Case WX210 Excavator Electrical System Service Manual

WX210 WX240 HYDRAULIC EXCAVATOR Service manual

Print No. 9-91270 English

THIS ALERT SYMBOL SIGNALS IMPORTANT MESSAGES INVOLVING YOUR SAFETY.

Read and heed carefully the safety instructions listed and follow the precautions recommended to avoid potential risks and to safeguard your health and your safety.

You will find this symbol in the text of this Manual referred to the following key words:

WARNING - Cautions directed to avoid improper repair interventions involving potential consequences for the safety of the personnel performing the repairs.

DANGER - These warnings qualify specifically potential dangers for the safety of the operator or other persons directly or indirectly involved.

IMPORTANT NOTICE

All maintenance and repair interventions explained in this Manual must be performed exclusively by the Service Organisation of the Manufacturer, observing strictly the instructions explained using, whenever necessary, the recommended specific tools. Whoever performs the operations reported without following exactly the precautions is responsible on his own, for the damages that may result.

Neither the Factory nor any Organisations in its Distribution Network, including but not limited to national, regional or local distributors, are responsible for any liability arising from any damage resulting from defects caused by parts and/or components not approved by the Factory for use in maintaining and/or repairing products manufactured or merchandised by the Factory.

In any case, no warranty of any kind is made or shall be imposed with respect to products manufactured or merchandised by the Factory, when failures are caused by the use of parts and/or components not approved by the Factory.

Case WX210 WX240 Excavator Electrical System Service Manual

PLEASE CLICK HERE

Then back to the site.

At the bottom of the page,

Then get more free information

Power coupling

Transmission

Four-Wheel Drive (4WD) system

Front axle system

Rear axle system

Power Take-Off (PTO)

Case WX210 WX240 Excavator Electrical System Service

Manual

Brakes and controls

Hydraulic systems

Pneumatic system

Hitches, drawbars, and implement couplings

Steering

Wheels

Cab climate control

Electrical systems

Platform, cab, bodywork, and decals

Electrical Schematic

Hydraulic Schematic

AVOID ACCIDENTS

Most accidents, whether they occur in industry, on the farm, at home or on the road, are caused by the failure of some individuals to follow simple and fundamental safety rules and precautions. For this reason MOST ACCIDENTS CAN BE PREVENTED by recognising the real cause and doing something about it before the accident occurs. Regardless of the care used in the design and construction of any type of equipment, there are many conditions that cannot be completely safeguarded against without interfering in the reasonable accessibility and efficient operation. A careful operator is the best insurance against an accident. The complete observance of one simple rule would prevent many serious accidents. The rule is simple: never attempt to clean, lubricate or maintain a machine while it is in motion.

WARNING

Prior to engaging in any maintenance, adjustment or repair operation on machines having hydraulically, mechanically, and/or cable controlled equipment (such as shovels, loaders, dozers, excavators etc.) be certain the equipment is lowered to the ground.

If it is necessary to have the equipment partially or fully raised to gain access to certain items, be sure the equipment is suitably supported by means other than the devices used for controlling the equipment.

Service manual

Section 0 Safety Instructions

WX210 - WX240

REPRODUCTION OF THESE OPERATING INSTRUCTIONS IN WHOLE OR IN PART IS STRICTLY PROHIBITED EXCEPT WITH THE WRITTEN CONSENT OF THE PUBLISHER

The data contained in this handbook were valid at the time of publication. As we constantly endeavour to improve our products and to provide additional options, modifications or changes made in this context may have an impact on the procedures described in this handbook. Please contact your local dealer if you find any discrepancies.

This page left blank intentionally

PREFACE

To the reader

The Technical Manual (TM) has been written for the repair specialist. It provides important information on carrying out repair work expertly.

Please go carefully through the Technical Manual as well as the Owner’s Manual for the hydraulic excavator before starting any repair work. Use the Technical Manual as well as the Ow ner’s Manual and spare-parts list as a reference book and source of information even if you are familiar with hydraulic excavator technology.

Using the Technical Manual, the experienced construction machine mechanic can carry out any necessary repairs expertly.

Handling

The Technical Manual is divided into eight sections and covers the originally delivered version of the machine. Any additions or modifications undertaken at a later date are not described in this manual.

- Introduction

- Safety Instructions

- Technical Data and Special Tools

- Description of Functioning

- Performance Testing

- Troubleshooting

- Repair Instructions

- Annex

The Safety Instructions section describes the recommended procedures to be observed in order to prevent any risk of accidents to the operator and to the personnel responsible for the works and for machine servicing measures.

