means of flushing air during drilling. If the blowhole at the bit tip is stuffed, the flushing air pressure is increased. If the blowout of the flushing air becomes weak, cuttings cannot be discharged normally to easily result in hole stuffing and jamming. ★ When the anti-jamming switch is anti-jamming position, the drifter moves backward automatically

when the flushing air pressure has increased, or the airflow has dropped due to stuffing of bit tip.

Clean the Drilling Hole If the cuttings cannot be discharged normally or the flushing air pressure increases, stop the impact and move the drifter up and down 2 – 3 times to clean the hole before re-starting drilling. ★ When the anti-jamming switch is set to anti-jamming position , the drifter is automatically stopped

moving forward if the rotation pressure is excessively increased .

Beware of Spring Water If dirty water is collected, the filter element in the dust collector degraded. If spring water comes out during drilling, tilt the dust collector switch backward and stop the dust collector operation.

4-5-7

may be clogged and dust collection

Drilling Work

4.5.4 End of Drilling Work Mounting and Dismounting the Rods

NOTICE Long time no-rotation free-impa ct causes the bit and rod to slip off. When the screw is loosened in the rod or sleeve, the impacting sound is changed. Pay attention to the impacting sound during rotation-free impact.

The rods are added to each other, and drawn by loosening screws of the sleeves and rods by means of rotation-free impact after the end of all drilling work. These rods are mounted and dismounted by operating the rod changer without an y direct handling of these rods by a worker.

1. After drilling return all operation levers and switches, except for the anti-jamming switch (1), to “NEUTRAL” or “OFF”.

2. Push the dust collector switch (2) forward in order to start

1

the dust collector. 2

3. Pull the flushing lever (3) backward. 4. Pull the feed lever (4) backward by one step and push the bit tip against the drilling hole bottom. Move feed lever (4) to be neutral. 4 3

5. Pull the impact lever (5) backward fully. The drifter performs rotation-free impact to loosen the screws of the sleeves and rods.

5

4-5-8

Drilling Work

6. Push the impact lever (5) forward to neutral in order to stop the impact.

7. Push the flushing lever (3) forward fully in order to stop the flushing air. 3 5

8. Recover the rods by operating the rod changer control lever.

Inspection after Drilling Work

CAUTION If there is any abnormality perform maintenance or repair and replace the faulty component.

After drilling, check each part of the machine, to maintain the machine safety and avoid breakdown. 1. Look around the machine to check for oil leakage and visible damage. 2. Check the boom and boom mounting part for deformation and damage. 3. Check the bit for excessive wear and damage. 4. Check the guide shell for deformation and damage. 5. Check the drifter for visible damage, leakage and damage to

fittings.

6. Check the joints of high-pressure hose and hoses for proper connection and leakage. 7. Check the rod changer for excessive oil leak, excessive deformation, and damage. 8. Check the rods for bending, damage, cracking, other defects, or wear of threaded sections. 9. Check the engine room inside for loose or missing parts and oil leakage. 10. Check the carriage and remove mud.

4-5-9

Rod Changer Operation

4.6 Rod Changer Operation

WARNING Do not touch any rotation section such as the rod (1), sleeve (2) or shank rod (3) during rod changer or drifter operation; otherwise your finger or other part of your body might be caught. If your finger or other part of your body is caught by the moving part of the centralizer (4), it causes cutting or crushing. When the centralizer (4) is opened or closed to install or remove the sleeve (2), decide upon signals between the operator and other workers to avoid being caught by the centralizer (4).

3 2 1 17412025

2 4

17412024

Now, the rod changer operation procedures will be described from “Loading” to “Adding” and “Drawing” of the rod.

4-6-1


4.6.1 Loading of Rods

WARNING The rods are heavy. When it is loaded in the rod changer, lift the rods using a vehicle such as crane dedicated to heavy lifting. For loading the rods, decide upon signals between the operator of the rod changer and the worker who connects the rods and maintain a good communication during the work.

NOTICE Screw the sleeve in the rods to be loaded.

Warm the engine and heat the hydraulic oil before loading the rods.

1. Lower the guide shell down to a position where the rod can be screwed in easily, while keeping the guide shell in parallel to the ground.

2.

Set the engine throttle switch (1) to the [III] position.

1

3. Push the feed lever (2) forward fully in order to move the drifter fast backward.

4. When the drifter speed is changed from fast backing to normal backing, return the feed lever (2) to neutral.

4-6-2

2


5. Push the rod changer control lever (3) forward to move the front and rear carriers to the refuge position. Return the rod changer control lever (3) to neutral. 3

Carriar (F)

17612020

Carriar (B)

17612021

6. Operate the hood & centralizer switch (4) to allow the auxiliary sleeve (5) to be caught by centralizer (6). Push the sleeve (5) until its end face touches the offset part of centralizer (6). 4 6

4-6-3

5


7. Set the lifting tools such as nylon sling to the rod (7), and lift the rod (7) by a crane. 5

7

8. Screw the rod (7) into the auxiliary sleeve (5) by two or three turns.

176M12002

9. Pull the rotation lever (8) and feed lever (2) backward. 10. Move the drifter forward with the shank rod (9) turned normally and screw the shank rod (9) into the sleeve (10). Fully screw in the shank rod (9) of the drifter to the sleeve (10).

2

11. When the shank (9) rod has been completely screwed into 8

the sleeve (10), the rod (7) is normally turned and moved forward.

10

9

7 176M07005

12. When the rod (7) is screwed one or two turns into the auxiliary sleeve (5), move each lever to the neutral position.

13. Remove the nylon sling or other lifting tools from the rod

2

(7). 8

4-6-4


14. Pull the rod changer control lever (3) backward in order to move the front and rear carriers to the drilling center from their refuge position. When the rod changer control lever

3

(3) is returned to neutral, rotator roller catches the rod (7) and catches the sleeve (10) by the sleeve clamp.

Rod

17612022

Sleeve

17612023

15. Push the rotation lever (8) forward fully and push the feed lever (2) forward into the detent.

2 8

4-6-5


16. Move the drifter backward, while turning the shank rod (9) reversely. Separate the shank rod (9) and sleeve (10) from each other.

10

9 176M12003

17. Reset rotation lever (8) to the neutral position. Push the feed lever (2) forward fully in order to move the drifter fast backward. When the drifter stops at the rear end of the guide shell, return the feed lever (2) to neutral.

2

8

18. Push the rod changer control lever (11) forward. The rotator roller rotates reversely to move the entire rotator backward while rotating the rod to separate the rod (7) and the sleeve (5).

11

5

7 176M12004

4-6-6


19. Move the rod changer control lever (3) toward the right in order to load the rod (7) from the drilling center position into the carrier.

3

Rod

Drilling Center 17612024

20. Push the rod changer control lever (3) forward in order to move the front and rear carriers to the refuge position. Return the rod changer control lever (3) to neutral. 3

21. Repeat steps 5 – 20 to load the rods into the carrier.

4-6-7


4.6.2 Adding of Rod When the rod is added, open the centralizer for rotation-free impact and loosen the shank rod and sleeve.

1. Push the flushing lever (1) forward fully in order to stop flushing air.

1

2. Tilt the dust collector switch (2) forward in order to operate the dust collector.

2

3. Push the feed lever (3) forward fully. Move the drifter fast backward until the lower end of the sleeve reaches 30cm above the centralizer. Then stop the drifter.

About 3 0 cm

4-6-8


4. Pull the feed lever (3) backward into the detent in order to move the drifter forward slowly. When the centralizer can catch the lower end of the sleeve, then stop the drifter.

5. Tilt the hood & centralizer lever (4) toward the right in order to catch the sleeve by the centralizer. Return the hood & centralizer switch to neutral.

4

6. Pull the feed lever (3) backward into the detent in order to move the drifter forward slowly. When the sleeve touches the offset part of the centralizer, then stop the d rifter.

4-6-9


7. Push the feed lever forward (3) into the detent in order to move the drifter backward slowly.

3

8. If play of the shank rod appears, push the rotation lever (5) forward fully and push the feed lever (3) forward into the detent. The shank rod is reversely turned and separates the shank rod from the sleeve.

9. After the shank rod and sleeve have been separated from each other, move the feed lever (3) to the neutral position. Press the greasing switch (6) to apply grease to the thread section on the shank rod. 2

6

4-6-10


10. Move the rotation lever (5) to the neutral position.

5

11. Push the feed lever forward (3) fully in order to move the drifter fast backward. When the drifter speed is changed from fast backing to normal backing, return the feed lever (3) to neutral.

12. Pull the rod changer control lever (7) backward. The front and rear carriers move to the adding position. After operations of front and rear carriers are stopped, return

7

the rod changer control lever (7) to neutral.

13. Move the rod changer control lever (7) toward the left in order to send the rod to the drilling center. If the lever is moved a little right, centering is easy. 7

4-6-11


14. Pull the feed lever backward (3) into the detent in order to move the drifter forward slowly. Stop the drifter when the distance between the shank rod and upper sleeve reaches about 10 – 15cm.

About 1 0 -15 cm

15. Pull the rotation lever (5) and feed lever (3) backward. Move the drifter forward with the shank rod turned normally and screw the shank rod into the upper sleeve.

16. When the shank rod has been completely screwed into the upper sleeve, the rod is normally turned and moved

3 5

forward. When the rod is normally turned, press the grease switch (6) to apply grease to the thread section on the shank rod. Release your finger from the grease switch (6).

6

17. When the shank rod has been completely screwed into the upper sleeve, the rod is normally turned and moved forward. Then the rod is screwed into the lower sleeve. Move the levers to the neutral position after the rod has been screwed into the lower sleeve by 2 – 3 threads.

17612009

4-6-12


18. Push the rod changer control lever forward (7) in order to move the front and rear carries to the refuge position.

19. After operations of front and rear carriers are stopped, 7

return the rod changer control lever (7) to neutral.

Rod

17612026

Rod

17612027

20. Tilt the hood & centralizer lever (8) toward the left in order to open the centralizer. Re-star t drilling.

17612011

4-6-13


21. After the lower sleeve has passed the centralizer, tilt the hood & centralizer lever (8) toward the right in order to close the centralizer.

176M12006

4-6-14


4.6.3 Drawing of Rods

NOTICE If the screw for the lower sleeve and rod becomes excessively loose when separating the shank rod and sleeve from each other, the rod may slip down. If the screw has been loosened excessively, screw the rod into the lower sleeve.

1. After the end of all drilling, loosen each screw thread part by rotation-free impact.

2. Tilt the hood & centralizer lever (1) toward the left in order to open the centralizer .

1

3. Push the feed lever (2) forward fully. Move the drifter fast backward until the lower end of the sleeve reaches 30cm above the centralizer. Then stop the drifter.

About 3 0 cm

4-6-15


4. Pull the feed lever (2) backward into the detent in order to move the drifter forward slowly. Stop the drifter if the position that can catch the end of the sleeve by the centralizer is arrived at.

5. Tilt the hood & centralizer lever (1) toward the right in order to catch the lower end of the sleeve by centralizer.

1

6. Pull the feed lever (2) backward into the detent in order to move the drifter forward slowly. When the sleeve touches the offset part of the centralizer, then stop the d rifter.

4-6-16


7. Push the flushing lever (3) forward fully in order to stop flushing air. When the rod is withdrawn from the drilled hole, pull the flushing lever (3) backward in order to flush the air.

3

8. Pull the rod changer control lever (4) backward in order to move the front and rear carriers from the refuge position to the rod drawing position.

4

9. Release the rod changer control lever (4). The rotator roller catches the rod and catches the sleeve by the sleeve clamp.

Rod 17612028

10. Push the feed lever forward (2) into the detent in order to move the drifter backward slowly.

4-6-17


11. If play of the shank rod appears, push the rotation lever (5) forward fully and push the feed lever (2) forward into the detent. The sleeve clamp catches the sleeve for easy separation. The shank rod is reversely turned and separates the shank rod from the sleeve.

