Case CX15B CX18B Series 2 Mini Excavator Operator's Manual 84371704 - PDF DOWNLOAD

CX15B / CX18B Series 2 Mini Excavators

CX15B CX18B Series 2 Mini Excavators

Operator’s Manual

Print No. 84371704 1st Edition English 04/11 - ORIGINAL INSTRUCTIONS From serial no. NBLN00001

CX15B CX18B Series 2 Mini Excavators

Operator’s Manual

Print No. 84371704 Ist edition English 04/11 - ORIGINAL INSTRUCTIONS From serial no. NBLN00001

INDEX FOREWORD...................................................................................................................................................... 0-1 DESIGNATED USE ........................................................................................................................................... 0-1 GENERAL INFORMATION................................................................................................................................ 0-2 PERIODIC INSPECTIONS ................................................................................................................................ 0-2 NOTE ................................................................................................................................................................. 0-2 REMARKS RELEVANT TO ORDERS ............................................................................................................... 0-3 NOISE LEVELS (2000/14/EC)........................................................................................................................... 0-4 SOUND POWER LEVEL ............................................................................................................................... 0-4 SOUND PRESSURE LEVEL AT THE OPERATOR’S SEAT ........................................................................ 0-4 LEVEL OF VIBRATIONS TRANSMITTED TO THE OPERATOR ..................................................................... 0-5 OPERATOR PROTECTIVE STRUCTURE........................................................................................................ 0-6

1. SAFETY PRECAUTIONS 1.1 GENERAL SAFETY INFORMATION ........................................................................................................ 1-3 1.2 SAFETY PRECAUTIONS .......................................................................................................................... 1-4 1.3 INSPECTION BEFORE TRAVELLING WITH THE MACHINE.................................................................. 1-6 1.4 SAFETY DURING OPERATION ............................................................................................................. 1-12 1.5 INSPECTION AND MAINTENANCE SAFETY ........................................................................................ 1-20 1.6 PRECAUTIONS DURING BATTERY USE.............................................................................................. 1-28 1.7 WARNING LABELS AND SAFETY DECALS .......................................................................................... 1-30 1.7.1 NOTES FOR WARNING LABELS AND SAFETY DECALS.............................................................. 1-30 1.7.2 LOCATION OF WARNING LABELS AND DECALS ......................................................................... 1-31 1.8 FORBIDDEN USE ................................................................................................................................... 1-39 1.9 PRECAUTIONS AT THE END OF DAILY WORK ................................................................................... 1-42 1.10 TRANSPORTATION................................................................................................................................ 1-43 1.11 TOWING THE MACHINE ........................................................................................................................ 1-45

2. MACHINE FAMILIARIZATION 2.1 MACHINE FAMILIARIZATION .................................................................................................................. 2-3 2.2 GENERAL NOMENCLATURE .................................................................................................................. 2-3 2.2.1 FRONT, REAR, RIGHT AND LEFT..................................................................................................... 2-3 2.2.2 MAIN COMPONENTS ......................................................................................................................... 2-3 2.3 OPERATOR’S CAB NOMENCLATURE .................................................................................................... 2-5 2.4 INSTRUMENT AND CONTROL NOMENCLATURE ................................................................................. 2-6 2.4.1 INSTRUMENT PANEL ........................................................................................................................ 2-6 2.4.2 SWITCHES.......................................................................................................................................... 2-9 2.4.3 LEVERS AND PEDALS..................................................................................................................... 2-13 2.4.4 SEAT BELT ....................................................................................................................................... 2-19 2.4.5 CAB ................................................................................................................................................... 2-20 2.4.6 ENGINE GUARD WITH LOCKING DEVICE AND COVERS ............................................................ 2-23 2.4.7 SEAT ADJUSTMENT ........................................................................................................................ 2-24 2.4.8 WORK LIGHT .................................................................................................................................... 2-24 2.4.9 OPERATOR’S MANUAL COMPARTMENT ...................................................................................... 2-24

3. MACHINE OPERATION 3.1 MACHINE OPERATION ............................................................................................................................ 3-3 3.1.1 DAILY INSPECTION ........................................................................................................................... 3-3 3.1.2 CHECKS BEFORE ENGINE START-UP ............................................................................................ 3-4 3.1.3 MACHINE WARM UP........................................................................................................................ 3-10 3.1.4 STARTING THE ENGINE.................................................................................................................. 3-11

INDEX 3.1.5 CHECKS AFTER ENGINE START-UP ............................................................................................. 3-15 3.1.6 STOPPING THE ENGINE ................................................................................................................. 3-17 3.1.7 MACHINE OPERATION .................................................................................................................... 3-18 3.1.8 PRACTICE TO IMPROVE EFFICIENCY........................................................................................... 3-27 3.1.9 MACHINE PARKING ......................................................................................................................... 3-31 3.1.10CHECKS AND VERIFICATION AFTER WORK ................................................................................ 3-32 3.1.11PRECAUTIONS AFTER OPERATION .............................................................................................. 3-32 3.1.12MEASURES AFTER AN EMERGENCY STOP OF ENGINE ............................................................ 3-33 3.1.13EMERGENCY MEASURES FOR SUDDEN FAILURE OF MACHINE .............................................. 3-34 3.1.14CAUTION WHILE USING RUBBER CRAWLERS............................................................................. 3-38 3.1.15MACHINE OPERATION WITH ADVERSE WEATHER CONDITIONS ............................................. 3-42 3.1.16PRECAUTIONS WHEN STORING THE MACHINE FOR A LONG PERIOD.................................... 3-44

4. MAINTENANCE 4.1 GENERAL SAFETY INFORMATION......................................................................................................... 4-3 4.2 GENERAL RULES AND SAFETY PRECAUTIONS .................................................................................. 4-4 4.3 LUBRICANT, FUEL AND COOLANT SPECIFICATIONS ....................................................................... 4-11 4.4 MAINTENANCE GENERAL TABLE ........................................................................................................ 4-12 4.5 TAG MAINTENANCE IN PROGRESS .................................................................................................... 4-13 4.6 TORQUE SPECIFICATIONS FOR CAPSCREWS AND NUTS .............................................................. 4-14 4.7 TORQUE SPECIFICATIONS FOR JOINTS AND HYDRAULIC HOSES ................................................ 4-15 4.8 INSTALLING FITTINGS, HYDRAULIC HOSES AND TUBES................................................................. 4-16 4.9 RELEASING INTERNAL PRESSURE FROM THE HYDRAULIC SYSTEM ........................................... 4-17 4.10 BLEEDING AIR IN FUEL SYSTEM ......................................................................................................... 4-19 4.11 REPLACEMENT OF RUBBER CRAWLER ............................................................................................. 4-20 4.11.1REPLACEMENT OF RUBBER CRAWLER ....................................................................................... 4-21 4.11.2INSTALLING RUBBER CRAWLERS................................................................................................. 4-22 4.11.3CHECK AND ADJUSTMENT OF TENSION ON RUBBER CRAWLER ............................................ 4-23 4.12 INSPECTION AND MAINTENANCE TABLE ........................................................................................... 4-27 4.13 WHEN NECESSARY............................................................................................................................... 4-30 4.14 PRE-START (EVERY 8 HOURS) INSPECTION AND MAINTENANCE ................................................. 4-40 4.15 50-HOUR (WEEKLY) INSPECTION AND MAINTENANCE .................................................................... 4-43 4.16 250-HOUR (3-MONTH) INSPECTION AND MAINTENANCE................................................................. 4-49 4.17 500-HOUR (6-MONTH) INSPECTION AND MAINTENANCE................................................................. 4-56 4.18 1000-HOUR (12-MONTH) INSPECTION AND MAINTENANCE............................................................. 4-59 4.19 2000-HOUR SERVICE INSPECTION AND MAINTENANCE.................................................................. 4-62 4.20 BIODEGRADABLE HYDRAULIC OIL...................................................................................................... 4-70

5. TRANSPORTATION 5.1 WHEN PREPARING TRANSPORTATION PLANS ................................................................................... 5-3 5.2 LIFTING PROCEDURES OF COMPLETE MACHINE .............................................................................. 5-6

6. SPECIFICATIONS 6.1 MAINTENANCE OPERATIONS SUMMARY DECAL ................................................................................ 6-3 6.2 DIMENSIONS ............................................................................................................................................ 6-4 6.2.1 CAB DIMENSIONS.............................................................................................................................. 6-4 6.2.2 CANOPY DIMENSIONS ...................................................................................................................... 6-5 6.3 GENERAL SPECIFICATIONS ................................................................................................................... 6-6 6.4 DIGGING PERFORMANCE ...................................................................................................................... 6-8 6.5 LIFTING LOADS ........................................................................................................................................ 6-9 6.5.1 LIFTING LOADS (CX15B) ................................................................................................................... 6-9 6.5.2 LIFTING LOADS (CX18B) ................................................................................................................. 6-11

INDEX 7. OPTIONAL ATTACHMENT 7.1 OPTIONAL ATTACHMENT PEDAL (HYDRAULIC BREAKER AND NIBBLER)7-3 7.1.1 SELECTION OF HYDRAULIC BREAKER AND NIBBLER ................................................................. 7-3 7.1.2 BEFORE OPERATING HYDRAULIC BREAKER AND NIBBLER....................................................... 7-3 7.1.3 PREVENTION OF HYDRAULIC OIL CONTAMINATION.................................................................... 7-3 7.1.4 ATTACHMENT OPERATION .............................................................................................................. 7-4 7.1.5 SETTING SELECTOR VALVE ............................................................................................................ 7-6 7.2 SAFETY INSTRUCTIONS ......................................................................................................................... 7-7 7.3 REGULAR INSPECTION AND MAINTENANCE..................................................................................... 7-11

8. TROUBLESHOOTING 8.1 GENERAL TROUBLESHOOTING ............................................................................................................ 8-3

9. ELECTRICAL SYSTEM 9.1 GENERALITIES......................................................................................................................................... 9-3 9.2 BATTERIES ............................................................................................................................................... 9-4 9.3 FUSE BOX (MAIN) .................................................................................................................................... 9-6 9.3.1 VARIOUS FUSES................................................................................................................................ 9-6 9.4 RELAY BOX .............................................................................................................................................. 9-7

ATTACHMENT 1 - “EC” DECLARATION OF CONFORMITY

INDEX

FOREWORD

FOREWORD The crawler mini excavators are hydraulic machines.

They consist of two main parts: the upper frame and the lower frame.

These components are coupled by means of a slewing bearing which enables the upper frame to slew with respect to the lower frame.

The boom, tanks, radiators, counterweight, diesel engine and all hydraulic components for the operation of the excavator are fastened to the upper frame.

The lower frame is equipped with crawlers which can be made of rubber or metal and with a blade for levelling operations.

DESIGNATED USE The machine has been built in accordance with state-of-the-art standards and the recognized safety rules.