The Description of Functioning section provides technical information on operating the main devices and systems.

The Technical Data and Special Tools section lists service data, conversion tables and special tools and servicing materials required.

The Performance Testing section gives the information required for carrying out performance testing.

The Troubleshooting section contains information on detecting faults in the machine.

The Repair Instructions section gives the technical information needed to carry out servicing and repair work on the machine, describes the equipment needed for servicing works, and provides

information on maintenance standards, removal and installation procedures, and dismantling and assembly procedures

The required information can easily be found by referring to the table of contents.

For reasons of clarity, some of the illustrations are presented in simplified form. Differences from the actual version at the hydraulic excavator are therefore possible if this adds to the clarity of the information.

Repair

Carry out any necessary repair work as soon as possible. This reduces repair costs and increases the availability of your hydraulic excavator.

When doing any work on the hydraulic excavator, always observe the instructions given in the Technical Manual and in the Owner’s Manual.

Extensive works not described in the Technical Manual will gladly be executed for you by the O&K after-sales service.

Always use original spare parts only.

Further information material

Please consult the following documents in addition to this Manual:

- Owner’s Manual

- Spare-parts catalogue

Warnings and symbols

The following signs are used in the Technical Manual to designate exceptionally important information:

Precautionary rules and measures designed to protect the operator and other persons from lifethreatening hazards or injury and to prevent extensive damage to property.

Risks resulting from failure to observe the safety instructions

This hydraulic excavator has been built in accordance w ith state-ofthe-art standards and recognized safety regulations.

Nevertheless, its use may constitute a risk if it continues to be operated despite damage being suspected or having occurred, or if it is inexpertly repaired.

There is then a risk of

Information and precautionary measures designed to prevent damage to the machine and other property

- life-threatening injury

- irreparable damage to the machine and other assets.

The hydraulic excavator must be stopped immediately if suspected damage or damage that has occurred affects the safety of the operator, other persons at the excavator deployment site, or other assets. All components are carefully coordinated. Trouble-free operation and a long service life are assured only if original spare parts are used.

SAFETY INSTRUCTIONS

Personal safety instructions

Observe the safety instructions

- Read carefully through all safety instructions attached to the machine and observe them; read all safety instructions in this manual in addition.

- Safety instruction stickers/plates must be affixed, maintained and replaced when necessary

- If a safety instruction sticker/plate or this manual is damaged or missing, obtain a replacement from your dealer. The procedure is the same as w hen ordering spare parts (it is essential to quote the machine type and the serial number).

- Familiarize yourself w ith the correct, safety-oriented procedure for operating the machine and its control elements.

- Allow only trained, qualified and authorized persons to operate the machine.

- Keep the machine in good w orking order.

- Unauthorized modifications to the machine may affect its efficiency and/or safety and reduce its service life.

- The instructions given in this Safety Instructions section are designed to show the fundamental safety procedures for the machine. However, they cannot cover all hazardous situations w ith w hich you may be confronted. If in doubt, consult your immediate superior before operating the machine or carrying out servicing w ork.

Protection from noise

40000004-en

Sustained effects of noise may lead to impaired hearing or deafness. Wear appropriate ear protectors such as earplugs or muffs for protection from disturbing or intolerable noise.

Preparing for emergencies

Be prepared for the event of a fire breaking out or an accident occurring.

Keep the first-aid box and the fire extinguisher readily accessible at all times.

Read the instructions for operating the fire extinguisher and learn how to use it properly.

Stipulate emergency procedures for the event of fire or accidents.

Keep the emergency numbers of doctors, emergency services, hospitals and the fire service in the immediate vicinity of the phone.

Wearing protective clothing

Wear close-fitting clothing and protective equipment suited to the work.

You need:

- a safety helmet

- safety footwear

- goggles or face guard

- protective gloves

- ear protectors

- reflective clothing

- waterproof clothing

- respirator or filtering mask. Ensure that you w ear the right equipment and clothing for the job.

- Never take risks.

- Never w ear loosely fitting clothing, jewellery or other objects that might get caught on operating levers or other machine components.

Safe operation demands the operator’s complete attention. Never wear headphones to listen to the radio or to music while operating the machine.

Safety instructions before starting work

Checking the machine

Before starting up the machine each day or before each shift, give the outside of the machine a careful visual inspection to prevent damage and injury.

- Check the machine for superficial damage.

- Check before starting work that all covers and caps are closed and locked.

Keeping the working area clean

Clean

- Remove any objects that might endanger the mechanics or persons in the working area.