12. Loosen the screw according to the following procedure when you cannot separate the shank rod and the sleeve.

13. Push the rod changer lever (4) forward in order to move

4

the front and rear carries to the refuge position.

Rod

17612026

Rod

17612027

4-6-18


14. Pull the impact lever (6) backward fully under the condition where centralizer catches the lower sleeve and loosen the screw by rotation-free impact.

6

15. Repeat step 9 - 12 after the end of rotation-free impact.

16. After the shank rod and sleeve have been separated from each other, move the rotation lever (5) to the neutral position. Push the feed lever (2) forward fully in order to move the drifter fast backward. When the drifter speed is changed from fast backing to normal backing, return the feed lever (2) to neutral.

17. Push the rod changer control lever (7) forward in order to separate the rod from the lower sleeve. The rotator moves backward while reversely rotating the rod, and separates the rod.

18. If the rod cannot be separated from the lower sleeve, again screw the shank rod into the upper sleeve. Move the front and rear carries to the refuge position, and loosens the screw by rotation-free impact.

NOTICE

Before performing the rotation-free impact, move the front and rear carries to the refuge position. Otherwise, the rod changer will be damaged.

19. Repeat step 9 – 18 after the end of rotation-free impac t.

4-6-19

7


20. After the rod and sleeve have been separated from each other, press the grease switch (8). Apply grease to the thread section on the rod. Release your finger from the grease switch (8).

8

21. When the rod is separated from the sleeve, but the rod slips and does not lift up, separate the rod and the sleeve with the following procedure.

22. Move the rod changer control lever (7) toward the left in order to move the rotator forward.

7

23. Push the rod changer control lever (7) forward. The rotator moves backward while reversely rotating the rod, and lifts the rod.

7

4-6-20


24. Make sure that the lower end of the separated rod is higher than the rod slide guide. Rod Slide Guide

17412014

25. Move the rod changer control lever (4) toward the right in order to withdraw the rod from the drilling center position into the carriers. After operations of front and rear carriers are stopped, return the rod changer control lever to neutral.

4

Rod

Drilling Center 17612024

26. Push the rod changer lever forward (4) in order to move the front and rear carries to the refuge position.

4

4-6-21


27. Pull the feed lever backward (2). Stop the drifter when the distance between the shank rod and lower sleeve reaches about 10 – 15cm.

About 1 0-15 cm

28. Pull the rotation lever (5) and feed lever backward (2). Move the drifter forward with the shank rod turned normally and screw the shank rod into the lower sleeve.

29. Move the levers to the neutral position after the shank rod has been screwed into the lower sleeve by 2 – 3 threads.

30. Repeat step 3 – 29 to drawing the residual rods.

4-6-22

Auto Greaser

4.7 Auto Greaser The grease nozzle is a device that applies grease on the thread part of the shank rod and the rod. Auto greaser supplies grease through the grease nozzle (1) when the grease switch (2) is being pushed.

1

2

Adjustment of Application Quantity You can adjust the grease application quantity. Adjust the grease application quantity before starting the drilling work. The handle (1) of the needle valve on the grease pump adjusts the grease application quantity.

1

4-7-1

Auto Greaser

Grease Change

WARNING If grease gets into your eyes or on your skin, it might be dangerous. When the grease can (pail can) is to be replaced, wear the necessary protective gear such as protective glasses and protection gloves. If it gets into your eye, wash it with clean running water for more than 15 minutes and consult your doctor.

NOTICE If dust or soil attach to the grease pump or follower disk, such abnormality as malfunction of the grease pump might be caused. Particularly is careful not to attach dust, soil, or sand to them when replacing the grease can (pail can).

When grease has come to an end or when replacing grease according to the open-air temperature, remove the grease pump and replace the grease can (pail can). ★ The grease pump is accessible when opening the right side cover of the engine room.

Replacement Procedure The grease pump can be used by mounting it to a grease can (pail can) being available on the market.

1. Remove the air hose (2) and grease hose (3) from the grease pump (1). Loosen the three screws (4) and remove 2

the grease pump (1).

1 3

2. Remove the follower disk (6) from the grease can (5) and replace the grease can (5) by a new one.

6

3. Level the grease surface to prevent air from being introduced into a clearance between follower disk (6) and grease surface. Put and lightly press the follower disk (6).

4. Attach the grease pump (1) and tighten the screws (4).

4 5

Then attach the air hose (2) and grease hose (3). 17312034

4-7-2

Auto Greaser

Operation Check Check the grease pump normal operation to see if grease is coated normally after replacing the grease can (pail can). Press the grease lubrication switch. Check that grease nozzle is activated and grease is extruded. If the air motor in the grease pump does not operate, press the reset button (1) at the bottom of the motor.

1 17312035

Wash Grease Pump If grease is not extruded from the grease nozzle when operating the

air motor in the grease pump (1),

wash the grease inlet pipe (2). Wash the grease inlet pipe (2) with light oil or kerosene. After 1

washing, check there is no clogged, damage or distortions in the grease inlet pipe (2). If any abnormality is found, replace the grease pump (1).

2 17312036

4-7-3

5. Transporting When the machine is to be transported, use a trailer or truck dedicated to transporting construction machinery. Investigate travel route for road width and overpass. Check any bridges for

mass limits.

Obey local laws governing mass, width and length of a load. Observe all regulations governing wide loads.

5.1 Loading Machine on a Trailer

DANGER If the direction of the machine is changed on the ramps, it might fall. When the direction of the machine is unavoidably to be changed on the ramps, temporarily lower the machine to the ground, and change the direction.

WARNING A work supervisor is necessary for loading and unloading the machine. As the work is jointly performed, decide procedures in advance and follow the instructi ons of the instructor. Use a ramp of sufficient length, width, and strength and also with claws so that it doesn't come off the trailer bed. If something slippery such as dirt, oil, or snow is attached to the trailer bed or ramps, remove it before loading or unloading.

When loading the machine on a trailer or unloading it from the

trailer, set the oscillating lock lever (1)

at “OFF” position.

1

5-1-1

Loading and Unloading

Loading and unloading of the machine on and off the trailer is as follows:

1. Select a level and solid place and stop the trailer at the loading or unloading position.

Ramp

Chock the trailer wheels before you load the machine.

2. Place the end of the ramps securely on the trailer bed so that it doesn't come off, and set the slope angle to 15

°

or

15 or less °

less. Chock

3. Adjust the arrangement of the ramps to align the centerline

17316012

of the trailer with the centerline of machine.

4. Move the machine at low speed following the guiding personnel. Stop it just before the ramps and re-check the loading or unloading position.

5. Set the direction on the ramps and go up or down the machine at low speed.

Safety Transfer 1. After stopping the machine on the specified position on the trailer bed, let it take the transportation posture. 2. Tilt safety lock to fix travel levers not to be movable. 3. Set the engine throttle switch to the [I] position. 4. Stop the engine and pull out the starter switch key . 5. Close the windows and lock the door cover and engine covers and attach any vandalism protection. 6. Use chocks at the front and rear tracks to prevent movement. 7. Fix the machine to the trailer using wire ropes on the track shoes and through the attachment for towing, so that the machine cannot move during transport.

5-1-2

Towing

5.2 Towing

DANGER Incorrect towing of the machine that can’t move under its own power is very dangerous and might cause accidents resulting in injury or death. When the machine is to be towed, comply with the following precautions.

NOTICE For releasing of the parking brake, ask your nearest distributor.

Don't tow the machine except where it can't move under its own power, due to breakdown of the drive motor or malfunction of the hydraulic system. If it can’t move, release the parking brake before starting its towing. When the machine is towed, take care of the following: Tow the machine with it set to "traveling posture”. Movement of a towed machine should only be for checking or maintenance. Do not tow the machine more than 100m. If a longer distance is required, transport it on a vehicle such as a trailer. Tow the machine at 2km/h or less, otherwise the drive motor might seize. Use a tow wire rope of 1.5 times or more of the strength needed to tow a vehicle of the mass of the machine to be towed. Do not use a twisted or kinked wire rope. Do not use a chain to tow the machine because a link might break. The size of the tractor should be equivalent to or larger than the machine to be towed. Move and set the wire rope so that the coupling section of the tractor is aligned with the attachment to the machine. Before towing, make sure there is nobody between the tractor and th e machine. If the tractor moves suddenly the wire rope might break. Operate the tractor slowly and at a steady speed. Do not tow the machine on sloping ground because the machine might run away under its own mass.

5-2-1

Lifting Procedure

5.3 Lifting Procedure

WARNING When the machine is lifted, always set it to the “traveling posture”, otherwise, it might cause a drop of the machine due to imbalance.

CAUTION Take the greatest care not to let the lifting wire touch the machine.

★ For the traveling posture, refer to Item 4.4.1 “Traveling Posture”. ★ When the machine is to be lifted, remove the step, pre-cleaner, suction hose, lamps and mirrors.

Installing Eye Plates When the machine is to be lifted to load on ship, hook the lifting wire to the eye plates (1) installed front and rear of the track frame. Mount the eye plates (1) at the position shown in the label indicating the lifting position.

17316011

Tighten the eye plates (1) with the bolts (2) and spring washers (3), into the right and left track frames. 2

After lifting, remove the eye plates (1) and store them together

3

with the bolts (2) and spring washers (3) in the cab.

No.

Part Name

Part Number

Remarks 1

1

Eye Plate

040002-01039

2

Bolt

101032-20040

3

Spring Washer

145012-20000

17216004

M20×40-11T

5-3-1

Lifting Procedure

Balance Lifting 1. Set the guide shell horizontal to the machine body. 2. Place the bracket of the guide shell on the pedestal and set the machine to the traveling posture. 3. Install the eye plates on each of the right and left track frames and pass the wire rope through them.

4. Lift the machine, taking care not to touch the wire rope against the drill.

Lifting Posture

Bar or Spacer

Wire Length: 5000mm or less 3600mm or more

B

C

A

Model Item Mass

Standard Cab

ROPS/FOPS Cab

10450 kg

10490 kg

A: Overall Length

8465 mm

8465 mm

B: Overall Height

2830 mm

2830 mm

C: Overall Width

2400 mm/ 2500 mm ( ※)

2400 mm/ 2500 mm ( ※)

※) The folding step is installed

5-3-2

6. Electrical Equipment 6.1 Control Panel

WARNING Do not modify the inside of the control panel (1) or change the wiring; otherwise an accident might be caused due to the machine malfunction.

CAUTION There is precise electrical equipment in the control panel (1). Do not open/close it in a place where flammable gas is generated, or where there is dust or salt, or where water or oil has been splashed.

Electrical devices that control the machine are housed in the

control panel (1).

★ The control panel (1) is located in the engine compartment

on the left side of the machine.

1

6-1-1

Control Panel

Opening 1. Insert the key and turn counterclockwise to undo the lock. 2

2. When the push button (1) is pressed, the lower side of the lever (2) pops up.

3. Hold the lower side of the lever (2) the turn it at an angle of 90° counterclockwise to open the control panel cover .

1 17310022

Closing 1. Close the cover gently. Hold the lower side of the lever (1) and turn it to an angle

1

of 90° clockwise and press the lever until a "click" sound is heard.

17310022

2. Insert the key and turn it clockwise and lock the control panel cover (2) so as not to be opened.

2

6-1-2

Control Panel

6.1.1 Fuses

CAUTION When a fuse is replaced, pull out the starter switch key. Install fuse with correct amperage rating to prevent electrical system damage from overload. A higher capacity fuse could cause damage and even start a fire. Never use anything made of metal to pry out a fuse: it could cause a short circuit.

NOTICE If new fuse immediately blows out, there is a problem with electrical system . Contact your nearest distributor corrects it as soon as possible.