The machine must be used in accordance with its designated use, by observing the safety and precautionary rules and by strictly following the operating instructions. Any functional disorders, especially those affecting the safety of the machine, should therefore be rectified immediately.

The Excavator is intended to be used in digging and loading operation (with bucket), ground levelling (with blade) and use of hydraulic hammer to break concrete or other solid material.

NOTE: by using appropriate lubricants, the excavator can work with temperatures ranging from -20 °C to + 40 °C (-4 °F to + 104 °F).

For the correct operation of the machine in this temperature range, please refer to the table of lubricants contained in this manual.

The manufacturer/supplier cannot be held responsible for any damage resulting from other than the designated use. The risk involved in such misuse lies entirely with the user.

S DANGER For clarity purposes, some figures in this Manual show the machine with protection panels or covers removed. Never operate the machine with any protection panels or covers removed.

S DANGER It is absolutely forbidden to tamper and/or change the setting of any of the hydraulic system valves to avoid damaging machine components with consequent risks to personal safety.

S DANGER Using the excavator and its attachments differently from the way described in this manual will be deemed as improper use. Please find below some examples of improper use of the excavator: - for lifting or transporting persons; - as a working platform; - for pulling slung loads; - for driving in posts, supports, sheet-piles, without the attachment being approved for this purpose.

Improper use may cause injury or life-threatening risks for the operator and for other persons.

0-1

FOREWORD This manual may contain attachments and optional equipment not available in your area. Please contact your Dealer for any optional attachment required.

S WARNING READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS AND PROCEDURES FOUND IN THIS MANUAL BEFORE ATTEMPTING ANY OPERATION, INSPECTION, MAINTENANCE OR REPAIR OF THIS MACHINE, ATTACHMENT OR ANY OF ITS SYSTEMS. THE MANUFACTURER CANNOT ANTICIPATE EVERY POSSIBLE CIRCUMSTANCE THAT MIGHT INVOLVE A POTENTIAL HAZARD. THE WARNINGS IN THIS PUBLICATION AND ON THE PRODUCT ARE THEREFORE NOT ALL INCLUSIVE. IF A TOOL, PROCEDURE, WORK METHOD OR OPERATING TECHNIQUE NOT SPECIFICALLY RECOMMENDED BY MANUFACTURER IS USED, YOU MUST SATISFY YOURSELF THAT IT IS SAFE FOR YOU AND OTHERS. YOU SHOULD ALSO ENSURE THAT THE PRODUCT WILL NOT BE DAMAGED OR MADE UNSAFE BY THE OPERATION, LUBRICATION, MAINTENANCE AND/OR REPAIR PROCEDURES YOU CHOOSE.

We expressly stress the fact that this manual is written on the presupposition that only genuine Manufacturer’s parts are to be used. Not including cases where parts locally procured were used and/or the machine was arbitrarily modified by the user locally.

Materials and specifications are subject to change without notice.

PERIODIC INSPECTIONS After delivery of a machine, the Dealer will make periodic service inspections. Contact your Dealer for any service related to issues not explained in this manual.

NOTE

GENERAL INFORMATION

The contents of this manual may not reflect the specifications of the machine delivered. Contact your Dealer to obtain detailed information about specifications for machines provided with optional equipment not described in this manual.

This manual contains procedures to aid the operator gain peak performance through effective, economical machine operation and maintenance for the Hydraulic Excavators.

Owing to the policy of continual improvement, changes may be made by Manufacturer to any of its products without any obligation on the part of Manufacturer.

Before operating the machine, operators must thoroughly read and understand all safety, Operation and Maintenance instructions found in this manual.

Failure to follow the instructions given in this manual, may lead to serious injuries to persons and or to equipment failure.

Operators and persons working with this machine should continually study this manual until proper Safety, Operation and Maintenance procedures are completely understood.

This manual describes the basic operating techniques. Skill is gained as the operator utilizes these techniques and perfects them with an actual machine.

Some illustrated pictures may differ from the real version of your machine. As technical updating and improvement of products is continuous. The manuals are constantly updated to reflect these changes.

0-2

FOREWORD

REMARKS RELEVANT TO ORDERS To order spare parts or call for service, inform your Dealer of your machine’s serial number and engine serial number, as well as of the hourmeter reading.

These numbers are reported on the plates shown in

the illustration below. For future and quick reference, record these numbers in the appropriate spaces in the plates on your machine:

MACHINE No. ENGINE No. MACHINE No.

F47090

ENGINE No.

HOUR COUNTER

0-3

FOREWORD

NOISE LEVELS (2000/14/EC) SOUND POWER LEVEL Lwa = 93 dB (A) Plate (1) shows the guaranteed sound power level, determined in compliance with 2000/14/EC European Standard.

SOUND PRESSURE LEVEL AT THE OPERATOR’S SEAT Lpa = 74 dB (A) Sound pressure level continuous, equivalent and weighted, measured at the driver’s seat inside the cab with door and windows closed and with the heater/air conditioner blower operating at 2nd speed, measured on an identical machine, in compliance with standard ISO 6396:2008.

0-4

FOREWORD

LEVEL OF VIBRATIONS TRANSMITTED TO THE OPERATOR The vibration level transmitted to the operator depends mainly on the conditions of the soil where the machine is being operated and on the use conditions of the machine and its equipment.

The weighted average acceleration value to which the operator’s arms are subjected does not exceed 2.5 m/s2 (8.20 ft/s2).

The weighted average acceleration value to which the operator’s body is subjected does not exceed 0.5 m/s2 (1.64 ft/s2).

The exposition to vibrations can be remarkably reduced if the recommendations here below are followed:

These results have been obtained by using an acceleration gauge during the excavation works.

- use equipment suitable for the machine and the type of work to be carried out;

NOTE: the Whole-body exposure value is determined under particular operating and terrain conditions and therefore may not be representative of all the possible operating conditions within the intended use of the machine. Consequently this single vibration emission value is not intended to determine the whole-body vibration exposure as required

by European Directive 2002/44/EC. For this purpose it is recommended to conduct actual working condition measurement. If this is not feasible use of information provided in the table below, from ISO/ TR 25398:2006 (*), is suggested.

- adjust and lock the seat in the correct position; regularly check the seat suspensions, if provided, and carry out adjustments or maintenance as required; - carry out regularly the ordinary maintenance of the machine at scheduled intervals; - operate the attachment evenly, avoiding sudden motion or extreme shocks, if possible; - as far as possible, avoid travelling on particularly uneven soils or the impact with possible obstacles, such as large rocks.

The exposure is dependant on machine operating techniques and can be controlled by following the instructions described in this manual.

Basic emission value Operating conditions

Standard deviation

1.4*aw,eqx m/s2 (ft/s2)

1,4*aw,eqy m/s2 (ft/s2)

aw,eqz m/s2 (ft/s2)

1.4*Sx m/s2 (ft/s2)

1.4*Sy m/s2 (ft/s2)

Sz m/s (ft/s2)

Digging

0.33 (1.08)

0.21 (0.69)

0.19 (0.62)

0.19 (0.62)

0.12 (0.39)

0.10 (0.32)

Use of the hydraulic hammer

0.49 (1.60)

0.28 (0.92)

0.36 (1.18)

0.20 (0.65)

0.13 (0.42)

0.17 (0.56)

Transfer movement

0.45 (1.47)

0.39 (1.27)

0.62 (2.03)

0.17 (0.56)

0.18 (0.59)

0.28 (0.92)

(*) ISO/TR 25398:2006 Mechanical vibration Guideline for the assessment of exposure to wholebody vibration of ride on operated earth-moving machines - Using harmonized data measured by international institutes, organizations and manufacturers.

0-5

2

FOREWORD

OPERATOR PROTECTIVE STRUCTURE S WARNING THE MANUFACTURER HAS PROVIDED THE MACHINE WITH OPERATOR PROTECTIVE STRUCTURES, SUCH AS: A SIDE TIP OVER PROTECTIVE STRUCTURE (TOPS) AND A FALLING OBJECT PROTECTIVE STRUCTURE (FOPS). REFER TO THE IDENTIFICATION PLATE IN THE CAB (1) OR ON THE CANOPY (2) AND (3) IN ORDER TO IDENTIFY THE CHARACTERISTICS OF THE PROTECTIVE STRUCTURES. The protective structure and interconnecting components are a certified system.

Never attach towing devices to the protective structure. Do not drill holes on the protective structure.

The protective structure and interconnecting components are a certified system. Any damage, fire, corrosion or modification will weaken the structure and reduce your protection.

If this occurs, the protective structure must be replaced so that it will provide the same protection as a new protective structure. Contact your Dealer for protective structure inspection or replacement.

F47091

After an accident, fire or roll over, the following must be performed by a qualified technician before returning the machine to field or job site operation: • Check the protective structures and, if necessary, replace them.

• The mounting or suspension of the protective structure, operator’s seat, safety belts, mounting components and cables within the operator’s protective system must be carefully inspected for damage.

• All damaged parts must be replaced.

DO NOT WELD, DRILL HOLES, ATTEMPT TO STRAIGHTEN OR REPAIR THE PROTECTIVE STRUCTURE. MODIFICATION IN ANY WAY CAN REDUCE THE STRUCTURAL INTEGRITY OF THE STRUCTURE WHICH COULD CAUSE DEATH OR SERIOUS INJURY IN THE EVENT OF FIRE, TIP, ROLLOVER, COLLISION OR ACCIDENT.

F47092

0-6

1. SAFETY PRECAUTIONS

1-1

1. SAFETY PRECAUTIONS

1-2

1. SAFETY PRECAUTIONS

1.1

GENERAL SAFETY INFORMATION Safety messages appear in this manual and on the machine. All safety messages are identified by the words “DANGER”, “WARNING” and “CAUTION”.

S WARNING DO NOT OPERATE OR PERFORM ANY MAINTENANCE ON THIS MACHINE UNTIL ALL INSTRUCTIONS FOUND IN THIS MANUAL HAVE BEEN THOROUGHLY READ AND UNDERSTOOD.

Indicates an imminently hazardous situation which, if not prevented, will result in death or serious injury.

S DANGER

IMPROPER OPERATION OR MAINTENANCE OF THIS MACHINE MAY CAUSE ACCIDENTS AND COULD RESULT IN SERIOUS INJURY OR DEATH. ALWAYS KEEP THIS MANUAL OPERATOR’S SEAT POCKET.

IN

Indicates a potentially hazardous situation which, if not prevented, will result in death or serious injury.

THE

S WARNING Indicates a potentially hazardous situation that, if not prevented, will result in minor or moderate injury. It may also be used to alert against possible damage to the machine and its components.

IF PARTS ARE MISSING OR DAMAGED, CONTACT YOUR DEALER TO HAVE THEM REPLACED. IF YOU HAVE ANY QUESTIONS, PLEASE CONSULT YOUR DEALER.