- Keep your cab clean and cleared; loose items may disturb the machine operation.

Fig. 1

Fig. 2

Using grab handles and steps

Falls are one of the main causes of injury.

- Alw ays face the machine when entering or leaving it, and use only the aids provided, e.g. steps and handrails.

- Never use operating elements as grab handles.

- Never jump dow n from the machine.

- Never climb up onto or dow n from a moving machine.

- Watch for slippery platforms, steps and handles w hen leaving the machine.

Adjusting the operator’s seat

A seat that is poorly adjusted w ith respect to the operator or the w orking conditions may result in premature operator fatigue and thus in faulty operation.

- The seat must be adjusted w ith any change of machine operator.

- The operator must be able to depress the pedals completely and move the control levers effortlessly w ith his back resting against the backrest.

If that is not possible, move the seat forw ard or back and check the setting again.

Consult the relevant section in the Ow ner’s Manual.

Fig. 3

Fig. 4

Applying the safety belt

If the machine overturns, the operator may be injured and/or throw n out of the cab. He may be severely injured or even crushed to death by the overturning machine.

- Before operating the machine, check the belt fabric, the closure and the fastening components carefully. If one of the parts is damaged or worn, replace the safety belt or the components before starting up the machine.

- Alw ays remain seated and keep the safety belt fastened while operating the machine. This w ill help minimize the risk of injury in the event of an accident.

The safety belt must be replaced after any serious accident even if it appears to be undamaged.

Working from the operator’s seat only

Starting up the engine incorrectly may cause the machine to make unexpected movements that might lead to severe, even fatal, injury.

- Alw ays start up the engine from the operator’s seat only.

- Never start the engine by shortcircuiting the starter.

- After starting up the engine, check that all driving levers, driving pedals and control levers are in neutral position.

Never take passengers on the machine

Passengers on the machine may suffer injury e.g. from foreign bodies or through being thrown off.

- Only the operator is allowed onto the machine. Never take passengers.

- Passengers also obstruct the operator’s view so that the machine is no longer safely operated.

Fig. 5

Fig. 6

Safety instructions for machine operation

Before setting off

Remove any soil, mud, snow , ice, grease and oil from your w orking footwear before operating the machine. You might otherw ise slip from steps and pedals and thus initiate inadvertent movements.

Adjust the driver’s seat and the mirror before setting off.

Close the front w indow and the cab door.

If the machine is equipped w ith a restraining belt for the operator, fasten the belt.

Before setting off, sound the horn to warn any persons in the immediate vicinity

Never allow other persons to travel with you on the machine.

Note the position of the working equipment

Never drive w ith the w orking equipment extended, as that may impair the stability of the machine. Bring the working equipment as close as possible to the machine.

Taking care during operation

40000022-en

If the front equipment or another part of the machine collides w ith a higher obstacle, e.g. a bridge, both the machine and the other object are damaged, and persons may be injured.

Take care to prevent the boom or stick from colliding with higher obstacles.

Fig. 7

Taking care when trenching

The inadvertent severing of underground cables or gas pipes may cause an explosion and / or fire. This may result in severe, potentially fatal injury.

- Before doing any trenching w ork, check the course of cables, gas pipes and water pipes.

- Observe the statutory minimum distance from cables, gas pipes and w ater pipes. Never look into the end of an inadvertently severed fibre-optics cable, as that may severely injure the eyes.

Contact the local authorities and / or supply enterprises (electricity, gas, w ater, sew age, telecommunications etc.) to obtain information on underground supply lines.

Distance from overhead power lines

Severe, potentially fatal injury may result from the machine or the front equipment not being kept w ell clear of overhead pow er lines.

- If w ork is being done close to an overhead power line, no part of the machine or the load must come w ithin a distance of 3 m plus tw ice the length of the overhead power line insulator from the pow er line.

- Check out and observe the relevant local regulations.

- Wet ground increases the range in which a person may get an electric shock.

- Keep all persons or colleagues clear of the location.

After contacting live w ires

- Do not leave the machine.

- Drive the machine out of the hazard zone. Warn others against approaching and touching the machine.

- Have the live w ire de-energized. Do not leave the machine until the contacted / damaged line has been de-energized w ith absolute certainty.

Fig. 8 Fig. 9

Accident Prevention when reversing and slewing

Any person in the immediate vicinity of the machine may be hit or run over w hen the machine is being reversed or the superstructure is being slew ed. This may result in severe, potentially fatal injury

To prevent accidents during reversing and slewing:

- Enlist the assistance of a marshaller if your view is restricted.