Fuses protect an e lectrical circuit current overload. If the electric equipment cannot be activated, check the fuses in the fuse box (1). If the fuse was blown out, locate and eliminate its cause, and replace the fuse with new one having the same capacity.

★ The fuse box (1) is located in the control panel.

1

6-1-3

Control Panel

Fuse Capacities and Circuit Name

5 1

5 1

0 3

5 1

5 1

5 1

5 1

Fuse No.

Fuse Capacities

F1

15A

Main Power, Engine Electric Control Module (Always ON), Starter Switch, Radio

F2

15A

Compressor Activation, Engine Diagnosis Monitor, Engine Throttle, Hydraulic Oil Temperature Gauge, Compressor Discharge Air Temperature Gauge, Emergency Stop Switch, Monitor Lamps

F3

30A

Front Floodlight, Rear Floodlight, Horn, Back Horn, Travel Detection Switch

F4

15A

Control Circuit, Air Flush, Dust Collector Pulse Jet

F5

15A

Air-Conditioner, Engine Electric Control Module (Starter Switch ON Signal)

F6

15A

Wiper, Wind Washer, Room Lamp, Radio

F7

15A

Circuit Name

(Spare)

6-1-4

Control Panel

6.1.2 Energy Saving Switch This switch saves the highest engine

speed during drilling.

It is possible to control the highest engine speed during drilling by changing the selector switch (1). The selector switch (1) is at

the backside of the control panel’s door .

In the normal mode, the highest engine speed is In the economy mode, it is controlled to 2000min

2200min -1

-1

.

.

1

6-1-5

Battery Servicing

6.2 Battery Servicing

DANGER Battery gas can explode. Do not smoke near battery, keep flame and sparks away. Battery electrolyte is a dilute sulfuric acid solution. If the electrolyte contacts skin, wash the electrolyte with soap and water. If the electrolyte contacts eyes, flood eyes with running water for 10 to 15 minutes. Get medical attention immediately.

WARNING A spark of static electricity might cause an explosion. Do not clean the battery with a dry cloth. Leakage of the electrolyte might cause inflammation or burn. Do not turn the battery over or let it suffer any impact.

Open the engine side cover on the left side of the machine. The batteries (1) are located in the battery box.

1

6-2-1

Battery Servicing

In Cold Weather If the temperature falls, the performance of the battery is degraded. If the charge rate is low the battery electrolyte might be frozen. Keep the charge rate always near to 100%. Replenish with distilled water before work (or before charging) to prevent freezing.

17310060

In Hot Weather If the temperature rises, water in the battery fluid tends

UPPER LEVEL

evaporate. If the battery electrolyte become low the plates might be damaged and the life of the battery might shortened. Before engine start, check the battery electrolyte level.

UPPER LEVEL LOWER LEVEL

LOWER LEVEL 26110071

Check Electrolyte Specific Gravity Measuring the specific gravity of battery electrolyte can indicate the charge rate. Check specific gravity of electrolyte in each battery cell with hydrometer. The relationship between the electrolyte specific gravity and the battery conditions are as follows:

Specific Gravity

Battery Condition

Over 1.300

Over 100% (Over charged)

1.290 – 1.270

100%

1.260 – 1.230

75%

Below 1.230

Below 50% (Insufficiently charged)

6-2-2

Battery Servicing

Gravity Conversion The

specified

electrolyte

temperature

for

the

gravity

measurement is 20°C. Measure the electrolyte temperature and do the conversion in accordance with the following formula when the temperature does not fall to the specified temperature. S = St + 0.007(t - 20) S: gravity at 20°C St: gravity measured t: electrolyte temperature

6-2-3

Battery Servicing

6.2.1 Replace Batteries

CAUTION When the battery clamps are removed, wear protective gear such as rubber gloves and safety glasses so as not to damage your eyes due to a spark. Disconnect the battery clamps connected to the negative (-) terminal. When installing, connect from the positive (+) terminal. If a clamp connection is loose, a spark might be generated due to loose connection. When the battery is fixed or the clamps are installed, fix or install securely. When the battery is to be changed or the battery clamps connected or disconnected, stop the engine and pull out the starter switch key.

Remove the battery clamps from the negative (-) terminal.

17310061

Install the battery clamps from the positive (+) terminal.

17310062

6-2-4

Battery Servicing

Precautions in Battery Change The battery is very heavy. When the battery is removed or installed, use a lifting machine such as a crane. The nylon sling to be used for lifting the battery should be adequate for the battery mass. When the battery is to be replaced, replace both batteries at the same time with the same type.

Using Battery Charger Do not use the battery charger as a booster if a battery has a 1.230 specific gravity reading or lower. Turn off the battery charger before connecting or disconnecting it. An explosive gas is produced while the batteries are in use or being charged. Keep flames or sparks away from the battery area. Charge the batteries in a well-ventilated area. Connect the batteries in the correct polarity (positive (+) to positive (+) and negative (-) to negative (-) ). Disconnect the battery ground wire before you charge the battery in the machine to prevent damage to electrical equipment. Do not charges a battery if the battery is frozen or the battery may explode.

Engine Start When the engine is to be started: Start-up takes no more than 10 seconds. If the engine does not start within that time, re-start more than 2 minutes later. If this is repeated 5 - 6 times and the engine still does not start, check the battery and engine electric circuit.

6-2-5

Battery Servicing

6.2.2 Using Booster Batteries

WARNING Battery gas can explode. When the battery clamps are connected, do not connect the positive (+) to the negative (-), otherwise a spark might explode the battery. When starting from another machine, never allow machines or booster cable clamps to touch each other. This prevents sparks near the battery, which could ignite hydrogen gas given off the battery, causing the battery to explode.

CAUTION Always turn the starter switch kept to OFF position before connecting booster batteries. When using booster batteries, be sure to wear glasses to protect your eyes from sparks. Connect the booster cables correctly. POSITIVE (+) to POSITIVE (+) and NEGATIVE (-) to NEGATIVE (-). To prevent sparking around the battery, connect clamp to rear frame as far from the battery as possible and remove paint. Do not attempt to jump-start the machine with frozen batteries. The battery could rupture and explode. If you suspect a frozen battery, remove vent caps and check the fluid. If there seems to be no fluid or if you see ice, do not attempt a jumper start until fluid thaws.

17310098

6-2-6

Battery Servicing

The machine to be started should be parked on the flat and solid place. Set the machine to travelling posture or guide shell to downward, and press the foot pad against the ground. Pull up the safety lever to set it to LOCK.

Connecting the Booster Batteries Connect the booster cable in following order.

1. Stop the engine of the machine on which booster batteries 4

is mounted.

To rear frame of the machine

2. Connect a one cable (A) to the positive terminal (1) of the

Troubled Batteries

battery. 1

3. Connect the opposite end of cable (A) to the positive terminal (2) of the booster battery .

B

A

4. Connect the other cable (B) to the negative terminal (3) of 3

the booster battery.

5. Connect the opposite end of cable (B) to the frame (4) of machine.

6. After connecting, check if the clamps are securely connected to the battery terminals before starting the engine.

7. Start the engine.

6-2-7

Booster Batteries

2

Battery Servicing

Disconnecting the Booster Batteries Remove the booster cables after starting the engine by completing same procedure as connection but in reverse order.

1. After engine starts, remove the cable (B) from the frame

1

(1) first.

To rear frame of the machine

2. Remove the opposite end of cable (B) from the negative

Troubled Batteries

terminal (2) of the booster cable. 4

3. Remove the cable (A) from the positive terminal (3) of the booster battery.

B

A

4. Remove the opposite end of cable (A) from the positive 2

terminal (4) of the battery.

Booster Batteries

6-2-8

3

7. Operation in Cold Weather In extremely cold weather conditions, special measures should be taken to

operate the machine.

Fuel Oil Use fuel oil appropriate to atmospheric temperature. Open the drain cock of fuel tank to drain out water periodically. Fill the fuel tank as much as possible.

Engine Oil Use oil viscosity meets for atmospheric temperature.

Battery The battery capacity will decrease as atmospheric temperature falls. Keep the battery fully charged at all times. If the battery is not to be used during cold weather, remove the battery and store it indoors. After distilled water has been added or, when specific gravity is very low, discharged the battery could freeze.

Coolant If the radiator cooling water does not contain the anti-freeze, fully drain out the cooling water in advance when storing the machine in cold weather. No draining is required if the anti-freeze is mixed.

Precautions for Operation As any ice or dirt on the piston rod of the hydraulic cylinder might damage the seal, wipe it out carefully. In extremely cold weather, the tracks may freeze to the ground and cannot move occasionally after operation. Do not place the machine directly on the ground, but place it on wood or concrete blocks.

7-1

8. Storage When storing the machine for more than 3 weeks, pay attention to following item.

Prepare the Machine for Storage Inspect the machine. Repair worn or damaged parts. Install the new parts, if necessary to avoid needless delays later. Clean the primary elements of the engine air cleaner a nd the compressor air cleaner. After washing each section of the machine, dry the machine completely. Paint necessary areas to prevent rust. Replace safety signs, where needed. Retract all hydraulic cylinders, if possible. If not, coat exposed cylinder rods with multi-purpose grease. Lubricate all grease points. Discharge the nitrogen gas sealed in the accumulator on the drifter. When the battery cut switch is installed, set the battery cut switch to OFF position. Set the machine to the traveling posture and store the machine indoors with g ood ventilation. If the machine must be stored outdoors, selects a flat place with good ventilation and water drainage, and covers the machine with a sheet.

Remove the Machine from Storage

CAUTION Whenever the engine is started indoors, open windows and doors for ventilation, otherwise the exhaust gas might poison you.

When the machine is used after a long period of storage, perform the following checks and maintenance before operation. Drain water and sediment from the fuel tank and receiver tank. Remove grease from cylinder rods if coated. Check all fluid levels. If low, check for leaks and add oil as required. Fill the fuel tank. Check the electrolyte level. Charge and install the batteries. Charge nitrogen gas in the accumulator on the drifter. Start the engine and run at low idle for 5 minutes. Cycle all hydraulic functions several times. Check condition of all hoses and Carefully check all systems before operating the machine with full load.

8-1

connections.

9. Troubleshooting Failure may occur due to combination of various causes, and if any failure occurs, the cause should be investigated for each item and remedial steps should be taken. If it seems that there are other troubles or causes than the following items, ask also your nearest distributor for check. For troubleshooting malfunctions of the drifter, refer to “Hydraulic Drifter Maintenance Manual” (separate volume).

NOTICE For detailed troubleshooting malfunctions of the engine, refer to Operation and Maintenance Manual of Caterpillar C7 Engine.