S CAUTION

Most accidents occurring during operation are due to negligence of precautionary measures and safety instructions. Sufficient care should be taken to prevent these accidents. Incorrect operation, lubrication or maintenance are very dangerous and may cause injury or death of the personnel.

Therefore all precautionary measures, NOTES, DANGERS, WARNINGS and CAUTIONS contained in this manual and on the machine should be read and understood by all personnel before starting any work with or on the machine.

It is very difficult to forecast every danger that may occur during operation. However, safety can be guaranteed by fully understanding the operating procedures for this machine according to the methods recommended by the Manufacturer.

While operating the machine, be sure to perform work with great care, so as not to damage the machine, or allow accidents to occur.

Continue studying this manual until all Safety, Operation and Maintenance procedures are completely understood by all persons working with the machine.

Operation, inspection and maintenance should be carefully carried out, and safety must be given the first priority. Safety messages are indicated with marks. The safety information contained in this manual is intended only for supplement of safety codes, insurance requirements, local laws, rules and regulations.

1-3

1. SAFETY PRECAUTIONS

1.2

SAFETY PRECAUTIONS If possible, make all repairs with the machine parked on a level and firm surface. Block the machine so it does not roll while working on or under the machine. Hang a “Maintenance in progress” tag in the operator’s compartment.

S WARNING THE PROPER AND SAFE LUBRICATION AND MAINTENANCE FOR THIS MACHINE, RECOMMENDED BY MANUFACTURER, IS OUTLINED IN THE OPERATOR’S MANUAL FOR THIS MACHINE. IMPROPER PERFORMANCE OF LUBRICATION OR MAINTENANCE PROCEDURES ARE DANGEROUS AND COULD RESULT IN INJURY OR DEATH. READ AND UNDERSTAND THE OPERATOR’S MANUAL BEFORE PERFORMING ANY LUBRICATION OR MAINTENANCE.

Do not work on any machine that is supported only by lift, jacks or a hoist. Always use blocks or stops for the jack before carrying out any disassembly operation.

S WARNING DO NOT OPERATE THIS MACHINE UNLESS YOU HAVE READ AND UNDERSTOOD THE INSTRUCTIONS IN THE OPERATOR’S MANUAL. IMPROPER MACHINE OPERATION IS DANGEROUS AND COULD RESULT IN INJURY OR DEATH.

The operator or serviceman may be unfamiliar with many of the systems in this machine. This makes a careful use of the systems very important when performing maintenance operations. Getting familiar with the system or its components is very important before removing or disassembling any of them.

Relieve all pressure in air, oil or water systems before any lines, fittings or related devices are disconnected or removed. Always make sure all raised components are blocked correctly and be alert for possible pressure when disconnecting any device from a system that utilizes pressure.

Because of the size of some of the machine’s components, the operator or serviceman should check the weights noted in this manual. Use proper lifting procedures when removing any components.

The following is a list of basic precautions that must always be observed.

Read and understand all warning labels and safety decals before operating, servicing or repairing this machine.

Lower the bucket, dozer or other attachments to the ground before performing any operation on the machine. If this cannot be done, make sure the bucket, dozer or other attachment is blocked correctly to prevent it from dropping unexpectedly.

Always wear protective glasses and protective shoes when working around machines.

In particular, wear safety goggles when using hammers, punches or drifts on any part or attachment of the machine. Use welders gloves, hood/goggles, apron and the protective clothing appropriate to the welding job being performed. Do not wear loose fitting or torn clothing. Remove all rings from fingers, loose jewellery, confine long hair and loose clothing before working on this machinery.

Use the steps and the grab handles when mounting or dismounting a machine. Remove any debris or mud from steps, walkways or work platforms before using them.

Always face the machine when using steps, ladders and walkways. When it is not possible to use the designed access system, provide ladders, scaffolds, or work, platforms to perform safe repair operations.

Refer to paragraph “MOUNTING ON OR DISMOUNTING FROM THE MACHINE, 1-9”.

Disconnect the battery and hang a “Maintenance in progress” tag in the operator’s compartment.

Remove the starter key.

1-4

1. SAFETY PRECAUTIONS To prevent back injury, use a hoist when lifting components which weigh 20 kg (44 lb) or more.

Make sure all chains, hooks, slings, etc., are in good condition and have the correct capacity. Be sure hooks are positioned correctly. Lifting eyes are not to be side loaded during a lifting operation.

Make sure all protective devices including the operator’s protective devices are properly installed and functioning correctly before starting a repair operation. If a guard or shield must be removed to perform the repair work, use extra caution and replace the guard or shield after repair is complete.

In order to prevent burns, be careful not to touch hot machine parts and hot liquids in systems, tubes and sections.

Performing maintenance and repair operations while the bucket is lifted is dangerous, because there is the possibility of a device falling. Do not fail to lower such device and place the bucket to the ground before starting the operation.

Be careful when removing cover plates. Gradually back off the last two capscrews or nuts located at opposite ends of the cover or device and carefully pry the cover loose to relieve any spring or other pressure before removing the last two capscrews or nuts completely.

Loose or dirty fuel, lubrication and hydraulic systems, pipes and hoses may cause fires. Do not bend or strike high-pressure lines, nor install bent or damaged lines. Inspect lines, tubes and hoses carefully. Do not check for leaks with your hands.

Very small leaks from holes can result in a highvelocity oil jets that will be invisible close to the hose. This oil can penetrate the skin and cause personal injury. Use cardboard or paper to locate hole leaks.

Be careful when removing filler caps, breathers and plugs on the machine. Hold a rag over the cap or plug to prevent being sprayed or splashed by liquids under pressure. Danger is even greater if the machine has just been stopped, as liquids might be boiling hot.

Tighten the connections to the correct torque. Make sure that all protections against burns, the clamps and the operator’s protective devices are correctly installed in order to prevent excessive heat, vibrations or rubbing against other parts during operation. The protections against oil leaks from hot hoses or damaged seals must be correctly installed.

Always use proper tools that are in good condition and that are suited for the job at hand. Be sure you understand how to use them before performing any service work.

Reinstall all clamps with the same spare part number. Do not use clamps of inferior quality if replacement is necessary.

Do not operate a machine if any rotating part is damaged or contacts any other part during operation. Any high speed rotating component that has been damaged or altered should be checked for balance before reusing.

Repairs which require welding should be performed only with the benefit of the appropriate reference information and by personnel adequately trained and skilled in welding procedures. Determine the type of metal being welded and select the correct welding procedure and electrodes, rods or wires to provide a metal weld strength at least equivalent to that of the parent metal. Make sure to disconnect the battery before any welding operation is performed.

Block the machine to prevent it from moving when adjusting or replacing the crawlers.

Do not damage the cables during removal operations. Reinstall the cables so that they are not damaged during machine operation, by contacting the machine’s sharp corners or by rubbing against objects or hot surfaces. Do not connect the cables to a system containing liquids.

1-5

1. SAFETY PRECAUTIONS

1.3

INSPECTION BEFORE TRAVELLING WITH THE MACHINE

Many failures that occur during machine operation or servicing result from neglecting fundamental safety precautions. The following safety precautions are given to prevent such failures, but they are only a part of what you must follow.

Before operating the machine, carefully read and observe all precautionary measures given in this manual.

OBSERVE PRECAUTIONS Follow all safety instructions, precautions and operating procedures. If there are other persons or flagmen working near the machine, have them observe the conventional signs.

WEAR PROTECTIVE CLOTHING Wear well fitting safety shoes, hard hat, and working equipment, and put on protective glasses, face shield, ear protection and gloves. When necessary, wear reflective vest.

S WARNING DO NOT WEAR WORKING CLOTHES CONTAMINATED WITH OIL, SINCE IT IS WILL EASILY CATCH FIRE.

READ AND UNDERSTAND THE OPERATOR’S MANUAL Before operating the machine, read and understand this manual thoroughly in order to use the machine effectively and safely.

KEEP THE OPERATOR’S MANUAL Keep this manual in the specified storage compartment for quick reference. Should the operator’s manual become lost or damaged, contact your Dealer to order a new copy.

1-6

1. SAFETY PRECAUTIONS DO NOT OPERATE MACHINE WHEN YOU ARE TIRED OR UNDER THE INFLUENCE OF DRUGS A poor physical condition causes improper reactions. Voluntarily refrain from operating the machine when feeling excessively tired, and never operate the machine under the influence of drugs.

PREPARE FOR EMERGENCIES Have a fire extinguisher and first aid kit ready for emergencies. Know how to operate the fire extinguisher and know where the First Aid Kit is located for easy access in case of emergency.

Prepare beforehand the communication means to be used in case of any emergency, and take note of telephone numbers for emergency contact.

ENSURE SAFETY AT THE WORK SITE Know the work area! Before operating the machine, carefully survey and record the land and work site features to prevent the machine from falling or the soil from caving in.

1-7

1. SAFETY PRECAUTIONS ENGAGE THE SAFETY LOCK LEVER(S) BEFORE LEAVING THE MACHINE In models provided with cab, there is only one lever on the left side, while the models with canopy are provided with two levers, one on each side; by setting just one lever to the LOCKED position, the controls will be blocked.

Before leaving the operator’s seat, set the safety lock levers to the LOCKED (up) position. This will not allow operation of any hydraulic controls should they be accidentally moved. If the levers are not in LOCKED position and the hydraulic controls are accidentally operated, the machine may move unexpectedly, thus causing serious injury.

Before leaving the machine, lower the bucket to the ground, set the safety lock levers to the LOCKED (up) position, stop the engine, remove the starter switch key and make sure to set the slewing lock pin to the LOCKED position.

SIGNS, SIGNALS AND FLAGMEN Install signs on soft shoulders and ground areas.

Have a flagman direct the operation if necessary.

The operator should note marks and follow signals from the flagman. All personnel should know the meaning of the signs, marks, and signals. Only one flagman should give the signs and signals.

KEEP FIRE AWAY FROM FUEL AND OIL Oil, antifreeze, and especially fuel are highly flammable. Keep the machine away from fire sources. Securely tighten all fuel and oil caps. Keep fuel and oil in the designated storage areas.

Immediately clean the areas where fuel and oil residues are found and dispose of waste in compliance with the relevant regulations.

1-8

1. SAFETY PRECAUTIONS MOUNTING ON OR DISMOUNTING FROM THE MACHINE When getting on and off the machine, always maintain three point contact by using the handrails and step. Inspect and clean handrails, step, and mounting parts. Remove slippery materials, such as lubricants, and mud. Always place the cab entrance door parallel to the crawlers before stopping the engine to dismount.

PAY ATTENTION TO WORKING MACHINE Do not approach a working machine. Make sure to make visual contact with the operator before approaching a working machine.

USE SUITABLE OPTIONAL ATTACHMENTS Only use optional attachments approved by the Manufacturer. Read all the instructions in this manual regarding the optional attachments and make sure to understand and observe them. The use of any unsuitable or non-approved optional attachment can cause severe injury, damage the machine or its components or shorten the machine’s life. Consult your Dealer for the optional attachments available for the machine.