- Alw ays look in all directions before reversing or slew ing. Make sure there is no one in the immediate vicinity.

- Keep the acoustic reversing alarm (if present) in a good operating state.

- Alw ays be prepared for the possibility of persons entering the hazard zone. Use the horn or another signal to w arn any persons in the immediate vicinity.

- Enlist a marshaller for reversing if your view is restricted. Always ensure that the marshaller is w ithin sight.

- The machine must not be moved until agreement has been reached with the marshaller on correct interpretation of the signals.

- Familiarize yourself w ith the meaning of all markings, signs and designations used in the operation and come to an agreement on them with the marshaller.

- Keep w indows, mirrors and headlamps clean and in good order.

- Dust, heavy rain, fog, etc. may reduce visibility If this is the case, reduce your speed and switch on appropriate lighting.

Read the Owner’s Manual carefully

Fig. 10

Fig. 11

Rules for driving on the road

The machine must not be driven on the public highway unless the conditions of the “General Operating Permit” are observed or, in the event of deviations from the “General Operating Permit”, a vehiclespecific operating permit has been granted. These permits must be present in the cab during such travel.

- Alw ays have a w arning triangle, warning lamp and first-aid kit on board.

- Bring the w orking equipment into a position in which the maximum machine dimensions are not exceeded.

- Sw itch the bucket/grab switchover valve to "Grab" position. The bucket cylinder is then hydraulically blocked.

- Mount clearance lamp on stick and connect to a socket.

- Raise levelling blade completely and attach a reflector.

- Raise claws (option) completely and block mechanically.

- Sw itch off floodlamps.

- Lock superstructure..

Recovering and towing the machine

Tow the machine w ith a tow -rod or tow ing rope only.

The tow-rod or rope must be free from damage. They must be dimensioned in such a w ay that the calculated breaking load is equal to three times the tractive power of the towing machine.

The tow ing vehicle must have adequate tractive pow er.

Drive slowly, carefully and smoothly.

All persons must keep clear of the tow-rod or rope.

- Tow only if the brakes and the steering of the machine are functioning properly and if the machine cannot be otherw ise transported.

- Tow defective machines only as far as necessary to recover the machine from hazardous areas.

- After the recovery, the machine must be secured against inadvertent movements and unauthorized starting.

- Have the machine repaired before transporting it over greater distances, or load it onto a transport vehicle.

- The machine is not suitable for tow ing trailers or other vehicles over longer distances; this w ould result in damage to axles and gearboxes. The tow coupling is designed solely for tow ing or recovering vehicles from hazardous areas or for lashing purposes on transport vehicles.

Travelling uphill and downhill

Before starting up the machine, read through the Ow ner’s Manual carefully

- Before driving the machine, put it into neutral position (see Ow ner’s Manual).

- Never drive dow n slopes w ith a gradient of more than 30°. Take an alternative route w ith lower gradients.

- Keep the bucket 20 - 30 cm above the ground on the uphill side w hile travelling uphill or dow nhill.

- If the machine starts to slip or to lose its stability, low er the bucket immediately.

- Driving across slopes may cause the machine to slip or overturn.

- Steering manoeuvres on slopes may cause the machine to overturn.

- Never coast dow nhill. This may result in a loss of control over the vehicle and in severe damage to property as well as fatal injury.

- Alw ays change to first gear before the downhill / uphill slope. This increases the brake action of the travel motor, preventing inadmissibly high travel speeds.

- When working on a slope, the fuel tank must be topped up as soon as the fuel indicator lights up.

Fig. 12

Fig. 13

Fig. 14

Preventing the machine from overturning Inspecting the deployment location

Working on slopes alw ays entails a risk of the machine overturning. This may result in severe, potentially fatal injury

To prevent overturning:

- Exercise special care w hen w orking on a slope.

- Prepare the working area of the machine by levelling it.

- Keep the bucket close to the ground and to the machine.

- Reduce the working speed of the machine to prevent overturning or slipping.

Avoid changing direction w hen driving on a slope.

- Alw ays try to avoid crossing a slope w ith a gradient of more than 5 degrees.

- When slew ing a load, reduce the slew ing speed to meet safety requirements.

Special care must be taken w hen working on frozen ground.

- A rise in temperature softens the soil, impairing the stability of the machine during travel.

Working at the edge of excavations or on the verge of a road entails a risk of the machine overturning. This may result in severe, potentially fatal injury.

- Before starting work, inspect the site and the ground conditions to prevent any risk of the machine overturning and of the ground, a stockpile or a wall giving w ay

- If necessary, the ground, excavation site edges and verges must be reinforced. Keep sufficient clearance w ith the machine from the edges of the excavation site and the verges.