Engine Accessories Abnormal Phenomena

Main Cause

Remedy

Starter motor rotates, but the engine does not start

○

Fuel is short Air mixed in fuel system ○ Battery is not charged enough ○ Fuel filter cartridge is clogged ○ Air cleaner element is clogged

○

○

○

Starter motor does not turn

○

Battery is not charged enough Emergency stop system is activated ○ Starter or starter switch is faulty

○

○

○

○

Coolant is short Radiator fins are clogged ○ Fan belt is damaged ○ Dust and scale deposited in cooling system

○

○

○

Water temperature is too high

9-1

Replenish Bleed air ○ Charge ○ Replace ○ Clean or replace Charge Reset it ○ Repair or replace Replenish Clean ○ Replace ○ Clean

Troubleshooting

Hydraulic System

Abnormal Phenomena

Main Cause Improper hydraulic oil Return filter element is clogged ○ Oil cooler fins are clogged

Remedy

Hydraulic oil temperature is too high

○

○

○

○

Dose not travels

○

Traveling is difficult

○ ○

Excessive tension of track link Pilot filter element is clogged ○ Drive control box is faulty ○ Drive motor is faulty

○ ○

Track links get out of place

○

Track link tension decrease Front idler is worn ○ Track links is worn

○

○

○

Hydraulic oil is short Return filter element is clogged ○ Oil seal in cylinder is damaged ○ Control valve is faulty

Hydraulic oil is short

Replace Replace ○ Clean ○

Replenish

Adjust Replace ○ Repair or replace ○ Repair or replace Adjust Replace ○ Replace

Boom does not move Boom moves at low speed

○

○

○

○

Replenish Replace ○ Repair or replace ○ Repair or replace

Carriage operation is slow Carriage dose not move

○

Poor adjustment of feed pressure Feed chain is extended

○

○

○

Adjust Adjust

○

Feed motor is faulty

○

Repair or replace

9-2

Troubleshooting

Drilling

Abnormal Phenomena

Main Cause

Cuttings cannot be discharged easily

○

Dust collector’s fan does not rotate

○

Remedy

Bit is clogged Compressor is faulty

○

Hydraulic oil is short Dust collector element is clogged

○

○

○

Replenish Clean or replace

Poor suction

○ ○

Suction hose is clogged Fan motor is faulty

○ ○

Clean Repair or replace

Receiver tank pressure does not reach 1.05 MPa

○

Compressor switch is set to OFF Air cleaner element is clogged ○ Regulator does not function normally ○ Safety valve is faulty

○

○

○

Mixing of oil into air

○

Oil level in receiver tank is too high Oil separator element is clogged ○ Drawing orifice is clogged

○

○

○

○

Oil filter cartridge is clogged Oil cooler fins are clogged ○ Improper compressor oil

○

○

○

Delivery air temperature rises abnormally

○

9-3

○

Clean Repair or replace

Set it to ON Clean or replace ○ Readjust ○ Replace Reduce Replace ○ Clean Replace Clean ○ Replace

Troubleshooting

Rod Changer

Abnormal Phenomena

Main Cause Hydraulic oil is short Control valve is faulty ○ Oil seal in cylinder is damaged ○ Orbit motor is faulty

Remedy

Rod changer does not function Slow operation

○

○

○

○

Replenish Repair or replace ○ Repair or replace ○ Repair or replace

Rod drops when adding or drawing Rod cannot be held

○ ○

Rod center is not aligned Proximity switch does not function normally Sleeve clamp is worn out Ratchet is worn out Roller holding power decrease Rollers are worn out Oil seal in cylinder is damaged Clamp shaft is damage

○ ○

Orbit motor is faulty Gear box is faulty

○

Sliding section is damaged Slide cylinder is faulty

○

○

○

Repair or replace Replace

Auto grease dose not

○

Air cylinder is faulty

○

Replace

function

○

Grease pump is faulty

○

Repair or replace

○ ○ ○ ○ ○ ○

Roller rotation failure

○ ○

Rotator does not slide

○

9-4

○ ○ ○ ○ ○ ○

○

Adjust Adjust Replace Replace Adjust Replace Repair or replace Replace Replace Repair or replace

Maintenance Section

10. General Safety Instructions The longevity of any piece of construction equipment is greatly influenced by operating techniques and the quality of the routine care it receives. Routine checks and service are essential for preventing breakdowns, maintaining performance and keeping operation costs down. Also, fuel and lubricant consumption, as well as any problems which the operator may have noticed, is an important part any good maintenance program.

Service Your Machine at Specified Intervals Lubricate make service checks and adjustments at intervals shown on the periodic maintenance chart and on the following pages. Perform service on items at multiples of the srcinal requirement. For example, at 500 hours also service those items (if applicable) listed less than 250 hours, 100 hours, 50 hours, and daily. Use correct fuels and lubricants. Refer to 11. “Fuels and Lubricants” when performing maintenance on your machine. Use the Hour Meter to determine servicing intervals. Intervals on the periodic maintenance chart are for operating in normal conditions. If you operate your machine in hard conditions, you should service it at Short

Intervals.

Safety 1. Before beginning any maintenance work, be sure to get a good idea of the general condition of the machine. You are about to work on in order to a void any danger to yourself.

2. Set the safety lock lever to the LOCK position to fix the travel levers. Set the oscillating lock lever at OFF position. Set all operation levers and switches to neutral or off.

3. Never do any maintenance work while the machine is in operation or engine running. 4. Hang a “DO NOT OPERATE” or similar warning tag near operator’s seat to warn others not to start or operate the machine.

5. Before doing any work, set the guide shell horizontal and lower the guide shell on the ground to avoid accidents. Place a block to each track shoe.

6. When workings on the electrical system, first turn starter switch OFF and then take off battery cable from battery negative terminal as a safety precaution, and to avoid any possible damage to electrical components.

10-1

General Safety Instructions

Maintenance Records It is advisable to keep accurate records of all maintenance, including checks. Record the date, what was checked, or serviced. Any oil changes, amounts of fuel or lubricants added, and any problems which may have been noticed.

10-2

11. Fuels and Lubricants 11.1 Emergency Measures

WARNING Careless handling of fuels and lubricants might cause not only environmental destruction , but also accident resulting in injury or death. Take the greatest care in handling fuels and lubricants.

First Aid If fuel or lubricant accidentally splashed in your eyes, flush eyes with water for 15 minutes. Get medical attention immediately . If it gets on your skin, wash it with soap and water. If you inhale it, go out into fresh air and keep warm with your body wrapped in a blanket. Keep quiets and get medical attention immediately. If you drink it, do not force yourself to vomit. Get medical attention immediately . If inside of your mouth is contaminated, wash with large amount of water.

Treatment for Leakage If fuel or lubricant leaks, do not send it into the sewage system or river, so that secondary disaster or environmental pollution is not caused. Find the leakage point and stop leaking. Prepare such fire extinguishing equipment a s a fire extinguisher. Do not allow any burning cigarette, spark or naked flame close to the leaking point. Use protective gear with good conductivity in order n ot to generate static electricity . If required, wear a gas mask. If the leakage is small, dry it with soil, saw dust or a rag. If the leakage is large, contain the flow by surrounding it with soil. Cover the liquid's surface with bubble fire extinguishing liquid and retrieve it in an empty container. If leakage occurs indoors, ventilate the room by opening windows and doors.

Measures in Fire Wear protective gear for fire extinguishing, such as a gas mask and protective gloves and extinguish the fire from the windward. Stop everybody except for the fire fighters from coming near the fire. Fire extinguishing with bubble fire extinguishing liquid and intercepting air is effective. Do not use water because it might spread the fire. Sprinkle water around the srcin of a fire to cool the spot and prevent the spread of a fire.

11-1-1

Fuels and Lubricants

11.2 Fuel

NOTICE The diesel fuel quality greatly affects the performance and life of the engine. Use only clean, high quality fuel.

Fuel Specifications The following specific natures are required for the diesel fuel. Must be free from minute dust particles. Must have adequate viscosity. Must have high cetane value. Must have high fluidity at low temperature. Muse is less sulfur content. Must have little residual carbon. Caterpillar recommends the use of fuel meeting the Grade No.2-D requirements of the American Society for Testing and Materials (ASTM) D975, Standard Specifications for Diesel Fuel

Oils.

At operating temperatures below 0°C, use a blend of No.1-D and No.2-D fuels, also know as “winterized” No.2-D. ★ For a more detailed description of fuel properties, refer to Operation and Maintenance Manual of

Caterpillar C7 Engine.

Fuel Storage The engine fuel injection pump and nozzle are sensitive components. Any fuel with water or dust will cause them to break down. In handling fuel, comply with the following: Fill the fuel tank at the end of operation. Keep fuel in a clean fuel storage tank in a protected area. Drain water and sediment from the fuel storage tank weekly. Drain water and sediment before the tank is refilled. If possible, install a water separator at the fuel storage tank outlet. Keep the area around the fuel tank filler neck clean of debris in order to prevent contamination of the fuel tank. Drain water and sediment from the fuel tank daily. Do not use de-icers to remove water from fuel. Do not depend on fuel filters to remove water. Before the engine is started, drain any water and sediment accumulated at the bottom of the fuel tank.

11-2-1


11.3 Lubricants

NOTICE Do no mix lubricants of different brands with each other. Fully wipe off oil filler ports, grease nipples, hands, tools, etc. to prevent ingress of foreign substances during lubrication.

Engine Oil Pan The engine oil greatly affects the performance, starting ability and life of

the engine.

If unsuitable oil is used, or oil change is neglected, it may result in damage, and a shorter engine life. The Brand Name of Engine Oil Recommended Type Manufacturer キャタピラー Caterpillar

Engine Oil API Classification CI-4 or Higher Cat DEO 10W-30 Cat DEO 15W-40

昭和シェル石油 Showa Shell Sekiyu

リムラシグニア 10W-40 RIMULA Signia 10W-40

エクソンモービル Exxon Mobil

モービルデルバック1 5W40 Mobil Delvac 1 5W-40

Use the multi-grade diesel engine oil of the SAE 15W-40 as your engine oil. For further details and discussion of engine lubricating oils, refer to Operation and Maintenance Manual of Caterpillar C7 Diesel Engine.

Hydraulic Oil Selection and maintenance of hydraulic oil is important for fully exhibiting the machine performance and maintaining a high efficiency. Use industrial-type hydraulic oil ISO VG46. Contaminants such as metal powder and dust mixed with the hydraulic oil will cause rapid wear and malfunction of the hydraulic equipment. If the hydraulic oil contamination level exceeds NAS-11 class, change the hydraulic oil more frequently. The hydraulic oil recommends the use to NAS-11 class based on the NAS-1638 standards. NAS: National Aerospace Standard Committee

11-3-1


The Brand Name of Hydraulic Oil Recommended Type

Hydraulic Oil (Standard) ISO32

Manufacture r 昭和シェル石油 Showa Shell Sekiyu

ISO46

テラスオイル 32 Shell Tellus Oil 32

テラスオイル 46 Shell Tellus Oil 46

モービルDTE 24 Mobil DTE 24

モービルDTE 25 Mobil DTE 25

ヌトー H32

ヌトー H46

Nuto H32

Nuto H46

コスモ石油 COSMO OIL

コスモハイドロAW32 Cosmo Hydro AW32

コスモハイドロ AW46 (*) Cosmo Hydro A W46 (*)

ＪＸ日鉱日石エネルギー JX Nippon Oil & Energy

スーパーハイランド 32 スーパーハイランド 46 SUPER HYRANDO 32 SUPER HYRANDO 46


Type

Hydraulic Oil (High Viscosity Index) ISO32

Manufacture r

ISO46

昭和シェル石油 Showa Shell Sekiyu

テラスオイル T32 Shell Tellus Oil T32

テラスオイル T46 Shell Tellus Oil T46


モービルDTE 10 Excel 32 モービルDTE 10 Excel 46 Mobil DTE 10 Excel 32 Mobil DTE 10 Excel 46

コスモ石油 COSMO OIL

コスモハイドロHV32 Cosmo Hydro HV32


32 46 ハイランドワイドハイランドワイド SUPER HYRANDO 32 SUPER HYRANDO 46

コスモハイドロHV46 Cosmo Hydro HV46

The machine shipped from the factory is filled with lubricants marked with (*).

Compresso r Oil Recommended compressor oil for Hokuetsu Industry (AIR MAN)

is as follows.

The Brand Name of Compressor Oil Recommended Type

Compressor Oil ISO32

Manufacturer 昭和シェル石油 Showa Shell Sekiyu

RS32 コレナCorena オイルOil Shell RS32


モービルレーラス 424 Mobil Rarus 424


フェアコールRA32 FAIRCOL RA32

北越工業(AIRMAN) オールシーズン(*) HOKUETSU INDUSTRIES All Seasons (*)

The machine shipped from the factory is filled with lubricants marked with (*).

11-3-2


For further details of compressor oil, please contact the Hokuetsu Industry (AIR MAN) service network.

Gear Oil Since gear oil is used under severe conditions, proper oil must be selected. It must satisfy the following characteristics. Proper viscosity. High viscosity to tooth surfaces without being scattered by the centrifugal force. Fluid without any solidification or exfoliation at a low temperature. Excellent resistance to extreme pressure. Bubble-free. Excellent oxidation stability. Excellent water separation.