PREVENT FIRES Leaking or spilled fuel, lubricants and hydraulic oil can cause fire and serious injuries. Clean and properly dispose of spills as they occur. Repair or replace all leaking components to prevent fires.

Also, clean the machine regularly removing all debris to help prevent fires. Pay particular attention to removal of leaves, sticks, paper etc.

Keep a fire extinguisher in an accessible area and know how to use it in case of fire.

1-9

1. SAFETY PRECAUTIONS KEEP CLEAN CAB FLOOR AND OPERATOR’S SEAT Do not place any parts and tools in the operator’s cabin to prevent injury due to slipping and stumbling.

Remove any debris from the cab floor, control levers, handrails, etc.

Make sure that all control levers are always clean.

COMMISSIONING INSPECTION Walk around the machine before commissioning it, perform a pre-start inspection of the same and make note of any fault. If any problems are found, repair or replace defective components immediately. Do not start the machine until all faults have been solved.

Always keep the windshield, the work lights and the rearview mirrors clean for a good visibility.

APPLY NOTICE OF MAINTENANCE IN PROGRESS Before performing any inspection or maintenance procedures to the machine, apply to the controls a “Maintenance in progress” tag, to warn persons not to start the machine.

Be sure to inform the supervisor and all operator that the machine is under inspection or maintenance and they will be informed when the machine is ready for normal operation.

USE CAUTION NEAR NOISE If noise is high during operation the loss of hearing can result. Approved hearing protection should be used if personnel will be exposed to high noise levels for a long period of time.

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1. SAFETY PRECAUTIONS AVOID HOT SURFACES AND AREAS Immediately after the machine is operated, the temperature and pressure of the engine coolant, engine oil, and hydraulic oil are very high. Burns may result if caps are removed, or oil, water, or filters are changed under these conditions. Let the components cool down first.

1-11

1. SAFETY PRECAUTIONS

1.4

SAFETY DURING OPERATION

PASSENGERS This equipment is not intended or designed for the transportation of persons. Nobody is allowed on the machine except for the driver. Serious injury or death can result from allowing passengers on or in the machine.

ENGINE START-UP Start engine from the operator’s seat. Do not shortcircuit the starter with the battery to start. This may cause serious injury or damage to the electrical system.

Make sure to fully tighten the screw (1), in order to prevent unintentionally operating the slewing lock pin (2).

SOUND THE HORN WHEN THE ENGINE IS STARTED Sound the horn before starting the engine to alert people the machine is being started. Make sure no one is near the machine.

S CAUTION DO NOT START THE ENGINE IF A “MAINTENANCE IN PROGRESS” TAG HAS BEEN HUNG.

CHECK AFTER THE ENGINE START Be sure to check machine for proper operation after the engine start. Slowly cycle attachments, swing, and travel functions in an area with sufficient space, without obstacles, and personnel. Failure to do so could result in injury or machine damage. Make note of any abnormalities and repair as needed.

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1. SAFETY PRECAUTIONS WARM UP MACHINE BEFORE OPERATION Take sufficient time to warm up the machine, especially in the cold season, otherwise the response of machine to the operation of operating levers is delayed. This may cause injury and/or machine damage.

Set the throttle lever (1) to intermediate position, between low and high idle. Operate the engine for around 5 minutes with no load.

CHECK OPERATING LEVERS PATTERN Check the operating levers pattern before working on the machine.

The figure shows the standard configuration of operating levers according to ISO.

CHECK THE TRAVEL DIRECTION Before activating the control pedals/levers ensure the position of the travel motors.

If the travel motors (1) are on the front side of the machine, the travel control levers must be shifted in the opposite direction (2).

Sound horn before moving the machine to inform any personnel around the machine that the machine is now in operation.

DO NOT HIT THE MACHINE WITH THE ATTACHMENT Check clearance between bucket and machine before operation. Exercise care when operating a bucket near machine.

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1. SAFETY PRECAUTIONS SWINGING Make sure that nobody stays in the slewing range of the machine. Make sure that the area around, above and underneath the machine is clear of persons or objects, before operating it. Before moving the machine sound the horn or send an acoustic signal, so that nobody can approach the dangerous area.

Have a flagman signal operator during operation to help prevent injury to persons or damage to obstacles and equipment.

TRAVELLING ON SLOPES When travelling on slopes, the machine could turn over or slide.

Keep the bucket at a height of 30 ~ 40 cm from the ground and always keep the safety belt fastened.

Never make a change of direction on a slope.

FROZEN OR SNOW-COVERED WORK SITES Use extreme caution when operating the machine on frozen or snow-covered work sites. Operate the machine controls slowly and carefully to avoid sudden movements which could cause the machine to slip or move out of control. Even on the slightest slope, when snow is present or work area is frozen, the machine may unexpectedly move. Snow on shoulders or snow drifts can be much deeper than expected. The machine can easily sink under such conditions. Use extreme caution while operating the machine around or in snow.

Be careful for frozen ground that becomes soft along with the increase of temperature.

TRAVEL Before start-up position the attachment as shown in the illustration. On rough terrain move the machine at slow speeds, and do not turn suddenly. Avoid travelling over obstacles. If this cannot be avoided, keep the attachment close to the ground and travel at extremely slow speed.

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1. SAFETY PRECAUTIONS COVERED OR UNSTABLE WORK SITES Make sure that the work site is stable and capable of supporting the machine weight during its movements. Do not operate the attachment too close to the machine. Operation of the machine on shoulders or filled areas could cause the machine to become unstable presenting accident hazard.

Position the crawler at right angle to shoulder and the travel motors to the rear of the machine, allowing for quick reversal, should the work area become unstable.

OPERATING ON SLOPES When operating on a slope the machine risks to become unstable or unbalanced. Work up and down inclines or slopes, never across. Never slew or turn machine on slopes. Prepare a level and safe platform for the machine operation. Operate controls carefully to prevent sudden movements that may cause the machine to slip or tip over.

WORKING AROUND ELECTRIC POWER LINES If it is suspected that utility lines such as telephone or electrical power lines are in the work area, contact the local utility authority for line location BEFORE beginning work in the area. Use extreme caution around electrical power lines. Keep a sufficient distance away from electrical lines during operation.

See chart below for minimum distances.

Line voltage

Minimum distance metres (ft)

0~50000

≥ 3 (9.84)

50000~200000

≥ 4.5 (14.76)

200000~350000

≥ 6 (19.68)

350000~500000

≥ 7.5 (24.60)

500000~750000

≥ 10.5 (34.45)

750000~1000000

≥ 13.5 (44.29)

1-15

NO

OK

1. SAFETY PRECAUTIONS LIFTING This machine is an excavator. Use extreme caution when lifting or moving heavy loads. Use proper lifting equipment rated at a capacity to handle the load.

Never use the bucket teeth to lift or move heavy loads.

WORKING AROUND UTILITY LINES UNDERGROUND When working in the presumed area of power, water or gas lines under the ground, ask the organization concerned for the actual location and carry out a trial digging. Once located the lines, proceed with your work carefully.

PARKING THE MACHINE Always park the machine on a firm, level surface.

If no level and firm surface is available, block the crawlers with wedges (1), lower the bucket (2) and the dozer (3) to the ground to prevent any unexpected movement of the machine and set the slewing lock pin.

Should the machine be parked on a roadway, move the machine to the shoulder to allow passing of traffic. Also warn other drivers by placing warning signals and lights. To protect the work site, observe the local regulations in force.

RESTRICTED WORK AREAS In work sites with limited height and rotation areas such as tunnels, bridges, around electrical power lines, other utilities, or inside structures, use extreme caution in keeping the machine and its attachment a safe distance away to prevent personal injury and/or equipment or structure damage.

Use a flagman to direct the operator.

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1. SAFETY PRECAUTIONS DO NOT DIG UNDER PRECIPICES Do not dig under a precipice. Rocks could fall or the ground could slide down and this could cause personal injury or machine damage.

WORK WITH SUFFICIENT LIGHTING When working in dark places, turn on the work lights. If required, provide additional lighting facilities to ensure a good visibility.

When a sufficient lighting is impossible due to fog, snow or rain, stop working.

SET LIMITS TO WORKING AREAS Set limits around the working area to avoid collision or personal injury. Before starting to work, check for the presence of personnel or obstacles in the area around the machine. Use a flagman to guide the operator whenever necessary.

CAUTION FOR WORK IN URBAN AREAS It is dangerous to allow people to access the work site.

Make the work site off-limits to other people by installing warning plates.

Make sure to provide a flagman in working areas with heavy traffic to avoid accidents.

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1. SAFETY PRECAUTIONS DO NOT USE NON-SERVICED MACHINE The use of non-serviced machine may cause an unexpected accident or breakdown.

Stop operation of a faulty machine. Make sure to repair any abnormalities before resuming operation.

SLIPPERY GROUND Use caution when operating machine on boards or steel plates. Wet wood or steel ramps become slippery.

Pay special attention when working on ramps.

Provide protective devices against slipping and continue working with extreme care. Also dead leaves and branches may cause slips.

STRENGTHEN MUDDY GROUNDS When working on a soft ground or marshy area, the machine may sink.

To prevent this risk, provide logs or lumber to pave horizontally to reinforce the ground.

Frozen ground becomes soft along with the increase of temperature. Always check the ground conditions, so as to prevent possible accidents.

LOOSENED GROUND AFTER RAIN After rain, there is a possibility of the machine being exposed to the danger of tumbling down or falling down of the machine under the vibration and weight of the machine, due to the loosened shoulder of the road.

Pay attention to non-protected precipices or unstable road shoulders and approach such places with extreme care.

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1. SAFETY PRECAUTIONS LOOSE GROUND AFTER EARTHQUAKE OR DYNAMITING Pay attention to loose precipices or shoulders of roads, and falling rocks. Also pay attention to the unexploded dynamite.

BOOM, ARM AND ATTACHMENTS Give the work you are doing your undivided attention. Make certain the attachment being used is suited for the job at hand. Make certain of obstacles in the work area and operate the machine within those limits. If necessary have a flagman signal the operator to prevent injury to persons or damage to the machine or obstacles in the work area.

Before leaving the operator’s seat, lower the attachment to the ground and set the safety lock lever to the LOCKED (up) position.

SECURE ATTACHMENT Stabilize all attachments removed from the machine to prevent the attachment falling over.

1-19

1. SAFETY PRECAUTIONS

1.5

INSPECTION AND MAINTENANCE SAFETY

UNDERSTAND INSPECTION/MAINTENANCE PROCEDURES Incorrect maintenance may cause not only damages on the machine, but also injury.

Before performing any maintenance operation, it is necessary that you read and understand the instructions given in the operator’s manual.

MEETING PRIOR TO WORK To prevent any accidents or injury due to errors, have a meeting before start working. When a flagman is provided, make sure that all signals are understood accordingly.