- When working on a slope or on the verge of a road, enlist the services of a marshaller if necessary

- If the ground has a poor loadbearing potential, reinforce it before starting work

- Special attention is needed w hen working on frozen ground. If the ambient temperature rises, the ground becomes soft and slippery

Fig. 16

Fig. 15

Parking the machine safely

To prevent accidents:

- Park on a flat, horizontal surface.

- Turn the brake sw itch to braking position.

- Set the working equipment dow n on the ground.

- Low er the levelling blade and/or the outrigger claw s onto the ground.

- Engage the superstructure lock.

- Run the engine unloaded at minimum speed for ca. 5 minutes.

- Turn the ignition key to OFF position to sw itch off the engine. Then withdraw the key

- Move the steering safety lever to block the machine.

- Lock the w indow s, the sliding roof and the cab door.

- Lock all covers and flaps.

Preventing accidents when the machine is moving

Severe or fatal accidents may result from an attempt to enter or leave a moving machine.

- Before leaving the operator’s seat, select a flat, horizontal area for parking if possible.

- Park the machine safely

- Block both wheels and set the working equipment down on the ground.

- Park at a reasonable distance from other vehicles.

Confirming the direction of machine travel

Inadvertent activation of the operating pedal may result in severe damage or fatal accidents.

Check the machine position. Read the corresponding section in the Ow ner’s Manual.

Fig. 18

Fig. 17

Avoid caving out high banks

The edges may cave in or there may be a landslide. This can result in severe, potentially fatal injury

Protection from rockfall and landslides

Before w orking at locations w ith a risk of rockfall, make sure your machine has a cab with a Falling Object Protective Structure (FOPS).

Fig. 19

Fig. 20

Caving prevention

To reverse aw ay from the edge of an excavation in the event of the ground giving w ay, the tracks must always be positioned w ith the rear travel motors at right angles to the edge of the excavation.

Do not panic if the ground starts to give way and adequate withdrawal is impossible. In such cases the machine can often be secured by lowering the front equipment.

Never move the bucket above persons

The bucket must never be lifted, moved or slew ed above persons or a truck cab.

Material falling from the bucket or a collision w ith the bucket may result in injury and in damage to the machine.

Fig. 21

Fig. 22

Safety instructions, maintenance/servicing

Safety during transport

There is a risk of the machine overturning when it is being loaded onto a truck or trailer and when it is being unloaded.

- Ensure that local regulations are observed w hen the machine is being transported on the public highw ay.

- An appropriate truck or trailer must be provided for the transport of the machine.

When loading/unloading the machine, the follow ing precautions must be taken:

- Find firm, horizontal ground.

- Alw ays use a loading platform or drive-on ramp

- A marshaller must be enlisted to help w ith loading/unloading the machine.

- When loading or unloading the machine, the automatic speed reset must always be sw itched off to prevent an unexpected increase in speed due to inadvertent activation of an operating lever.

Alw ays set the transmission stage sw itch to "slow " .

In the "fast" transmission stage, the travelling speed may be automatically increased.

- Avoid steering movements w hen driving up or down the ramp, as that is extremely dangerous. If steering is absolutely essential, first drive back onto the ground or the loading area, correct the driving direction, and set off again.

- At the top end of the ramp, w hich adjoins the loading area, there is a joint. Drive over it w ith care.

- When slew ing the superstructure, avoid fast movements as they might cause the machine to overturn, resulting in potential injury

- Keep the stick retracted and turn the superstructure slow ly to ensure maximum stability

- Secure the machine frame w ith chains or cables.

Details are given in the appropriate sections of the Ow ner’s Manual.

Fig. 23

Safety during servicing operations

To prevent accidents:

- Before starting work, familiarize yourself w ith the servicing procedure.

- Keep the w orking area clean and dry.

- Never perform any lubrication or servicing w ork w hile the machine is in motion.

Before carrying out servicing work on the machine:

- Park the machine safely.

- Never leave the machine unsupervised if servicing work has to be carried out with the engine running.

- If the machine has to be raised, the boom and stick must be positioned at an angle of 90 - 110°. Secure the machine components that have to be raised for servicing or repair work w ith appropriate supports.

- Work must never be done under a raised machine that is supported by the boom.

Certain components have to be checked at regular intervals and repaired or replaced if necessary. Details are given in the corresponding sections of the Owner’s Manual.

- Use original spares only.