Grease NLGI No. 2 Grade is suitable for most temperatures. Use NLGI No. 1 Grade for extremely low temperatures.

Multipurpose Grease Continue lubricating until old grease comes out when lubricating pins

and bearings with grease.

Heat-resistant Extreme-pressure Grease This grease is applicable to screw threads of rods, sleeves, bits, and shank rods. Use molybdenum disulfide or graphite-filled heat-resistant extreme-pressure grease.

11-3-3

Oil Supply Pump

11.4 Oil Supply Pump

CAUTION Supply the hydraulic oil after stopping the engine and making sure that the hydraulic tank has cooled down to normal temperature. When the stop valve handle (3) is set to OPEN the hydraulic oil might flow back. After oiling, always set the handle (3) to CLOSE. The hydraulic oil is flammable. Wipe off spilled oil carefully .

By using the oil supply pump, h ydraulic oil can be supplied, contaminating hydraulic oil.

1. Open the engine cover that is located on the left right side of the machine.

2. Loosen the adapter (1) and remove the suction hose (2). Wipe any dirt from off the suction hose (2) with a rag. 2

3. Put the suction hose (2) into drum can filled with hydraulic oil.

1

4. Open the stop valve handle (3). 5. Turn the oil supply pump handle (4) clockwise and supply the hydraulic oil. Open

3 4

Close

17505009

6. Maintain the hydraulic oil level between the upper and lower marks in the level gauge (5).

7. Close the stop valve handle (3). 5

8. Carefully wipe any hydraulic oil from the suction hose (2) and screw the suction hose (2) into the adapter (1).


11-4-1

12. Coolant Many engine failures are related to th e cooling system. Maintenance of the engine coolant is important to the engine life and to the performance.

Water Use soft water with low impurity content as the coolant. Do no use hard tap water or salt softened tap water in engine cooling systems. Distilled water or deionized water is recommended for use in engine cooling

system

Antifreeze

WARNING Antifreeze is poisonous; if ingested, it can cause serious injury or death. Induce vomiting and get emergency medical attention immediately. If antifreeze accidentally splashed in your eyes, flush eyes with water for 15 minutes. Get medical attention immediately. If it gets on your skin, wash it with water. When storing antifreeze, be sure to keep it in a clearly marked container with tight closing lid. Always keep antifreeze out of the reach of children.

Antifreeze must be used in any climate for both freeze and boiling point protection. Furukawa recommends a 1:1 mixture of water/ethylene glycol base antifreeze. The mixture ratio of water/antifreeze when the factory is

shipped is 1:1.

★ For more detailed description of coolant, refer to Operation and Maintenance Manual of


12-1

13. Refill Capacities

Compartment or System

For Temperature Range (°C)

Category and Classification

Quantity

Diesel Fuel Oil （*1）

330 L

-10

0

10

20

30

No.2-D

Fuel Tank

No.2-D

SAE 10W-30

Engine Oil Pan

Diesel Engine Oil （*2）

25 L SAE 15W-40

Hydraulic Tank

Hydraulic Oil

170 L

ISO VG46

Receiver Tank

Screw Compressor Oil （*3）

14 L

ISO VG32

Feed Motor

Gear Oil API: GL-4

1.1 L

SAE 90

Drive Motor

Gear Oil API: GL-4

1.7 L (Each)

SAE 90

Front Idler

Gear Oil API: GL-4

0.15 L (Each)

SAE 80W90

Carrier Roller

Diesel Engine Oil API: CD

0.075 L

SAE 30

Track Roller

Diesel Engine Oil API: CD

0.11 L

SAE 30

*1）At operating temperatures below 0°C, use a blend of No.1-D and No.2-D fuels. *2）For the engine oil, refer to 11.3 “Lubricants”. *3）For the compressor oil, refer to 11.3 “Lubricants”.

13-1

40

Refill Capacities

Compartment or System

Fittings

Category and Classification

For Temperature Range (°C)

Quantity -10

0

10

20

30

Universal Grease NLGI No.2

－ NLGI No.1

Rod, Shank Rod and Sleeve, etc.

Molybdenum Grease

Cooling System

Soft Water and Antifreeze （*4）

18 L

*4）For the coolant, refer to 12 “Coolant.

13-2

Antifreeze

40

14. Maintenance Interval Schedule For inspection and maintenance, move the machine to a place, which is clean, and without dust, as in a service shop. For inspection and maintenance of the drifter, refer to “Drifter Maintenance Manual” (separate volume). ★ For details on the engine not described here, refer to Operation and Maintenance Manual of


When Required In non-periodic maintenance, the interval of inspection and maintenance varies with the work and conditions. Inspect and Adjust Track Shoes Tension ････････････････････････････････････････････････ 14-1-1 Test Air Conditioner ･･････････････････････････････････････････････････････････････････ 14-1-3 Check Window Washer ･･･････････････････････････････････････････････････････････････ 14-1-4 Inspect Wipers ･･････････････････････････････････････････････････････････････････････ 14-1-4 Clean Lubricator

････････････････････････････････････････････････････････････････････ 14-1-5

Check Carriage and Hose Reel

･･･････････････････････････････････････････････････････ 14-1-6

Replace Chain ･･････････････････････････････････････････････････････････････････････ 14-1-7 Bleed Fuel System

･･････････････････････････････････････････････････････････････････ 14-1-9

Periodic Maintenance The engine hour meter indicates periodic maintenance. Early inspection and maintenance according to the work and conditions prevent breakdown and irregularity.

Periodic Maintenance / 50 Hours or Weekly Clean Dust Collector Elements ････････････････････････････････････････････････････････ 14-3-1 Lubricate Center Shaft

･･･････････････････････････････････････････････････････････････ 14-3-2

Lubricate Oscillating Cylinder

･････････････････････････････････････････････････････････ 14-3-2

Lubricate Hose Reel ･････････････････････････････････････････････････････････････････ 14-3-3 ･･･････････････････････････････････････････････････････････････････

Lubricate Carriage 14-3-4 Lubricate Boom Pedestal ･････････････････････････････････････････････････････････････ 14-3-4 Lubricate Boom ･････････････････････････････････････････････････････････････････････ 14-3-5 Lubricate Guide Mounting

････････････････････････････････････････････････････････････ 14-3-6

Periodic Maintenance / 250 Hours or 3 Months Change Engine Oil and Oil Filter Cartridge ･･････････････････････････････････････････････ 14-4-1 Clean Air Cleaner Primary Element Replace Return Filter Element

････････････････････････････････････････････････････ 14-4-4

････････････････････････････････････････････････････････ 14-4-7

14-1

Maintenance Interval Schedule

Clean Radiator/Air Cooler Fins Clean Oil Cooler Fins

････････････････････････････････････････････････････････ 14-4-8

････････････････････････････････････････････････････････････････ 14-4-9

Clean Cab Air Filters ････････････････････････････････････････････････････････････････ 14-3-10 Clean Air Conditioner Condenser ･････････････････････････････････････････････････････ 14-3-12 Clean Drawing Orifice ･･･････････････････････････････････････････････････････････････ 14-4-13

Periodic Maintenance / 500 Hours or 6 Months Replace Dust Collector Elements ･･････････････････････････････････････････････････････ 14-5-1 Replace Air Cleaner Elements

････････････････････････････････････････････････････････ 14-5-2

Replace Primary Fuel Filter ･･･････････････････････････････････････････････････････････ 14-5-4 Replace Secondary Fuel Filter

････････････････････････････････････････････････････････ 14-5-6

Clean Fuel Tank Strainer ･････････････････････････････････････････････････････････････ 14-5-8 Clean Air Breather ･･･････････････････････････････････････････････････････････････････ 14-5-9 Check Drive Motor Oil Level

･････････････････････････････････････････････････････････ 14-5-10

Replace Pilot Filter Element

･････････････････････････････････････････････････････････ 14-5-11

Change Compressor Oil ･････････････････････････････････････････････････････････････ 14-5-12

Periodic Maintenance / 1000 Hours or 1 Year ･･････････････････････････････････････････････････････････････ 14-6-1

Change Drive Motor Oil Change Hydraulic Oil

････････････････････････････････････････････････････････････････ 14-6-2 ･･････････････････････････････････････････････････････････････ 14-6-5

Change Feed Motor Oil

Replace Dust Collector Diaphragm Valve Diaphragm ･････････････････････････････････････ 14-6-6 Replace Automatic Relief Valve Diaphragm ･････････････････････････････････････････････ 14-6-6 Replace Regulator Diaphragm ････････････････････････････････････････････････････････ 14-6-7 Replace Oil Separator ････････････････････････････････････････････････････････････････ 14-6-7

Periodic Maintenance / 2000 Hours or 2 Year Change Coolant and Clean System ････････････････････････････････････････････････････ 14-7-1 Change Front Idler Oil

･･･････････････････････････････････････････････････････････････ 14-7-3

Check Carrier Roller Oil ･･････････････････････････････････････････････････････････････ 14-7-4 Check Track Roller Oil ･･･････････････････････････････････････････････････････････････ 14-7-4 Replace Unloader O-Ring

････････････････････････････････････････････････････････････ 14-7-5

14-2

When Required

14.1 When Required Inspect and Adjust Track Shoes Tension

WARNING If the lubricate valve (2) is loosened carelessly, high-pressure grease bursts out. Do not loosen lubricate valve (2) more than three turns. If the track shoes tension cannot be adjusted, ask your nearest distributor for adjustment.

The wear conditions of the pins and bushes of the carriage vary with the work conditions and soil quality. Inspect and adjust the track shoes tension under the present working conditions and maintain the standard tension.

Inspection Move the machine 10m forward and stop the machine. Place a straight bar on the center between the carrier roller and idler and if the distance between the bar and shoe plate is 10 - 15mm, it is standard. If the track shoes are too tense or too slack, adjust.

Adjustment 1. Remove the lubricate valve cover (1).

1

14-1-1

When Required

2. Clean the grease nipple (2) and supply grease through grease nipple (2). The idler is moved forward to tighten the track shoes.

2

3. If the track shoes tension decreases loosen the lubricate valve (3) 1 - 2 turns and discharge grease. ★ If grease is not discharged normally, travel the

machine forward and backward about 2 - 3 m.

3 176S201001

4. Tighten the lubricate valve (3). 5. Install the lubricate valve cover (1).

14-1-2

When Required

Test Air Conditioner

DANGER The refrigerant (gas) is tasteless and odorless, and is harmless in the open air. However, if the liquid gets in your eyes or on your skin, you might be blinded or frostbitten. Do not loosen any part in the refrigerant (gas).

CAUTION When the refrigerant (gas) needs to be replenished, ask your nearest distributor for check.

Check the refrigerant (gas) quantity twice every year. The refrigerant (gas) uses R134a.


2

2. Start the engine and activate the air conditioning with the engine idling.

3. Monitor the flow of the refrigerant (gas) through the sight glass (2) of the receiver (1) after 5 – 10 minutes.

1

Supply the refrigerant (gas) if necessary. ★ The amount of the gas of the refrigerant is 1200g.


Refrigerant Quantity

Appropriate

Condition in the Site Glass

17316005

There is little bubble in the flow. As the engine speed is increased, bubbles disappear gradually and it becomes transparent.

Bubbles pass consistently.

Deficient

17316006

Something like a slightly flowing mist can be seen.

Almost nothing

17316007

14-1-3

When Required

Check Window Washer Check the window washer level in the washer tank. The washer tank is on the rear of the cab. Remove the cap of the washer tank and add the window washer, if necessary. In cold weather use all season washer fluid that will not freeze.

1

Inspect Wipers Inspect the condition of the wiper blades. Replace the wiper blades if the wiper blades are worn or damaged. If the wiper blades streak the windshield, replace the wiper blades.