ORGANIZE AND CLEAN UP WORKING AREA Organize and clean up the working area. Remove any obstacles and also remove any grease, oil, paint, broken pieces, etc., from the working area to avoid injury.

APPLY NOTICE OF MAINTENANCE IN PROGRESS Before performing any inspection or maintenance procedures to the machine, apply to the controls a “Maintenance in progress” tag, to warn persons not to start the machine. Inform the supervisor and all other drivers that the machine is under inspection or maintenance and that they will be informed when the machine is ready for operation.

1-20

1. SAFETY PRECAUTIONS SUITABLE TOOLS AND ATTACHMENTS Always use tools that are designed for the task at hand. Know the correct use of the tools and material before starting any maintenance or inspection procedure.

POSITION THE WORKING ATTACHMENT PROPERLY Before starting any inspection or maintenance procedure, park the machine on a level and firm ground in the hydraulic oil check position and lower the attachment to the ground. If this is not possible, secure the boom, arm and attachment to help prevent sudden movements.

Before leaving the operator’s seat, lower the attachment to the ground and set the safety lock lever to the LOCKED (up) position.

CLEAN THE MACHINE Keep the machine clean and free of debris, excess or spilled lubricants, fuel and fluids. Use approved solvents, detergents and water to clean the machine and its components on a regular basis. Be careful not to allow water to reach electrical components.

Serious damage can occur to the electrical system by allowing water to reach the electrical components. Never clean inside of cab, or electrical components with pressurized water or steam.

STOP THE ENGINE Before starting any inspection or maintenance operation on the machine, make sure that the engine has been stopped and set the safety lock lever(s) to the LOCKED (up) position. Failure to stop engine could result in serious bodily injury or death.

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1. SAFETY PRECAUTIONS REFUELLING Move the machine to a well ventilated area for refuelling. Use only specified fuel as described in the MAINTENANCE section of this operator’s manual.

Immediately clean up all spilled fuel and dispose of waste properly. After refuelling is complete, securely tighten fuel cap.

Never use the fuel for cleaning.

SUPPORT THE MACHINE If it is necessary to raise the machine for inspection or maintenance operations, always support the same by positioning it as shown in the illustration and use safety supports (1) with sufficient capacity or safety wedges (2) under the crawlers or wooden boards.

Never inspect or perform maintenance procedures under a raised machine that is not sufficiently supported.

HYDRAULIC PRESSURE Under normal conditions, all circuits of the hydraulic system are under extreme pressure. When inspecting for leaks, use a small piece of cardboard, wood or metal to locate leaks. Also small (pinhole) leaks can be dangerous if hydraulic oil comes into contact with skin or eyes.

Wear approved safety goggles or face shields, gloves, a hard hat, safety shoes and work clothes during all inspection and maintenance procedures.

Seek for immediate medical assistance if injury occurs.

PRESSURIZED FLUIDS AND LUBRICANTS Always release pressure from hydraulic tank, engine coolant, fuel system and all systems containing pressure before removing any caps or components.

Escaping fluid under pressure can penetrate the skin causing serious injury.

Be cautious of hot fluids and gases from engines that have just been stopped. Carry out inspection and maintenance operations only after the systems have cooled down.

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1. SAFETY PRECAUTIONS CARE FOR PROPER VENTILATION Maintenance for the machine indoor or in a place with poor ventilation, may cause poisoning by gas.

Pay special attention to ventilate any exhaust gas, fuel, cleaning oil, paint or similar articles.

Ensure proper ventilation in the working area when the machine is operated indoors. Provide a fan for ventilation, if required.

PREVENTIVE MEASURES AGAINST FIRE During maintenance, it is unavoidable to handle flammable materials such as batteries, fuel, lubricating oil, etc.

To prevent fire: • use a nonflammable cleaning oil; • extinguish any naked flame capable of causing fires; • provide appropriate fire fighting equipment such as a fire extinguishers; • refrain from smoking during maintenance work; • keep away all flammable materials during grinding or welding.

USE APPROVED WORK LIGHTS Only use approved work lights when performing inspection and maintenance procedures to prevent possible fires or explosions. Certain types of lights cannot be used as there is a risk of some types of liquids or gases inflaming.

DO NOT HEAT HYDRAULIC EQUIPMENT OR PIPING Hot hydraulic components or piping will cause gas expansion, which can easily catch fire.

Dangerous works like welding, brazing, torch heating, etc. on components or ducts of the hydraulic system, or in the vicinity of it are not allowed.

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1. SAFETY PRECAUTIONS WORKING ON HIGH PLACES To work on high places can generate danger of falls.

Be careful not to approach edges.

• Make sure to use the appropriate equipment, such as: ladders, man lifts etc.

In addition, strap yourself to the proper equipment accordingly.

• Avoid spillage of any oil or grease.

• Do not leave any tools around the working area.

• Use extreme caution to avoid slipping while walking.

• Never jump into or from climbing equipment. Use a step-ladder or handrail and securely maintain a three point contact while mounting or dismounting at all times.

• Make sure to read the man lift equipment operator’s manual before using.

• Comply with climbing equipment weight ratings.

DO NOT DROP TOOLS AND PARTS Dropping of any tools and parts in the working area may cause injury or faulty machine operation.

Do not leave tools or articles in the working area or component compartments. Be sure to store all tools properly when the work is completed.

ELECTRIC SYSTEM Before performing any inspection work or maintenance on the electrical system, or performing any welding procedures, disconnect the negative (-) cables from the battery terminals. Not disconnecting the negative (-) cable could cause extensive damage to the electrical system.

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1. SAFETY PRECAUTIONS CAUTION WITH MODIFICATIONS We will not be liable for any injury or damages due to equipment modification without approval.

When any modification is intended, consult your Dealer.

AFTER COMPLETION OF MAINTENANCE WORK Always, be sure to check the machine for proper functioning when any maintenance work is completed: • once maintenance operations are completed, let the engine idle and check for leaks or anomalies; • slowly operate each machine control to confirm proper operation; • increase the engine speed gradually, and again check for leakages and abnormalities; • operate each control lever normally to confirm correct operation.

DISPOSE OF WASTE PROPERLY Dispose of oils, fuel, coolant, solvents, filters, batteries etc. according to federal, state and local codes and regulations regarding hazardous waste disposal. Contact local authorities for proper disposal methods of such materials.

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1. SAFETY PRECAUTIONS GENERAL GUIDELINES FOR WELDING Welding work must be performed by a certified welder with sufficient experience. In addition, safety practices must be followed by any personnel involved in such work. Identify all cracks or areas to be welded by thoroughly cleaning the suspected surface, remove paint and check with dye penetrant or magnetic particle tester. The life expectancy of the welded area depends on the work quality and the attention given to details during welding.

• Avoid welding structures with surface temperatures below 16 °C (61 °F).

If needed, preheat surface with a hand torch. In cases where the machine components are extremely cold, we recommend to bring the components inside and to allow them to warm up to 16 ~ 20 °C (61 ~ 68 °F) for at least 12 hours prior to welding.

• Remove paint from any surface to be heated or welded. Painted surfaces produce unhealthy gases when heated or welded. Use mask and proper skin protection when removing paint from any surface. When removing paint sanding, do not breath the generated dust. Be sure to use plenty of soap and water to rinse the surface to be welded, since chemicals will generate unhealthy gases when heated and/or welded.

S WARNING HAVE A FIRE EXTINGUISHER ON HAND AT ALL TIMES WHILE GRINDING, HEATING, OR WELDING. BE SURE TO CLEAN OIL AND/OR FLAMMABLE MATERIALS FROM ANY SURFACE TO BE CUT. PROTECT ALL FLAMMABLE PARTS AND SURFACES FROM SPARKS AND/OR FLAMES. BE SURE TO PERFORM WORK IN A WELL VENTILATED AREA. KEEP SPARKS AND FLAMES AWAY FROM PAINT AND/OR SOLVENT. KEEP SPARKS AND FLAMES FROM CYLINDER RODS, SEALS, ELECTRICAL WIRES, AND/OR HYDRAULIC HOSES.

1-26

1. SAFETY PRECAUTIONS ADJUSTING CRAWLERS TENSION The grease used to adjust the crawler shoe tension is under extreme pressure in the cylinder. Use extreme caution when adjusting crawler tension.

Keep face, hands and legs away from grease nipples.

Carefully and slowly loosen the grease nipple when adjusting crawler tension. Do not loosen the grease fitting more than one turn.

PAY ATTENTION TO BROKEN PIECES WHEN HAMMERING Flying particles may cause injury when hammering hard metal parts, such as pin, edge, tooth, bearing, etc.

Wear protective clothes such as protective glasses, safety hat, etc. during maintenance.

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1. SAFETY PRECAUTIONS

1.6

PRECAUTIONS DURING BATTERY USE

WEAR PROPER PROTECTIVE CLOTHES Wear a long sleeve shirt, gloves and approved safety glasses or face protection when working with or around batteries. Battery electrolyte (acid) will cause severe burns if allowed to make contact with clothing, skin or eyes. Should electrolyte (acid) come in contact with clothes, skin or eyes, immediately remove effected clothing, flush area with clean water for 15 minutes and get prompt medical attention.

KEEP AWAY FROM FIRE OR FLAMES Never allow batteries in the vicinity of fire or naked flames and do not smoke when working with batteries. In batteries, an explosive mixture of hydrogen and oxygen is released. Always work with batteries in a well ventilated area.

USING BOOSTER CABLES • When using the another machine’s or vehicle’s battery to boost a discharged battery, make sure that the machine or vehicle does not come into contact with the disabled machine.

• Ensure the position of positive (+) and negative (-) terminals on booster battery and battery of disabled machine, before connecting booster cables.

• Connect the positive (+) cable first, then the negative (-) one.

• Disconnect the negative (-) cable first, then the positive (+) one.

A. Battery charging B. Battery discharging C. Red cable D. Black cable E. Upper structure of the stopped machine Cable connecting order: 1>2>3>4 Cable disconnecting order: 4>3>2>1

1-28

1. SAFETY PRECAUTIONS

S WARNING IMPROPER BOOSTER CABLE CONNECTIONS CAN CAUSE AN EXPLOSION RESULTING IN PERSONAL INJURY. CONNECT BOOSTER CABLES FOLLOWING PROCEDURE:

USING

• CONNECT BOOSTER CABLE TO POSITIVE (+) BATTERY TERMINAL OF DISCHARGED BATTERY. CONNECT OTHER END OF BOOSTER CABLE TO POSITIVE (+) BATTERY TERMINAL OF NORMAL BATTERY. • CONNECT OTHER BOOSTER CABLE TO NEGATIVE (-) BATTERY TERMINAL OF NORMAL BATTERY. CONNECT THE OTHER END OF THE BOOSTER CABLE TO THE UPPER STRUCTURE OF THE TROUBLED MACHINE. • START ENGINE AND REMOVE BOOSTER CABLES IN REVERSE ORDER. OTHER PRECAUTIONS • Pay attention to danger of sparks triggered off by unintended contact between the positive (+) terminal of battery and the machine body with a tool, etc.