- All components must be kept in a good state and correctly installed. Any defect must be repaired immediately.

- Any damage must be rectified immediately Worn or nonfunctioning components must be replaced. Remove any lubricating grease, oil and dirt deposits.

Disconnect the cable from the negative pole of the battery before doing any work on the electrical system or arc welding on the machine.

Fig. 24

Fig. 25

Warning instructions for servicing work

Unexpected machine movements may result in serious injury.

- Prior to doing any w ork on the machine, display a notice "Servicing work in progress" to ensure that the machine is not used inadvertently

Correct machine support

Never carry out work on the machine w ithout first securing it.

- Alw ays low er the w orking equipment or the tool onto the ground before w orking on the machine.

- If you have to w ork on a raised machine or raised w orking equipment, stabilize the machine or working equipment w ith a support.

- The machine must not be supported w ith hollow blocks, tyres or supports that give w ay when continuously loaded.

- Never w ork under a machine that is supported with lifting gear only.

Fig. 26

Fig. 27

Working at greater heights

Alw ays w ear a safety harness w hen working at greater heights. Wear an approved safety harness; it must be equipped w ith stabilizers and safety cables.

Keeping clear of moving parts

Catching in moving parts may result in severe injury.

To prevent accidents, care must be taken to ensure that hands, feet, clothing, jewellery and hair cannot get caught in moving parts w hen work is being done close to them.

Fig. 28

Fig. 29

Prestressed units Safety instructions for accumulators

Never open defective prestressed systems but replace the entire system

Open only in exceptional cases, when the system and the operational sequence are exactly know n and the necessary special tools are available.

Never remove lead seals

Never change the rated pressure of pressure-reducing valves w ithout the explicit authorization of the manufacturer.

Never remove lead seals from pressure-reducing valves and accumulators.

Accumulators are installed in the hydraulic system. They contain nitrogen under high initial pressure.

Even w hen the hydraulic system has been depressurized, the nitrogen pressure is maintained in the accumulator

The accumulators are completely safe in operation. If incorrectly handled, how ever, there is a risk of explosion.

The accumulators installed in this machine cannot be repaired. Defective accumulators must be replaced.

Never handle accumulators mechanically, never w eld or solder them

Before dismantling the accumulator, put on goggles and w orking gloves, and depressurize the hydraulic system.

Use original spares only. If in doubt, contact your local agent or the aftersales service.

Never remove or paint over w arning and information plates, rating plates or type identification markings. Replace illegible or damaged plates immediately

Dismantling components

Never dismantle w hile the machine is still at operating temperature. Oils, greases, brake fluid or coolant may have a high temperature and thus result in burning or scalding. Wait for the machine to cool dow n. Depressurize pipelines and hoses, cylinders, radiator, hydraulic tank, compressed air reservoir and other systems or units before starting work.

Replace defective components in good time to prevent greater damage.

Clean the defective component carefully before dismantling it.

Mark dismantled components in the correct sequence to facilitate installation.

When dismantling the component, close exposed hose and pipe connections, open boreholes and housings w ith care to prevent dirt from penetrating.

After repair work

To prevent corrosion, coat all bright metal machine components w ith a grease film.

On completing the work, reassemble all protective devices, covers, and sound- and vibration-insulation material.

Never start up the driving motor while work is being done on the machine.

Check the repaired components and all machine functions w ith a trial run. Never release the machine for recommissioning until it is fully functioning.

Correct waste disposal

Incorrectly discarded waste is an environmental hazard. Hazardous substances used in excavators include lubricants, fuels, coolants, brake fluids, filters and batteries.

- Use sealed containers to discard fluids. Never use containers designed for food or drinks.

- Never discard waste onto the ground, into drains or into water.

Ask your local authorities, collection points or dealer about the correct procedure for recycling or discarding w aste.

Welding operations

Never perform welding operations unless you are qualified to do so. Observe the accident prevention regulations.

Any w ork on receptacles that contain or have contained substances

- that are flammable or encourage combustion,

- that are susceptible to explosion,

- that may develop noxious gases, fumes, vapours or dusts during welding operations may be performed only under expert supervision and only by experienced personnel authorized to do such w ork.

Detailed information on the proper execution of w elding operations is given in the corresponding sections of this manual.

Contact the O&K Service department w ith any problems or questions arising.

If machine components have to be dismantled, read and observe the sections:

- "Assembly of w orking equipmentsafety instructions,

- "Inspection and servicing - safety instructions",

- "Repair - safety instructions".

Before any welding operations on the machine:

- Disconnect the battery, first at the negative and then at the positive pole.