14-1-4

When Required

Clean Lubricator

WARNING Hydraulic oil is flammable. Wipe off any spilled hydraulic oil carefully .

If the bowl (1) of the lubricator is filled with sediment, remove and clean the bowl

1. Loosen the plug (2) slightly and release the inside pressure of t he lubricator. 2

2. Disconnect the oil hose from bottom of the bowl (1). Turn the bowl (1) clockwise and remove the bowl (1) from the body. Drain the oil and sediment in the bowl (1) into a suitable container. 1

3. Clean the bowl (1) with clean hydraulic oil. ★ When the bowl (1) is removed, do not touch the float or

valve in the bowl (1).

4. Install the clean bowl (1) to the body. Connect the oil hose.

5. Remove the plug (2) and pour clean hydraulic oil to about 2/3 level of the bowl (1). Install the plug (2).

14-1-5

(1).

When Required

Check Carriage and Hose Reel

CAUTION If the clearance does not meet the specified value, ask your nearest distributor for adjustment.

Check if the clearance between the carriage (1) and the slide base (2) meets the specified value.

1

2 17407005

Adjust the clearance between the carriage (1) and the slide 30 mm

base (2) so that the distance from the rear end of the carriage (1) to the front end of slide base (2) is 30mm when the slide base has been relocated backward to the rear end of the guide shell.

1

2 17407006

14-1-6

When Required

Replace Chain

CAUTION If the chain adjuster cannot adjust the chain tension any more, ask your nearest distributor for replacement.

★ For chain tension adjustment, refer to 4.2.3 “After Starting the Engine”.

Check Sprocket Wheel When the feed chain is replaced, inspect the sprocket wheel (1) for excessive wear or damage. Replace the sprocket wheel (1) with new one, if defective. ★ The sprocket wheel (1) is located on the front of the guide

1

shell. If the shaft (2) inserted in the sprocket wheel (1) loose, replace

2

the bush (3) and the oil seal (4).

4 4

1 3 17307003

14-1-7

When Required

Insert Lock Washer When the feed chain and the reel chain are replaced, inspect the chain joint bush and chain adjuster bush for wear or damage. Replace the chain joint with new one, if defective. When the chain joint (1) is mounted on the carriage, install the lock washer (2) and tighten the lock washer (2) with the bolts. 2

★ Bend the lock washer (2) to fix the bolts.

1

When the chain joint (3) is mounted on the guide shell, install the lock washer (4) under the guide shell and tighten the lock washer (4) with the bolts. ★ Bend the lock washer (4) to fix the bolts.

3 4

4

14-1-8

When Required

Bleed Fuel System

WARNING Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. Clean up all leaked or spilled fuel. Do not smoke while working on the fuel system.

NOTICE Do not keep turning the starter for more than 30 seconds. If the engine starting fails, re-start after an interval of more than 2 minutes.

Prime the fuel system in order to fill the fuel filter. Prime the fuel system in order to purge


2. Turn the priming pump plunger (1) counterclockwise.

3. Push down on the top of the fuel priming pump plunger (1) and release the fuel priming pump plunger (1) in order to operate the fuel priming pump.

1

4. The fuel system is primed when resistance is felt in the system.

5. Push the priming pump plunger (1) and turn the priming pump plunger (1) clockwise to lock.

6. Promptly start the engine. If the engine runs rough, continue to operate the engine at low idle. Continue to run the engine at low idle until the engine runs smoothly.

7. If the engine does not start, pull up the fuel priming plunger (1) and repeat steps 2-6 in order to start the engine.

8. If all other required work is completed, close the engine cover.

14-1-9

trapped air.

First Maintenance

14.2 First Maintenance The first maintenance on a new machine should be sooner than the specified interval. After that, the maintenance work must be given periodically as specified. ★

For details on the engine not described here, refer to Operation and Maintenance Manual of Caterpillar C7 Engine.

After Only First 250 Hours Change Compressor Oil ･････････････････････････････････････････････････････････････ 14-5-12 Change Compressor Oil Filter Cartridge ･･･････････････････････････････････････････････ 14-5-12 Change Feed Motor Oil

･････････････････････････････････････････････････････････････ 14-6-5

After Only First 500 Hours Change Drive Motor Oil

･･････････････････････････････････････････････････････････････ 14-6-1

14-2-1

Periodic Maintenance / 50 Hours

14.3 Periodic Maintenance / 50 Hours Clean Dust Collector Elements

WARNING Reduce compressed air to less than 0.2 MPa when using for cleaning purpose. Wear safety glasses at avoid injury to eyes.

If the dust collector elements are clogged, sludge intake during drilling is reduced and might cause hole clogging. Clean the elements periodically.

1. Open the dust collector cover (1).

1

2. Remove the element (2) from the collector body. Remove all four elements.

3. Blow dry compressed air against the inside of the element and along the pleats so as not to damage the element. Then blow the dry compressed air against the outside of

2

the element and along the pleats and then, again against the inside. 17511002

4. Blow dry compressed air against the inside of the dust collector body. Install the cleaned elements.

5. Close the dust collector cover (1).

14-3-1


Greasing When greasing, ground the guide shell and stop the engine. Tilt the safety lock to fix the travel levers. If grease is contaminated with dust or sand, it causes early wear of rotary parts. Wipe off extruded old grease after grease lubrication.

Center Shaft (1) Center shaft (2 points)

1

Oscillating Cylinder (1) Oscillating cylinder plate pin, track fram e (2 points)

2

(2) Oscillating cylinder plate pin, main frame (2 point s)

2

14-3-2


Hose Reel (1) Hose reel roller ( 10 points)

1

(2) Roller shaft (2 points)

2

(3) Cam follower (6 points) (4) Roller Bracket (2 points) (5) Sprocket shaft (1 point)

4

3 3

3

5

3

3 3

4

14-3-3

17416024


Carriage (1) Wear plate, front (2 poin ts)

1

(2) Wear plate, rear (2 poin ts)

2

Boom Pedestal (1) Boom swing cylinder plate pi n, head (1 point) (2) Boom lift cylinder plate pin, bottom (1 point)

1

2

(3) Boom swing cylinder pla te pin, bottom (1 point) 3

14-3-4


(4) Boom pedestal (1 point)

4

Boom (1) Boom plate pin (1 point)

1

(2) Boom lift cylinder plate pin, head (1 point) (3) Tilt body plate pin (1 point) (4) Tilt link plate pin (1 point)

4

2

3

(5) Tilt arm pin (1 point)

5

14-3-5


(6) Guide tilt cylinder pla te pin, bottom (1 point)

6

(7) Tilt link arm pin (2 points)

8

(8) Guide tilt cylinder bush (1 point) 7

7

(9) Guide mounting plate pin (1 poin t)

10

(10) Guide swing cylinder plate pin, head (1 point)

9

Guide Mounting (1) Guide swing cylinder plate pin, bottom (1 point)

1

14-3-6


14.4 Periodic Maintenance / 250 Hours Perform the 50 hours maintenance at the same time.

Change Engine Oil and Oil Filter Cartridge

WARNING Hot oil and components can cause injury. Do not allow hot oil or components to contact skin. Drain the oil only when engine is stopped and the oil is cool. The maintenance fluids must be draining into containers. Spilled oil must be cleaned up as it may cause fire.


When engine oil is changed, run the engine at a little higher speed than when idling, until the engine coolant temperature rises to about 60°C. When the engine oil is warmed, stop the engine.

1. Place a suitable container under the drain plug (1) on the left side of the main frame. Remove the drain plug (1) and drain the oil. ★ Capacity is approximately 30 liters.

NOTICE When checking the drained oil, if a large amount of metal powder or foreign matter is included, contact your nearest distributor.

2. Clean the drain plug (1) and inspect the O-ring of the drain plug (1). Replace the O-ring if damaged or wear is evident. Install the drain plug (1).

3. Open the rear cover

14-4-1

1


4. Clean the mounting section of the filter head and the filter cartridge (2).

5. Place a suitable container under the filter cartridge (2). Remove the filter cartridge (2) with a strap type wrench and discard the filter cartridge (2).

2

6. Clean the mounting surface of the filter head. Make sure that all of the old seal is removed from the filter

176S203008

head.

7. Apply clean engine oil to new filter cartridge gasket.

NOTICE Do not fill the filter cartridge with oil before installing the filter cartridge. This oil would not be filtered and could be contaminate d. Contaminated oil can cause accelerated wear to engine components.

8. Install the new filter cartridge as specified by the filter cartridge manufacturer.

9. Remove the engine cover (3) that is located on the top of the machine. 3

10. Remove the oil filler cap (4) and fill the engine oil to the 4

specified level. Oil capacity: 25 liters

11. Clean the oil filler cap (4) and install the oil filler cap (4). 12. Install the engine cover (3). 176S203009

14-4-2


13. Open the engine cover that is located on the left side of the machine. Check the oil level. Maintain the oil level between the “ADD” and “FULL” marks in the oil level gauge (5). ★ For engine oil level check, refer to 4.1 “Daily

Inspection”. 5

14. Set the engine throttle switch to the [I] position. Start the engine and run the engine for two minutes. Inspect the engine oil filter cartridge for leaks.

15. Check the oil level 10 minutes after stopping the engine. If necessary, remove the oil filler cap (6) to add oil. 6


14-4-3


Clean Air Cleaner Primary Element

CAUTION Never service the air cleaner when engine is running, to avoid engine damage.

NOTICE If the air cleaner monitor lamp is ON even when the cleaned element is attached, replace the element by new one. Replace the primary element by a new one after four cleanings or at 500 hours, together with replacement of the secondary element. Do not remove the secondary element except to replace.

When the air cleaner element become dirty, the suction airflow decreases to cause an engine output drop a starting failure, or other troubles. If compressor air cleaner element becomes dirty, the flushing air becomes weak; cuttings cannot be discharged normally to easily result in blowhole clogging and other troubles. ★ If the air cleaner warning light is ON, check and clean the air cleaner earlier than specified

intervals.


2. Push the evacuator valve (1) to remove garbage and dust

3

from the evacuator valve (1).

3. Loosen the clamps (2) that hold the cover (3) on the air 1

cleaner housing.

2

Remove the cover (3) from the air cleaner housing.

176S203010

4. Remove the primary element (4) from the air cleaner housing. Inspect the primary element (4). Replace a damaged primary element with a clean primary element.

5. If the primary element (4) is not damaged, clean the primary element (4). ★ For cleaning the primary element (4), refer to “Inspect

4

and Clean Element”. 176S203011

6. Clean the inside of the air cleaner housing with a clean cloth.

14-4-4


7. Clean inside the cover (3) with a clean cloth. 8. Check whether the secondary element (5) is fixed. Push the secondary element (5) when loosening.

9. Install a new or cleaned primary element.

5 176S203012

10. Install the cover (1) on the air cleaner housing and fasten the clamps (2).

11. Close the engine cover. 12. Clean the compressor air cleaner (6) according to the same procedure as 2 - 10. ★ The compressor air cleaner (6) is accessible when

opening the rear cover. 6

14-4-5


Inspect and Clean Element

CAUTION When using compressed air, wear necessary protective gear such as safety glasses and adjust the compressed air pressure to 0.2 MPa or less.

NOTICE Do not clean the element by bumping or tapping.

Blow dry compressed air against the inside of the element and along the pleats so as not to damage the element. Then blow the dry compressed air against the outside of the element and along the pleats and then, again against the inside.

17303003

Inspect the element after you clean the element. Shine a light from inside the element to inspect the filter. Do not use a element if the pleats, the gaskets or the seals are damaged.

17303004

14-4-6


Replace Return Filter Element

WARNING Hot oil and components can cause injury. Do not allow hot oil or components to contact skin.

If the hydraulic oil filter warning light is ON, replace the return filter element earlier than specified intervals. ★ The return filter element is located on the right side of the machine.