• Make sure to correctly tighten the caps of the battery elements.

• Securely tighten up the battery terminals.

• Leave the waste battery to a specialist for disposal.

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1. SAFETY PRECAUTIONS

1.7

WARNING LABELS AND SAFETY DECALS

Warning labels and safety decals are applied to the machine to remind users and personnel of specific safety instructions to be observed with the various machine parts. See the following examples of warning labels and safety decals along with their location.

1.7.1

NOTES FOR WARNING LABELS AND SAFETY DECALS

• Do not remove the warning labels and safety decals.

• Confirm whether warning labels can be easily read.

If words or illustrations are illegible, clean off or replace the labels.

• Use a cloth, water and a detergent for cleaning.

Never use organic solvents or gasoline.

• If warning labels are damaged, missing or illegible, replace them with new ones.

Contact your Dealer for new safety labels.

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1. SAFETY PRECAUTIONS 1.7.2

LOCATION OF WARNING LABELS AND DECALS

F47095

A. Canopy B. Cab

1-31

1. SAFETY PRECAUTIONS

F47096

C. Oil tank area

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1. SAFETY PRECAUTIONS DECAL OF ATTACHMENT SAFE AREA OF OPERATION Located on both sides of the arm.

Make sure the area is clear of obstacles or persons before operating the machine. Always look around before you start the swing operation. Make sure that nobody stays in the operation range of the machine.

Sound horn before moving the machine.

CRAWLER ADJUSTER DECAL Located on crawler frame.

It indicates that it is obligatory to consult the operator’s manual before adjusting the crawler idler.

Danger of severe injuries.

DECAL, COUNTERWEIGHT SAFE OPERATING AREA Located on the counterweight.

Make sure that the personnel standing in the work site are outside the operating range of the machine before starting it. Sound horn.

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1

2

3

1. SAFETY PRECAUTIONS ENGINE STOP DECAL Located on the engine guard.

It indicates that it is obligatory to stop the engine before opening the engine guard.

Danger of severe injury due to rotating parts such as fans, pulleys and belts.

PRESSURIZED FLUIDS AND LUBRICANTS Located on the radiator.

Always release pressure from hydraulic tank, engine coolant, fuel system and all systems containing pressure before removing any caps or components. Be cautious of hot fluids and gases from engines that have just been stopped. Carry out inspection and maintenance operations only after the systems have cooled down.

ELECTRICAL LINE SAFETY DECALS; SAFETY SYSTEMS Located on the roof (canopy version) or on the left window of the cab (cab version).

It warns about danger in the case of work near electrical lines.

It is imperative for the operator, when leaving the cab with the engine running even for a very short time, to set the safety lock lever to the LOCKED position. Controls are thereby disconnected and any accidental equipment movement is impossible.

WINDOW LOCK DECAL (ON CAB MODELS ONLY) Located inside the front window.

4

5

6

7

It indicates the danger of injury deriving from incorrect block of front windshield in open position.

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1. SAFETY PRECAUTIONS WINDSHIELD WIPER CONNECTOR TAG Located in the upper part of the cab next to the connector.

8

It indicates to disconnect the windshield wiper before removing the lower cab window.

FUEL TANK Make sure that the tank indicated by this decal only contains fuel.

BATTERY DECAL Located on the battery.

The battery releases highly flammable gases. Do not produce sparks and naked flames near a battery, to prevent this from catching fire and explode.

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9

10

1. SAFETY PRECAUTIONS DOZER / TRACK WIDTH ENLARGEMENT DECAL (ONLY ON CX18B MODELS) Located on seat stand cover.

It indicates to consult the Operator’s Manual before using the lever for the selection of dozer control or track width enlargement.

HYDRAULIC OIL TANK Make sure that the tank indicated by this decal only contains hydraulic oil.

ENGINE STOP DECAL It indicates that it is obligatory to stop the engine before performing any operation due to moving parts such as pulleys and belts.

Danger of severe injuries.

1-36

11

12

13

1. SAFETY PRECAUTIONS CONTROL LOCK

14

Located on seat stand cover.

Indicates the presence of the safety lock lever.

UPPER STRUCTURE SLEWING LOCK Directly located on the support of the upper structure slewing lock pin on the floor of the operator’s compartment.

15

Indicates the presence of the upper structure slewing lock and unlock pin.

TAG MAINTENANCE IN PROGRESS It is obligatory for maintenance operators to apply a tag warning about the incomplete efficiency of the machine and the presence of personnel performing maintenance in hidden positions. This tag must be applied to the left control lever or to the cab door.

1-37

16

1. SAFETY PRECAUTIONS LIFTING POINT DECAL Fastening means must be attached here when the machine is to be lifted.

17

F47098

BREAK THE GLASS TO EXIT (CAB ONLY) In case of emergency with the cab door locked, break the glass to exit.

18

Located on inside of front and rear window.

F47099

COOLING LIQUID TANK Make sure that the tank indicated by this decal only contains cooler liquid.

19

F47097

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1. SAFETY PRECAUTIONS

1.8

FORBIDDEN USE

Here are some examples of a forbidden use of the machine. The machine should never be used in this way also by the most experienced operators. Such abuse and misuse of this machine and its attachments can result in serious injury, death, DO NOT USE TRACTIVE FORCE OF THE MACHINE FOR LOADING THE BUCKET ATTACHMENT Doing so will exert excessive force on the machine structure, front end attachments and could cause severe equipment damage. Use crawlers for normal travel operations only.

DO NOT USE THE ROTATION AND SLEWING FORCE OF THE MACHINE Doing so will exert excessive force on the machine structure, front end attachments and shorten the life of the rotation and slewing system of the machine.

Also, serious injury or death could result from such operations.

DO NOT PERFORM HAMMERING OPERATIONS WITH THE BUCKET Performing operations such as hammering and piling will cause extensive damage to the machine and its components. Also, serious injury or death could result from such operations.

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severe equipment damage and shortened service life of the machine. Under no circumstance should any of these operations be attempted. Use common sense in understanding and following the instructions for use given in this manual.

1. SAFETY PRECAUTIONS DO NOT USE THIS MACHINE FOR ANYTHING OTHER THAN ITS INTENDED PURPOSE This machine is designed and manufactured for digging, loading and ground levelling operations only. Any other use could cause excessive strain to the machine, its components and systems and could cause serious accidents, even mortal, to the driver and to the personnel working near the machine.

DO NOT OPERATE BUCKET AND ARM CYLINDERS TO STROKE END REPEATEDLY If bucket and arm cylinders are forcibly driven to stroke end, to clean debris from the bucket, this will cause the vibration of the bucket cylinders and consequently their damaging.

Use high pressure water or manually remove stuck material from the bucket.

DO NOT OVER EXERT THE MACHINE Know the limitations of the machine and its attachments and operate the machine within those specifications.

Do not exceed the values specified in the carrying capacity table.

Never tip or raise the machine to obtain power to move material.

This could cause extensive damage to the machine and its components as well as result in serious bodily injury or death.

MAKE SURE THAT THE DOZER DOES NOT HIT OBSTACLES Pay attention that the dozer does not hit any obstacles such as rock lumps.

It causes damage to the dozer and cylinder.

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1. SAFETY PRECAUTIONS BE CAREFUL WHEN RETRACTING THE ATTACHMENT When the attachment is retracted for travel or transport, pay attention that the bucket does not to hit the dozer.

DO NOT SUPPORT THE MACHINE ON ONE SIDE WITH THE DOZER When the dozer is used as a stabilizer, do not support the machine at one end of the dozer only, but at both ends.

CAUTION WITH DEEP EXCAVATIONS During deep excavations, pay attention to the dozer in front. The boom cylinder could come in contact with the dozer.

Place the dozer at the back of the machine for deep excavations, unless the working area does not permit it.

1-41

1. SAFETY PRECAUTIONS

1.9

PRECAUTIONS AT THE END OF DAILY WORK

Perform all of the following procedures after each work shift is complete, to insure the machine is in optimal operating condition for the next work shift or job site: • move the machine to a level and firm ground; • lower the bucket to the ground; • fill the fuel tank to the “Full” mark to reduce air volume and condensation (moisture). This reduces the risk of ice and rust building in the fuel tank and prevents several problems at start-up and during operation; • close and lock all windows in place in order to prevent damage to the electrical systems of the machine due to water or moisture (for cab version only); • thoroughly clean and inspect the machine; • While washing the machine, pay attention not to direct the water jet directly onto the grids of the side doors, in order to prevent damage to the internal electrical components; • perform lubrication maintenance and repair or replace any problem areas found before restarting the machine; • if operating the machine in cold climates, it may be necessary to remove the batteries from the machine and store in a warm well ventilated area.

Install the batteries in the machine before next start up. This will help prevent premature battery deterioration; • remove the starter key, lock all doors with the key and lock all access covers.

1-42

1. SAFETY PRECAUTIONS

1.10

TRANSPORTATION

Use the following general guidelines for loading or unloading the machine on a transportation vehicle.

The machine must be loaded and unloaded on firm, level ground, away from the road shoulder. Do not use the attachments to load or unload the machine onto/from the trailer.

When necessary, use a ramp capable of bearing the machine’s weight. Check the ramp’s width, length and thickness to secure the loading/unloading work.

And when much warp appears on the ramp structure, support them with safety blocks or alike.

Remove any mud, oil and grease from the ramp surface as well as from crawlers in order to prevent the machine from slipping.

Do not change the travelling direction on the ramp.

When required, back down the machine to the ground, reposition and try again.

Always use low travel speed for loading or unloading onto/from the trailer.

After loading the machine, stop the engine and set the safety lock lever from the UNLOCKED (B) to the LOCKED (up) position (A).

1-43

1. SAFETY PRECAUTIONS Bring the slewing lock pin (3) from the UNLOCKED (B) to the LOCKED (A) position.

Use cables or wire ropes (1) with sufficient length to secure front and rear of the machine to trailer.

Provide blocks to the machine crawlers, to avoid any movement of the machine.

Protect wire ropes against edges with pads (2).

While transporting, observe the relevant regulations, keeping safety in mind.

Before transporting the machine, place the bucket against the dozer so that any involuntary rotation of the upper structure is prevented.

Choose the travel path taking the overall dimensions of the truck used for machine transport into consideration.

Refer to section “5. TRANSPORTATION” for the details of loading, unloading and fixing procedures of the machine.

A. Overall height B. Overall length

1-44

1. SAFETY PRECAUTIONS

1.11

TOWING THE MACHINE

NOTE: for CX15B models, the hook shown in the figure is provided but must not be used for towing; for CX18B models, instead, the hook is not provided.