- Disconnect the positive pole at the alternator.

- Protect disconnected terminals and plugs from short-circuiting and contamination by covering them w ith foil or adhesive strips. Bring the welding current terminals as close as possible to the w elding point.

The w elding current must not flow through the slew ing ring, pin couplings, link joints or hydraulic cylinders.

Restore all electrical connections after completion of welding operations.

When connecting the battery, connect first the positive pole terminal and then the negative pole terminal.

Starting the engine with starter batteries

Battery gas may explode, causing damage and injury.

If the engine is to be started up w ith starter batteries, ensure that all procedures described in the Owner’s Manual are observed.

- The operator must be seated on the driver’s seat to keep the machine under control when the engine starts up. Tw o persons are needed to start up the engine w ith starter batteries.

- Never use batteries that have been stored for long periods at low temperatures.

- Mistakes in implementing the procedure specified for starting up the engine w ith starter batteries may result in a battery explosion or unexpected machine movements.

Battery gases may explode.

- Keep sparks, lit matches or open flames away from the upper side of batteries.

- The battery charge must never be controlled by applying a metal object to both pole terminals. Use a voltmeter or an acidity meter.

- A frozen battery must not be charged; it may explode. Heat the battery up to 16 °C.

Battery acid is toxic. If the battery explodes, battery acid may splash into the eyes w ith a potential risk of blinding.

- You must wear eye protection when checking battery acidity.

Prevention of acid-induced burns

The sulphuric acid contained in the battery is toxic. It is so strong that it may burn the skin, burn holes in clothing and, if splashed into the eyes, lead to blinding. Therefore:

- Top up the batteries on well ventilated premises only

- Wear goggles and rubber gloves.

- Take care not to inhale the electrolyte vapours w hile topping up the batteries.

- Make sure no electrolyte is spilt or runs over.

- Use appropriate starting aids in an emergency.

If splashed with acid:

- Rinse the skin w ith plenty of w ater.

- Neutralize the acid by spreading sodium bicarbonate or fuller’s earth over it.

- Rinse out the eyes for 10-15 minutes with water.

- Seek medical advice immediately.

If acid has been swallowed:

- Drink large quantities of water or milk, milk of magnesia, raw beaten egg or vegetable oil.

- Seek medical advice immediately.

Fig. 30

Prevention of scalding Safe handling of fluids

Hot, spattering fluids:

- After machine operation the engine coolant is hot and under pressure. Hot w ater or steam is contained in the engine, radiator and heating lines. If escaping hot water or steam touches the skin, it may cause severe scalding.

- To prevent potential injury through hot, spattering water: Never remove the radiator cover until the engine has cooled dow n. To open the cover, turn it slow ly as far as the limit stop. Depressurize the radiator completely before opening the cover.

The hydraulic tank is under pressure. Depressurize it completely before removing the cover.

Hot fluids and surfaces:

Engine oil, gearbox oil and hydraulic oil also heat up during operation.

The engine, hoses, lines and other components also heat up.

Give the oil and the components time to cool dow n before starting servicing or inspection work.

Handle fuel w ith care: it is highly flammable. Igniting fuel may result in an explosion or a fire w ith the risk of severe, potentially fatal injury.

- When refuelling the machine, smoking and the use of open flames or sparks in the immediate vicinity are prohibited.

- Alw ays shut off the engine before refuelling.

- Refuelling must be done in the open air.

All fuels, most lubricants and some antifreezes are flammable.

- Flammable fluids must be stored where they are protected from fire.

- Pressurized containers must not be opened with force or incinerated.

Never keep oily rags: risk of selfcombustion and fire.

Fig. 32

Fig. 31

Fire prevention

Checking for leakages:

- Leakages of fuel, hydraulic oil and lubricants may cause fires.

- Check w hether clips are missing or loose, hoses are kinked, lines or hoses rub against one another, the oil cooler is damaged or oil cooler flange screws are loose, allow ing oil to escape.

- Missing, loose or damaged clips, lines, hoses, oil coolers or oil cooler flange screws must be replaced, tightened or repaired.

- High-pressure lines must not be bent or hammered.

- Never install bent or damaged lines, tubes or hoses.

Checking for short-circuits:

- Short-circuits may cause fires.

- Ensure that all electrical connections are clean and have a firm fit.

Check before each shift or after ca. ten operating hours w hether electric cables or lines are loose, kinked, hardened or worn through.

- Check before each shift or after ca. ten operating hours w hether terminal caps are missing or damaged.

- -Never start up the machine if cables or lines are loose, kinked, etc.