1. Clean the mounting section of the filter head and the filter element (1).

2. Place a suitable container under the filter element (1). Remove the filter element (1) with a strap type wrench and discard the filter element (1). 1

3. Clean the mounting surface of the filter head. Make sure that all of the old seal is removed from the filter head.

4. Apply a light film of clean hydraulic oil to the sealing surface of the new filter element.

5. Install the new filter element by hand. When the filter element sealing surface contacts the filter head, tighten the filter element for an additional 2/3 turn. Tightening torque: 27.5 N·m

6. Start the engine at low idle. Operate the hydraulic cylinder control levers and move the working equipment slowly. Circulate the hydraulic oil and bleed the air in the circuit.

7. Return the working equipment to the traveling posture and stop the engine.

8. Inspect the hydraulic system for leaks. 9. Check the oil level in the level gauge (2) on the front of the hydraulic tank. If the oil is low, add oil

14-4-7

2


Clean Radiator/Air Cooler Fins

CAUTION Reduce compressed air to less than 0.2 MPa when using for cleaning purpose. Wear safety glasses at avoid injury to eyes.

When the radiator fins and air cooler fins are clogged by dust or soil, airflow is disturbed which might cause overheating of the engine. ★ Clean the radiator fins and air cooler fins at earlier intervals if they are stuffed.

1. Remove the radiator cover (1) that is located on the left side of the machine.

1

2. Remove the dust and other debris from the fins using compressed air. ★ When the fins are cleaned using steam or water, dry

them completely.

3. When the cleaning of fins is completed, check for damaged hoses and loose or damaged hose clamps. If any, replace.

4. Install the radiator cover (1).

14-4-8


Clean Oil Cooler Fins


When the oil cooler fins are clogged by dust or soil, airflow is disturbed which might cause overheating of the engine or compressor, as well as malfunction of the hydraulic equipment. ★ Clean the oil cooler fins at earlier intervals if they are stuffed.

1. Remove the oil cooler cover (1) that is located on the rear of the machine.

1


them completely.


4. Install the oil cooler cover (1).

14-4-9


Clean Cab Air Filters


1. Remove the air filter (1) in the left side of the operator's seat.

1

2. Clean the air filter (1) with pressure air or wash the air filter (1) in warm water and a Neutral detergent.

3. Rinse in clean water and air dry thoroughly. 4. Install the air filter (1) 1

5. Release lock with the lock key, and pull down the filter cover (2) on the left side of the cab.

2

14-4-10


6. Remove the filter element (3). Clean the filter element (3) with pressure air. If the filter element (3) is damaged, replace by new ones.

7. Install the filter element (3). 3 2

17316002

8. Insert the key into the lock and lock it so that the filter cover (2) cannot open.

14-4-11


Clean Air Conditioner Condenser


If the air conditioner condenser (1) is clogged, ventilation is disturbed and cooling is reduced.

1

1. Remove the oil cooler cover (2) that is located on the rear of the machine.


them completely. 2


4. Install the oil cooler cover (2).

14-4-12


Clean Drawing Orifice If the drawing orifice is clogged, a lot of oil is included in the flushing air.


2. Disconnect the hose (1). 2

3. Remove the orifice (2) and remove the gasket (3). 1

Remove the check valve (4).

4. Remove the strainer (5) from orifice (2). Wash the strainer (5) with clean non -flammable solvent. Inspect the strainer (5) for damage. Replace the strainer (5), if necessary.

2

5. Inspect the gasket (3) for damage. Replace the gasket (3), 3

if necessary.

5

6. Install the check valve (4).

4

7. Lubricate the gasket (3) with clean compressor oil. Install the gasket (3) and strainer (5) in the orifice (2).

8. Install the orifice (2). 9. Connect the hose (1). 10. Close the engine cover.

14-4-13

17504005


14.5 Periodic Maintenance / 500 Hours Perform the 50 hours and 250 hours maintenance at the same time.

Replace Dust Collector Elements


1. Open the dust collector cover (1).

1

2. Remove the wing nut (2) and remove the element (3) from the collector body. Remove all four elements. Discard the elements. 3

3. Blow dry compressed air against the inside of the dust collector body to clean the collector body.

4. Install new elements and tighten the wing nut (2).

2 17511003

5. Close the dust collector cover (1).

14-5-1


Replace Air Cleaner Elements

WARNING Reduce compressed air to less than 0.2 MPa when using for cleaning purpose. Wear safety glasses at avoid injury to eyes.

CAUTION Never service the air cleaner when engine is running, to avoid engine damage.


2. Push the evacuator valve (1) to remove garbage and dust

3

from the evacuator valve (1).

3. Loosen the clamps (2) that hold the cover (3) on the air 1

cleaner housing.

2

Remove the cover (3) from the air cleaner housing.

176S203010

4. Remove the primary element (4) from the air cleaner housing and discard the primary element (4).

4

176S203011

5. Remove the secondary element (5) from the air cleaner housing and discard the secondary element (5).

6. Clean the inside of the air cleaner housing with a clean cloth.

7. Clean inside the cover (3) with a clean cloth. 5

8. Install a new secondary element.

176S203012

Install a new primary element.

14-5-2


9. Install the cover (3) on the air cleaner housing and fasten the clamps (2).

10. Close the engine cover. 11. Clean the compressor air cleaner (6) according to the same procedure as 2 - 9. ★ The compressor air cleaner (6) is accessible when

opening the rear cover. 6

14-5-3


Replace Primary Fuel Filter

WARNING Personal injury or death can result from a fire. Do not smoke while working on the fuel system. Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. Clean up all leaked or spilled fuel.

1. Open the rear cover. 2. Turn the fuel cock (1) clockwise to close the fuel cock (1). 3. Clean the mounting section of the fuel filter base and the fuel filter (2).

1

4. Place a suitable container under the fuel filter (2). Remove the fuel filter (2).

2 176S203014

5. Clean the mounting surface of the fuel filter base. Make sure that all of the old seal is removed from the filter head.

6. Remove the fuel filter bowl (3) from the fuel filter (2). Discard the fuel filter (2).

2

7. Wash the fuel filter bowl (3) with clean fuel. Wash the O-ring (4) removed the fuel filter bowl (3) with clean fuel.

4

Inspect the O-ring (4) for damage. Replace the O-ring (4) if it is necessary.

3

8. Apply clean diesel fuel to the clean O-ring and install the O-ring to the clean fuel filter bowl.

9. Install the clean fuel filter bowl on the new fuel filter by hand.

10. Apply clean diesel fuel to new filter gasket. Fill the new filter cartridge with clean fuel.

11. Install the new fuel filter by hand. Spin the new filter as specified by the filter cartridge manufacturer .

14-5-4

17303071


12. Turn the fuel cock (1) counterclockwise to open the fuel cock (1).

1

176S203015

13. Start the engine and check for leaks. Run the engine for one minute. Stop the engine and check the engine for leaks again.


14-5-5


Replace Secondary Fuel Filter

WARNING Personal injury or death can result from a fire. Do not smoke while working on the fuel system. Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. Clean up all leaked or spilled fuel.

1. Open the rear cover. 2. Turn the fuel cock (1) clockwise to close the fuel cock (1).

1

176S203014


4. Clean the mounting section of the fuel filter base and the fuel filter (2).

5. Place a suitable container under the fuel filter (2). Remove the fuel filter (2) with a strap type wrench and discard the fuel filter (2).

6. Clean the mounting surface of the fuel filter base. Make sure that all of the old seal is removed from the filter base.

7. Apply clean diesel fuel to new secondary fuel filter gasket.

NOTICE Do not fill the fuel filter with fuel before installing the fuel filter. The fuel would not be filtered and could be contaminated. Contaminated fuel will cause accelerated wear to fuel system parts.

14-5-6

2


8. Install the new fuel filter by hand. Spin the fuel filter onto the fuel filter base until gasket contacts the base. Tighten the fuel filter for an additional 1 turn by hand. This will tighten the fuel filter sufficiently.

9. Turn the fuel cock (1) counterclockwise to open the fuel cock (1).

1

176S203015

10. Bleed the air from the fuel system. ★ For the air bleeding from the fuel system, refer to

14.1 “When Required”.

11. Start the engine and check for leaks. 12. Close the engine cover. 13. Close the rear cover.

14-5-7


Clean Fuel Tank Strainer

WARNING Personal injury or death can result from a fire. Clean up all leaked or spilled fuel.

The strainer (2) prevents dust or soil from entering the fuel tank. Supply fuel with the strainer (2) attached.

1. Remove the fuel cap (1). 2. Remove the strainer (2) and wash the strainer (2) with clean light oil.

3. Inspect the strainer (2) for damage. Replace the strainer (2) if it is necessary.

4. Install the strainer (2) to the oil filler port. 5. Tighten the fuel cap (1) securely.

14-5-8

2

1


Clean Air Breather The air breather located on top of the hydraulic tank.

1. Loosen the wing nut and remove the cover (1) from the air breather housing (3).

2. Remove the element (2) and wash the element (2) with 1

clean non-flammable solvent.

3. Inspect the element (2) for damage. Replace the element (2) if it is necessary.

4. Clean inside the air breather housing (3) with a clean cloth.

5. Install a new or cleaned element.

1

6. Install the cover (1) on the air breather housing (3) and 2

tighten the wing nut finger tight. Do not use a tool. 3

17305008

14-5-9


Check Drive Motor Oil Level


1. Move the machine so that the drain plug (1) on the drive 2

motor comes lowest point.

2. Remove the level plug (2) and check the oil level. It is a

3

proper quantity if there is oil up to the vicinity of the edge under the plug hole.

3. If the oil is low, remove the oil filler plug (3). Fill the oil until the oil begins to overflow from the oil level plug (2). ★ For the oil, refer to 11. “Fuels and Lubricants”.

4. Clean the oil level plug (2) and install the oil level plug (2). 5. Clean the oil filler plug (3) and install the oil filler plug (3). 6. Using above steps 1 - 5, check the oil levels of the drive motors on the right and left.

7. Start the engine. Operate the machine on level ground for a few minutes and recheck the oil level.

8. The oil must be visible in oil filler plug (3) opening. Add oil, if necessary.

14-5-10

1


Replace Pilot Filter Element

WARNING Hot oil and components can cause injury. Do no allow hot oil or components to contact skin. The maintenance fluids must be draining into containers. Removed oil must be cleaned up as it may cause fire.


2. Clean the case (1) and mount body (2). Place a suitable container under the case (2).

2

3. Place a spanner on the projection on the bottom of the case (1) and remove the case (1).

1

Remove the element (3) and discard the element (3).

4. Wash the case (1) with clean non-flammable solvent. 2

5. Remove the O-ring (4) and back-up ring (5) from the

4

mount body (2). Discard the used O-ring (4) and back-up ring (5). Clean inside the mount body (2). 3

5

6. After cleaning, apply hydraulic oil lightly on the new O-ring and back-up ring and install them to the mount body (2).

7. Install the new element into the case (3) and tighten the case into the mount body (2).

1

17305009


14-5-11


Change Compressor Oil



★ When the compressor oil is changed, replace the compressor filter cartridge (2) at the same time.

1. Place a suitable container under the drain cock (1). Open the drain cock (1) and drain the compressor oil. ★ Capacity is approximately 15 liters.

2. Close the drain cock (1). 1

3. Open the rear cover. 4. Clean the mounting section of the filter head and the filter cartridge (2). Place a suitable container under the filter cartridge (2).

5. Remove the filter cartridge (2) with a strap type wrench and discard the filter cartridge (2).

6. Clean the mounting surface of the filter head. Make sure that all of the old seal is removed from the filter head.

7. Apply a light film of clean compressor oil to the sealing surface of the new filter cartridge.

14-5-12

2


8. Install the new filter cartridge by hand. When the gasket contacts the filter head, tighten the filter cartridge for an additional 1/2 turn. This will tighten the filter cartridge sufficiently.