Should the machine become stuck in soft soil, it may be necessary to tow it. Attach a metal cable or a chain with sufficient strength to the lower frame.

Attach other end to the vehicle used for towing.

Operate the machine’s travel lever in the proper direction while towing with the other vehicle.

S WARNING WHILE TOWING, DO NOT ENTER THE AREA BETWEEN THE MACHINE AND TOWING VEHICLE. DO NOT APPLY A SHOCK LOAD ONTO THE TOWING ROPE. DO NOT USE EYES ON MACHINE LOWER FRAME TO TOW MACHINE. KEEP THE WIRE CABLE HORIZONTAL, AND PERPENDICULAR TO THE CRAWLER FRAME. TOW THE MACHINE SLOWLY AT LOW SPEED. FOR TOWING THE MACHINE BODY, APPLY PADS AT THE CORNERS OF THE CRAWLER FRAME TO PREVENT THE METAL WIRE AND THE CRAWLER FROM BEING DAMAGED. NOTE: do not tow the machine using the brackets welded to the lower plates of the lower frame. These brackets are provided for towing lightweight objects.

1-45

1. SAFETY PRECAUTIONS

1-46

2. MACHINE FAMILIARIZATION

2-1

2. MACHINE FAMILIARIZATION

2-2

2. MACHINE FAMILIARIZATION

2.1

MACHINE FAMILIARIZATION

All operators, service mechanics and personnel responsible for operation, inspection and maintenance of the machine should become thoroughly familiar with the controls and components and their functions before working with or on this equipment. Study the information in this section to become familiar with the controls and components of this machine.

2.2

GENERAL NOMENCLATURE

2.2.1

FRONT, REAR, RIGHT AND LEFT

In this manual, the “front” (A), “rear” (B), “right” (D) and “left” (C) directions are based on the conditions where the travel motors are positioned at the rear (1) and the operator is facing the direction in which the machine advances (forward).

2.2.2

MAIN COMPONENTS

The nomenclature drawing below points out the location of the main components of the hydraulic excavator. Study these areas and locate these components on the machine. Specific information regarding these components are explained on the following pages of this section.

2-3

2. MACHINE FAMILIARIZATION

1. Bucket

16. Idler adjuster

2. Link rod

17. Dozer

3. Lever

18. Dozer cylinder

4. Bucket cylinder

19. Operator’s seat

5. Arm

20. Swing cylinder

6. Arm cylinder

21. Control valve

7. Boom

22. Pump

8. Fuel tank

23. Engine

9. Boom cylinder

24. Air filter

10. Counterweight

25. Battery

11. Hydraulic oil tank

26. Radiator

12. Crawler

27. Muffler

13. Travel motor

28. Left-hand safety lock lever

14. Canopy

29. Right-hand safety lock lever (only on models with canopy)

15. Lower roller

30. Upper structure slewing locking pin

2-4

2. MACHINE FAMILIARIZATION

2.3

OPERATOR’S CAB NOMENCLATURE

The operator’s cab nomenclature, see figure below, points out locations of operator controls in the hydraulic excavator operator cab. Study these areas and locate these components on the machine.

Specific information regarding these components are explained on the following pages of this section.

1. Left-hand safety lock lever

8. Breaker/nibbler control pedal

1A. Right-hand safety lock lever (only on models with canopy)

9. Horn

2. Start-up key

10. Dozer/track width enlargement control lever (only on CX18B models)

3. Direction-of-travel control lever

11. Throttle control lever

4. Travel speed selection button (only on models with 2-speed travel motors)

12. Dozer/track width enlargement selection lever (only on CX18B models)

5. Right hydraulic control lever

13. Right instrument panel

6. Left hand pilot valve

14. Operator’s seat

7. Lifting/slewing control pedal

15. Upper structure slewing locking pin

2-5

2. MACHINE FAMILIARIZATION

2.4

INSTRUMENT AND CONTROL NOMENCLATURE

The following information provides a brief description and function of the components and controls of the hydraulic excavator.

All personnel using this machine must read and understand this instructions before starting operation or working on this machine.

2.4.1

INSTRUMENT PANEL

The cluster consists of the following instruments.

TYPE A GAUGES

B WARNING LAMPS

C INDICATOR LAMP

No.

DESCRIPTION

1

FUEL LEVEL GAUGE

2

PREHEATING LAMP

3

HOUR COUNTER

4

BATTERY CHARGE LAMP (red)

5

ENGINE OIL PRESSURE LAMP (red)

6

COOLANT TEMPERATURE LAMP (red)

7

HIGH-SPEED TRAVEL LAMP (only on models with 2-speed travel motors)

A. GAUGES 1. FUEL LEVEL GAUGE When the fuel level gauge needle reaches the reference mark (E), the fuel tank is empty.

Immediately refuel the machine.

2. PREHEATING LAMP Engine preheating is activated by turning the starter switch key to ON (HEAT) (the lamp turns on). When the control lamp turns off, it is possible to start the engine.

2-6

2. MACHINE FAMILIARIZATION 3. HOUR COUNTER The hourmeter records the machine working hours.

B. WARNING LAMPS

S CAUTION When one of these warning lamps turns on, immediately stop working. Then investigate the cause for it, and carry out appropriate inspection and maintenance referring to the section MAINTENANCE. 4. BATTERY CHARGE LAMP (red) It warns about a fault in the battery charging system during engine running. This lamp turns on when the starter key is turned to ON, and must turn off after the engine has been started. If this lamp does not switch off, the battery does not charge correctly.

Check the charging system.

5. ENGINE OIL PRESSURE LAMP (red) The lamp turns on when the starter switch key is turned to ON, and must turn off after the engine has been started. During machine operation, if the engine oil pressure drops excessively, this lamp turns on. Stop the engine and check the quantity of engine oil.

S CAUTION The engine may undergo severe damage if the machine is operated while this lamp is on.

2-7

2. MACHINE FAMILIARIZATION 6. COOLANT TEMPERATURE LAMP (red) If the coolant temperature rises excessively, a warning lamp turns on.

The coolant temperature may rise irregularly, if the engine is overloaded.

S CAUTION The engine may undergo severe damage if the machine is operated while this lamp is on.

If the engine is overheating, stop operation immediately and let the engine idle, to lower its temperature.

Once the coolant has cooled down, stop the engine.

Check the coolant quantity, the fan belt tension and the radiator filter clogging, etc.

S WARNING DO NOT PERFORM ANY KIND OF MAINTENANCE ON AN ENGINE THAT HAS JUST STOPPED WORKING. IMMEDIATELY AFTER ENGINE STOP, FLUIDS AND SURFACES WILL BE EXTREMELY HOT. ALLOW THE ENGINE TO COOL, BEFORE PROCEEDING TO INSPECTION AND/OR MAINTENANCE.

C. INDICATOR LAMP This lamp indicates the working conditions.

7. HIGH-SPEED TRAVEL LAMP (yellow) This lamp turns on when the travel speed is switched to high. The travel speed selector switch is located on the grip of the right travel lever.

IMPORTANT: this lamp is only provided on models with 2-speed travel motors.

2-8

2. MACHINE FAMILIARIZATION 2.4.2

SWITCHES

1. Starter switch

3. Horn switch

2. Travel speed selector switch (only on models with 2-speed travel motors)

4. Working light switch 5. Wiper switch (on cab models only)

2-9

2. MACHINE FAMILIARIZATION 1. STARTER SWITCH This switch is used to start or stop the engine.

(1) OFF: In this position, the electric system is not powered and the engine is stopped.

(2) ON (HEAT): In this position all electrical circuits are powered.

Maintain the key in this position while the machine is operating.

(3) START: To start the engine, turn the key to the start position, then release it so that it automatically returns to ON. NOTE: by turning the starter switch key to ON (HEAT), all lamps on the right instrument panel turn on (lamp test) for approximately 3 seconds, except for the following warning lamps: • engine oil pressure lamp, which remains on until the engine is started.

If no lamp turns on during the CHECK function, there could be a fault in the electric system.

2-10

2. MACHINE FAMILIARIZATION 2. TRAVEL SPEED SELECTOR SWITCH (only on models with 2-speed travel motors) Use this switch to select HIGH (2nd gear) or LOW (1st gear) travel speed. When moving the starter key from ON to OFF, the travel speed automatically returns to LOW. Select the desired speed before starting travelling.

S WARNING TRAVEL WITH THE MACHINE IN LOW SPEED ON A SLOPE AND WHEN LOADING/UNLOADING THE MACHINE ONTO/FROM A TRUCK/TRAILER. A SUDDEN CHANGE OF THE MACHINE’S TRAVEL SPEED MAY CAUSE THE MACHINE TO ROLL OVER.

T Select LOW (1st speed) when travelling on rough or soft terrains, on slopes, in narrow places, when powerful tractive force is required, or loading or unloading from a truck/trailer.

U Select HIGH (2nd speed) when travelling on flat, hard grounds. The lamp turns on.

3. HORN SWITCH Depress the symbol of this switch on top of left control lever to sound the horn.

S CAUTION Sound the horn before starting engine, travelling, slewing or operating the attachments.

2-11

2. MACHINE FAMILIARIZATION 4. WORK LIGHT SWITCH This switch activates the boom work lights.

OFF: switched off ON: switched on

5. WIPER AND WASHER SWITCH (on cab models only) This switch activates the wiper and washer liquid.

WASH (left wash): the water jet for washing activates.

OFF: stop.

ON: windscreen wiper operation.

WASH (right wash): wipers and washer liquid jet activate.

NOTE: the windscreen washer motor can get damaged if the windscreen washer operates continuously over 20 seconds, or without liquid.

2-12

2. MACHINE FAMILIARIZATION 2.4.3

LEVERS AND PEDALS

1. Safety lock lever

7. Swing control pedal

2. Upper structure slewing locking pin

8. Optional attachment control pedal (hydraulic breaker and nibbler)

3. Control levers

9. Dozer/track width enlargement selection lever (only on CX18B models)

4. Travel control levers 5. Throttle control lever 6. Dozer/track width enlargement control lever (only on CX18B models)

2-13

2. MACHINE FAMILIARIZATION 1. SAFETY LOCK LEVER(S) In models provided with a cab there is only one lever on the left side (no access on the right side), while the models with canopy are provided with two safety lock levers, one on each side.

The safety lock lever(s) is provided to lock all attachments and prevent any unexpected machine movement due to an accidental shifting of the control levers.

S WARNING ALWAYS SET THE SAFETY LOCK LEVER(S) TO THE LOCKED (UP) POSITION BEFORE LEAVING THE OPERATOR’S SEAT. NOTE THAT, EVEN WITH THE SAFETY LOCK LEVER IN LOCKED (UP) POSITION, THE FUNCTIONS OF DOZER, TRACK WIDTH ENLARGEMENT (ONLY FOR CX18B MODELS) AND BOOM ARE STILL ENABLED.

A. CONTROL LOCK With the lever(s) in the LOCKED position, the controls for the attachment and for the rotation of the upper structure are locked.