Removal of flammable substances:

- Spilt fuel or lubricant, waste, lubricating grease, dirt, coal dust deposits and other flammable substances may cause fires.

- To prevent fires, the machine must be checked and cleaned once a day. Any spillages or deposits of flammable substances must be cleared away immediately

Checking the ignition key function:

- If the engine is not shut off w hen fire breaks out, the fire will spread, impeding fire-fighting operations

- Before starting daily machine operations, the ignition key must be checked for correct functioning.

Start up the engine and run it at a low idling speed.

To confirm that the engine is shut off, turn ignition key to OFF position.

- Any irregularities that are detected must be rectified before the machine is put into operation.

Checking heat shields:

The absence of heat shields or any damage to them may result in fire breaking out.

Damaged or missing heat shields must be repaired or replaced before the machine is put into operation.

Evacuation in case of fire

If a fire breaks out, evacuate the machine as follow s:

- If there is sufficient time, shut off the engine by turning the ignition key to OFF position.

- If there is sufficient time, use the fire extinguisher.

- Leave the machine.

Risks from exhaust gases

Prevent the risk of suffocation. Engine exhaust gases may cause nausea or even death.

- If you have to w ork in a building, make sure there is adequate ventilation.

Use an exhaust pipe extension to remove the exhaust gases, or open doors and window s to let in sufficient fresh air. 4100033

Fig. 34

Fig. 33

Risks from fluids in pressure systems

Pressurized fluids such as fuel or hydraulic oil may penetrate the skin or eyes, resulting in severe, potentially fatal injury or blinding.

- Cut out this risk by depressurizing the system before disconnecting hydraulic or other lines.

- Tighten all connections before pressurizing the system.

- Using a piece of card, search for any leakages; be sure to protect hands and body from fluids under high pressure. Wear a face guard or goggles to protect your eyes. Seek medical advice immediately after an accident. Any fluid that has penetrated the skin must be removed surgically w ithin a few hours to prevent severe infection (gangrene)

Fig. 35

Fig. 36

Fig. 37

Preventing heat build-up close to pressure systems

Heat generation close to pressurized fluid lines may result in a highly flammable spray, putting you and other persons in the immediate vicinity at risk of serious scalding.

Never carry out heat-generating welding or soldering work close to pressurized fluid lines or other highly flammable substances, and never use a flame cutter there.

Pressure lines may be inadvertently cut if the heat goes beyond the immediate flame area. To provide temporary protection for hoses or other materials, mount fire-resistant shields w hen carrying out w elding or soldering work.

Preventing heat build-up in lines carrying combustible fluids

- Never carry out w elding or flamecutting w ork on pipes or lines carrying combustible fluids.

- Flush them out w ith a non-flammable solution before welding or flame-cutting them.

Fig. 38

Removing paint before welding

Hazardous fumes may develop if paint is heated by w elding, soldering or the use of a flame cutter. These fumes may affect your health if inhaled.

- Avoid inhaling potentially toxic fumes and dust.

- Carry out such w ork only in the open air or on well ventilated premises.

- Paints and solvents must be discarded in accordance w ith local environmental regulations

Remove paint prior to welding or heating:

- When rubbing dow n paint, avoid inhaling the dust.

- Wear an approved respiratory mask.

- When using a solvent or paint remover, remove the agent w ith soap and water before any w elding operations. Remove all solvent or paint remover containers and other inflammable materials from the working area. Give the fumes at least 15 minutes to dissipate before any w elding or heating.

Fig. 39

Risks from breaking-away components

The tyres are inflated under pressure Bursting tyres and breakingaw ay rim parts may cause serious damage or fatal accidents.

- Tyres must be changed by experts only.

- Alw ays ensure that the tyre pressure is correct. Insufficient tyre pressure means greater wear on the tyres and poor machine stability.

- Excessively high tyre pressure means poor handling properties on terrain and a risk of bursting tyres.

- Prior to inflating tyres, check rims and rim components for damage, penetrating foreign bodies and a firm fit.

- Never inflate tyres above the recommended pressure.

- Leave tyres to cool dow n before working on them.

- Use only compressed ambient air to inflate tyres. Never use combustible gases: risk of explosion.

Use appropriate tools

Use only tools suited to the respective w ork.

Inappropriate tools, components and procedures may result in hazardous situations.

Use tools whose length is suitable for the tightening or loosening of safety elements to prevent injuries resulting from failure to control a wrench

Never use tools complying w ith US standards or British standards for metric connection elements.

Use original spares only (see spareparts catalogue).