9. Remove the filler cap (3) and fill the compressor oil to the specified level. Maintain the compressor oil should be within the STOP mark of the level gauge (4). Install the filler cap (3). ★ For the compressor oil, refer to 11. “Fuels and

Lubricants”. 3 4

10. Start the engine to activate the compressor. Inspect the receiver tank for leaks.

11. Check the oil level at level gauge (4). The oil level should be within the STOP mark of the level gauge (4). If the oil level is low, stop the engine and wait for 10 – 20 minutes. Remove the filler cap (3) and add oil.

12. Close the rear cover.

14-5-13


14.6 Periodic Maintenance / 1000 Hours Perform the 50 hours, 250 hours and 500 hour ’s maintenance at the same time.

Change Drive Motor Oil


1. Move the machine so that the drain plug (1) on the drive

2

motor comes lowest point.

2. Place a suitable container under the drain plug (1).

3

Remove the oil level plug (2) and remove the oil filler plug (3). Remove the drain plug (1) and drain oil. ★ Capacity is approximately 2 liters.

1

3. Clean the drain plug (1) and install the drain plug (1). 4. Fill the oil until oil begins to overflow from the oil level plug (2). ★ For the oil, refer to 11. “Fuels and Lubricants”.

5. Clean the oil level plug (2) and install the oil level plug (2). 6. Clean the oil filler plug (3) and install the oil filler plug (3). 7. Using above steps 1 - 6, change the oil of the drive motors on the right and left.

8. Start the engine. Operate the machine on level ground for a few minutes and inspect the drive motors for leaks.

14-6-1


Change Hydraulic Oil



Hydraulic units are constructed precisely . Dirty hydraulic oil may cause an unexpected trouble. Particularly be careful with oil control.

1. Operate the machine in order to warm the hydraulic oil 2. Park the machine on level ground. Set the machine to traveling posture. Pull up the safety lock lever to set it to LOCK and stop the engine.

3. Hydraulic tank is located on the front of the machine. Place a suitable container under the drain cock (1) on the front of the hydraulic tank. Open the drain cock (1) and drain the oil. ★ Capacity is approximately 170 liters.

1

176S205011

4. Remove the cover (2). 5. Remove the seal rubber from the top surface of the hydraulic tank. Discard the seal rubber.

14-6-2

2


6. Remove the holder (3) and remove the honeycomb core (4) from the tank.

7. Wash the honey comb core (4) with non-combustible

3

4

solvent. Inspect the honeycomb core (4) and replace it new one, if damaged.

8. Inspect that there is no foreign matter in the tank and wash the tank with non-flammable solvent.

9. Install the honey comb core (4). Install the holder (5).

17505004

10. Install the new seal rubber. Install the cover (2) and tighten bolts evenly.

2

Seal Rubber

17505003

11. Close the drain cock (1) 12. Fill the hydraulic tank to the specified level. Check the oil level in the level gauge (5). Maintain the hydraulic oil level between the upper and lower marks in the level gauge (5). If the oil is low, add oil by using the oil supply pump. ★ For supply the hydraulic oil, refer to Item 11.4 “Oil

Supply Pump”. ★ For

the hydraulic oil, refer to 11. “Fuels and

Lubricants”.

13. Bleed the air from the pump. For air bleeding, refer to the next item “Bleed Pump”.

14-6-3

5


Bleed Pump If the engine is started while there is air in the pump and there is no hydraulic oil, it might damage th e pump. When the hydraulic oil is to be changed, bleed the air at the same time.

1. Remove the engine cover (1) that is located on the top of the machine. 1

2. Wipe the surface of the pump and the plugs. 3. Remove the plug from the upper part of the P2 pump (2)

2

and remove the plug from the bottom of the P1 pump (3).

4. When the air is bled from the plugs and a small amount of oil flows out, the air bleeding is completed.

3

Clean the plugs and tighten them.

176S203019

5. Start the engine. Operate the hydraulic cylinder control levers to move the working equipment slowly. Circulate the hydraulic oil and bleed the air in the circuit.

6. Return the working equipment to traveling posture and stop the engine. Inspect the hydraulic system for leaks.

7. Check the oil level in the level gauge. Add hydraulic oil if it is necessary.

8. Install the engine cover (1).

14-6-4


Change Feed Motor Oil


1. Operate the hydraulic cylinder control levers to set the guide shell parallel to the ground.

2. Place a suitable container under the drain plug (1). Remove the oil filler plug (2). Remove the drain plug (1) and drain the oil. ★ Capacity is approximately 1 liter.

1

3. Clean the drain plug (1) and install the drain plug (1). 4. Fill the oil until oil begins to overflow from the oil filler plug (2). ★ For gear oil, refer to 11. “Fuels and Lubricants”.

5. Clean the oil filler plug (2) and install the oil filler plug (2).

6. Start the engine. Move the feed lever forward and backward several times to repeat the drifter's forward and backward movements and inspect that there is no oil leakage on the feel motor.

14-6-5

2


Replace Dust Collector Diaphragm Valve Diaphragm

NOTICE For the replacement of the diaphragm valve diaphragm, ask your nearest distributor.

★ Replace the diaphragms of four diaphragm valves installed

in the dust collector (1).

1

Replace Automatic Relief Valve Diaphragm

WARNING When the compressor is stopped, the air in the receiver tank is released at the automatic relief valve (1). When the diaphragm is replaced, wait for 5 minutes or more after the compressor is stopped and check that the air in the receiver tank is released completely.


2. Remove four bolts and the cover from the valve body. Remove the diaphragm and discard the diaphragm.

3. Clean the diaphragm attachment surface of the valve body. Install a new diaphragm and secure the cover (1) with four bolts. Tightening torque: 12 N·m


14-6-6

1


Replace Regulator Diaphragm

CAUTION When the diaphragm is to be replaced, the setting of the regulator (1) needs to be adjusted. For replacement of the diaphragm, ask your nearest distributor

When the diaphragm is replaced, remove the pressure regulator (1) from the regulator bracket and disassemble the pressure regulator (1) ★ The pressure regulator (1) that is located inside the left

side engine cover.

1

Replace Oil Separator

NOTICE For the replacement of the oil separator element, ask your nearest distributor.

The oil separator in the receiver tank (1) separates hydraulic oil fro m the compressed air discharged from the compressor, which discharges compressed air only. If the oil separator is clogged, there will be a lot of oil is in the

discharged air.

Replace an oil separator element periodically.

1

14-6-7


14.7 Periodic Maintenance / 2000 Hours Perform the 50 hours, 250 hours, 500 hours and 1000 hou r’s maintenance at the same time.

Change Coolant and Clean System

WARNING Hot coolant and steam can cause burns. To open radiator cap (1), stop engine, wait until radiator is cool. Remove the radiator cap (1) slowly to relieve the pressure.

NOTICE If well water or river water is used, deposit and rust are generated quickly. Use soft water of low impurity or tap water as the coolant. Change the coolant after 1000 hours or 1 year, whichever is earlier.

If deposit or rust is generated in the cooling system, the cooling effect is lowered and it might overheat. When the coolant is changed, clean inside the cooling system.

1. Put a cloth over the radiator cap (1) and slowly loosen the radiator cap (1) in order to relieve pressure.

1 176S203004

2. Open the engine cover that is located on the right side of the machine. Remove the under cover.

3. Place a suitable container to receive the drained coolant under the drain cock (2). The drain cock (2) is located on a lower side of the grease pump. 2

4. Turn the drain cock (2) counterclockwise to open the drain cock (2). Capacity is approximately 20 liters.

14-7-1


5. Close the drain cock (2). 6. Flush the cooling system with any available cleaning solvent. For the flushing procedure, comply with the instructions of the cleaning solvent manufacturer.

7. Start the engine. Keeping the engine coolant temperature at 80°C, operate the engine for 30 minutes and then stop the engine. Open the drain cock (2) and drain the cleaning solvent. Close the drain cock (2).

8. Fill the soft water into the radiator until the water reaches just under the hole.

9. Start the engine with the radiator cap opened. Keeping the engine coolant temperature at 80°C, operate the engine for 10 minutes and then stop the engine.

10. Drain the water by opening the drain cock (2). Flush system with soft water until draining water becomes

176S203018

clean.

11. Close the drain cock (2). Fill the coolant slowly until the water reaches just under the hole. For the coolant, refer to 12. “Coolant”.

12. Open the cap of the reservoir tank (3) and fill the coolant up to the “FULL” position.

13. Bleed the air from inside the cooling system. Start the engine with the radiator cap (1) removed and let it idle for 5 minutes, keeping the engine coolant temperature at about 80°C.

14. Stop the engine and wait until each part of the engine is cooled down to the normal temperature. Recheck the coolant level and add coolant as necessary.

15. Install the radiator cap (1). 16. Install the under cover. 17. Close the engine cover.

14-7-2

3


Change Front Idler Oil

CAUTION Spilled oil must be cleaned up as it may cause fire.

1. Place a suitable container under the plug (1). Remove the plug (1) and drain oil. Capacity is approximately 0.1 liter.

2. Move the machine so that the plug (1) on the front idler comes upper end. 1

3. Fill the oil until oil begins to overflow from the plug hole. Oil capacity: 0.06 liters. For the oil, refer to 11. “Fuels and Lubricants”.

4. Clean the plug (1) and install the plug after winding a seal tape.

5. Using above steps 1 - 4, change the oil of the front idler. 6. Start the engine. Operate the machine on level ground for a few minutes and inspect that there is no oil leakage on the plug.

14-7-3


Check Carrier Roller Oil

NOTICE If oil quantity of carrier rollers is not enough, contact your nearest distributor.

★ Check oil of right and left carrier rollers.

If oil oozes from the thread the hollow plug slowly when loosening the hollow plug slowly, no oil supply is necessary. Tighten the follow plug at once. If oil does not come out even after removing the hollow plug, repair or replace the carrier rollers.

Check Track Roller Oil

NOTICE If oil quantity of track rollers is not enough, contact your nearest distributor.

★ Check oil of right and left track rollers.

If oil oozes from the thread the hollow plug slowly when loosening the hollow plug slowly, no oil supply is necessary. Tighten the follow plug at once. If oil does not come out even after removing the hollow plug, repair or replace the track rollers.

14-7-4


Replace Unloader O-Ring

NOTICE For the replacement of the O-ring, ask your nearest distributor.

Replace the O-ring of unloader (1) installed on th e compressor.

1

14-7-5

15. Periodic Replacement of Maintenance Parts WARNING Replace the maintenance parts with new ones periodically every 2 years after purchase or every 4000 hours, whichever is earlier. Ask your nearest distributor to replace the maintenance parts.

To ensure safety in operation and work, the user of machine must carry out the periodical maintenance. To use the machine safely, be sure to replace the maintenance parts which may cause a fire periodically. The maintenance parts can be easily deteriorated or worn because their material is changed in quality with a passage of time. It is difficult to judge their damage degree in the periodical repair/inspection. After the maintenance parts have been used for a regular period, replace them with new ones even if you do not find any damage on them. If you find any trouble about the maintenance parts before the regular replacement period has passed, replace them with new ones at once. When you find any deformation, damage or crack on the clips, hose clamps or pipe clamps concerned with the hoses; replace the hoses together with the damaged parts at the same time. When you replace the hose equipped with seals such as O-ring or gasket, replace them together.

Fuel Tank

№

Maintenance Parts

Engine

Route

Fuel Hose

Fuel Tank → Injection pump

Fuel Hose

Engine → Fuel Tank

15-1

1

2

Hydraulic Crawler Drill

HCR910-DS Operation Manual & Maintenance Manual

Printed Matter No.: HCR910-DS-F101 Date of Issue: Feb. 2011

Address: 5-3, 1-CHOME, NIHONBASHI, CHUO-KU, TOKYO 103-0027, JAPAN Phone: +81-3-3231-6982 Fax: +81-3-3231-6994

Furukawa HCR 910

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