NOTE: the slewing and optional attachment controls are locked by means of the cover on the pedal. The controls for dozer, track width enlargement (only for CX18B models) and swing cannot be blocked.

B. CONTROL UNLOCK With the safety lock lever(s) in UNLOCKED position, all functions are enabled again.

2. UPPER STRUCTURE SLEWING LOCKING PIN The upper structure slewing lock pin is a device which locks the slewing of the upper structure while parking.

S WARNING ALWAYS SET THE PIN INTO LOCK POSITION (DOWN) BEFORE LEAVING THE OPERATOR’S SEAT.

2-14

2. MACHINE FAMILIARIZATION

A. SLEWING LOCK Set the pin (1) into lock position.

B. SLEWING UNLOCK Set the pin (1) into unlock position. Tighten the knob (2) to prevent an accidental movement of the pin while working.

3. CONTROL LEVERS (ISO CONFIGURATION) The control levers activate the functions illustrated on the right.

S WARNING • CONFIRM FOR SAFETY AROUND THE WORKING AREA. ALSO ENSURE THAT EACH LEVER OPERATION IS IN ACCORDANCE WITH THE OPERATING PATTERN INDICATED ON THE LABELS. • IF THE CONFIGURATION ON THE DECAL DOES NOT CORRESPOND TO THAT OF THE CONTROL LEVERS, IMMEDIATELY CHANGE THE DECAL TO PREVENT ACCIDENTS AND/ OR INJURY. NOTE: the control levers return to the NEUTRAL position when released, and the movement of the attachment is stopped.

All functions can be activated simultaneously.

LEFT CONTROL LEVER 2

E Arm out

RIGHT CONTROL LEVER 1

F Retracted arm 4

G Slewing left

A Boom down B Boom up

3

H Slewing right

C Loaded bucket D Dumped bucket

2-15

2. MACHINE FAMILIARIZATION 4. TRAVEL CONTROL LEVERS The travel control levers are located in front of the operator’s seat. The travel levers are used to move forward and backward the left or right machine crawler.

S WARNING USE CAUTION TO AVOID COMING IN CONTACT WITH OTHER MACHINES WHILE TRAVELLING. BE SURE TO KNOW THE LOCATION OF THE TRAVEL MOTORS BEFORE OPERATING THE TRAVEL FUNCTION. When travel lever is activated, the relevant alarm sounds to warn people nearby the machine.

S CAUTION If the travel alarm does not sound after the travel lever is operated, immediately stop the engine and contact the nearest authorized Dealer for repair.

Operation with a travel alarm failure may cause severe accidents resulting in injury or death.

A. To travel forward (push both control levers forward at the same time).

B. To travel in reverse (pull both control levers back at the same time).

C. Neutral position (release the levers to the central position to stop travel).

Travel control pedals: 1. Forward travel 2. Reverse travel NOTE: the travel alarm function is optional.

5. THROTTLE CONTROL LEVER This lever is located on the right side of the operator’s seat and is used to adjust the engine rpm.

A. By shifting the lever completely forwards, the rpm decreases to the minimum.

B. By shifting the lever completely rearwards, the rpm increases to the maximum.

2-16

2. MACHINE FAMILIARIZATION 6. DOZER/TRACK WIDTH ENLARGEMENT CONTROL LEVER (CX18B) CX15B:this lever only controls the dozer.

CX18B:this lever may control the dozer or the track width enlargement according to the selection made with the dozer/track width enlargement selection lever.

This lever is located on the right side of the operator’s right instrument panel and it is used to select the dozer control or the track width enlargement control (CX18B).

S WARNING THE DOZER/TRACK WIDTH ENLARGEMENT FUNCTION IS ALWAYS ACTIVE, EVEN WITH THE SAFETY LOCK LEVER IN LOCKED (UP) POSITION. DO NOT TOUCH THE DOZER/TRACK WIDTH ENLARGEMENT LEVER UNLESS ONE OF THESE FUNCTIONS MUST BE OPERATED. DOZER OPERATION This lever allows the operator to raise or lower the dozer (1).

E. Lower the dozer (push the lever forwards) F. Raise the dozer (pull the lever backwards) CRAWLER TRACK WIDTH ADJUSTMENT (CX18B) This lever changes the track width (crawler).

G. Push the lever forwards to narrow the crawler track width: 1003 mm (39.49 in).

H. Pull the lever backwards to enlarge the crawler track width: 1333 mm (52.48 in).

IMPORTANT: it is recommended to operate the machine with a large track width to make the machine more stable during operation.

Use the narrower track width only when the work site space is limited.

2-17

2. MACHINE FAMILIARIZATION 7. SWING CONTROL PEDAL This pedal allows the boom to slew.

CX15B:breaker and nibbler is optional CX18B:breaker and nibbler is standard

S WARNING LOCK OPTIONAL PEDAL IF THIS FUNCTION IS NOT USED. VERY SERIOUS ACCIDENTS MAY OCCUR, IF YOU PRESS ACCIDENTALLY THE UNLOCKED PEDAL. A. By pushing the pedal down and right, the right slewing is operated.

B. By pushing the pedal down and left, the left slewing is operated.

NOTE: the pedal can be locked by pulling the cover (1) downwards.

8. PEDAL FOR BREAKER AND NIBBLER Use this pedal to operate the hydraulic breaker and the nibbler.

S WARNING LOCK THE PEDAL IF ATTACHMENT IS NOT IN USE. CARELESS OPERATION OF THE UNLOCKED PEDAL MAY CAUSE SERIOUS ACCIDENTS.

NOTE: the pedal can be locked by pulling the cover (1) downwards.

9. DOZER/TRACK WIDTH ENLARGEMENT SELECTION LEVER (CX18B) This lever is located on the front lower side of the operator’s seat and it is used to select the dozer operation or adjust the crawler track width. Usually, this lever is to be set to (B) (dozer side). Only when it is necessary to change the machine width (crawler track width), is this lever to be moved to (A) (crawler track side) to allow the crawler track width enlargement through the relevant lever and the actuation of the adjusting cylinder

2-18

2. MACHINE FAMILIARIZATION 2.4.4

SEAT BELT

OPENING/CLOSING Check if the belt is twisted. Completely insert the flip into the buckle (1) of the belt until you hear a click.

Adjust the belt length so that there is no looseness (2).

Push down the red button (3) on the buckle to unfasten the seat belt.

S WARNING INSPECT SEAT BELTS DAILY. REPLACE SEAT BELT IF IT SHOWS SIGNS OF DEFORMATION OR DAMAGE. ALWAYS ENSURE THE SEAT BELT SUPPORT CAPSCREWS ARE PROPERLY TIGHTENED.

2-19

2. MACHINE FAMILIARIZATION 2.4.5

CAB

The following equipment are provided for the cab to ventilate or to facilitate operation.

S WARNING WHEN USING THE EQUIPMENT IN THE CAB, SET THE SAFETY LOCK LEVER TO THE LOCKED POSITION TO PREVENT UNEXPECTED MACHINE MOVEMENTS IF A LEVER IS ACCIDENTALLY OPERATED. THIS COULD CAUSE INJURY. DOOR Door opening To open the door from the outside, it is necessary to: • unlock the lock by means of the key; • press the button (1) towards the inside.

To keep the door open, push door until the hook (2) engages into the stop (3).

To open the door from the inside, it is necessary to: • press the lever (4) downwards.

• press the lever (5) towards the outside.

2-20

2. MACHINE FAMILIARIZATION SLIDING FRONT WINDSHIELD Open/close

S WARNING ENSURE TO MOVE THE MACHINE TO THE LEVEL GROUND WHEN OPENING/CLOSING THE FRONT WINDSHIELD, AND LOCK IT. IT CAN FALL DOWN IF IT UNLOCKS WHEN THE MACHINE IS TILTED FORWARDS. It is possible to slide the upper windshield on the deck and lock it in this position.

Move the machine to a level ground, set the safety lock lever to the locked position, then stop the engine.

Push down the levers (1) provided on the left/right sides of the upper windshield to unlock the windshield.

Grasp the handle (2) on windshield, hold it up and slide into backside ceiling.

Lock the front windshield housed in the roof by pulling the lever (1).

Lower the upper windshield by following the procedure in reverse order.

S WARNING WHEN CLOSING THE UPPER FRONT WINDSHIELD, SLOWLY GET DOWN IT PAYING ATTENTION NOT TO BE CAUGHT FINGERS, ETC. MACHINE OPERATION WITH INSUFFICIENT LOCKING IS QUITE DANGEROUS. MAKE SURE TO LOCK IT.

2-21

2. MACHINE FAMILIARIZATION LOWER FRONT WINDSHIELD To remove the front windshield (1), it must be removed from its guides (2). Then, it is necessary to fasten it to the rear supports (3) of the cab.

S WARNING DO NOT START WORKING WITH THE LOWER FRONT WINDSHIELD DISASSEMBLED.

CAB LIGHT Operate the relevant button (1): ON:

to turn on the light.

OFF: to turn off the light.

2-22

2. MACHINE FAMILIARIZATION 2.4.6

ENGINE GUARD WITH LOCKING DEVICE AND COVERS

S WARNING STOP THE ENGINE WHEN THE ENGINE GUARD OR RADIATOR COVER IS OPENED. The engine guard is provided with a lock. Use the key to open or close the engine guard.

A. OPENING Insert key in the lock.

After unlocking the lock, remove the key and open the engine guard (guard hinges guarantee its automatic opening).

Secure the engine guard in the opened position by means of the gas spring.

B. LOCKING Set the gas spring in the rest position.

Close the engine guard.

Insert the key and turn it counterclockwise to lock the engine guard. Then remove the key.

1. Start-up key 2. Engine guard lock IMPORTANT: insert the key completely for proper operation; otherwise damage may occur to the key or locking mechanism.

S WARNING WHILE OPENING, MAKE SURE YOU ARE NOT IN THE OPENING AREA OF THE GUARD.

2-23

2. MACHINE FAMILIARIZATION 2.4.7

SEAT ADJUSTMENT

Pull the seat adjustment lever to the right.

Move the seat forward or backward to desired position.

Release the lever to lock the seat in position.

2.4.8

WORK LIGHT

The boom is provided with a light which illuminates the visual field when working in conditions of poor visibility.

F37288

2.4.9

OPERATOR’S MANUAL COMPARTMENT

Store the Operator’s Manual in the relevant compartment behind the seat.

2-24

3. MACHINE OPERATION

3-1

3. MACHINE OPERATION

3-2

3. MACHINE OPERATION

3.1

MACHINE OPERATION

3.1.1

DAILY INSPECTION

Before starting the engine, walk around the machine to check for any loose nuts and capscrews, any oil, fuel or coolant leaks. Check also the condition of attachment and hydraulic system. Check for any looseness in the wirings and for any accumulated material (leaves, dirt, etc.) in hot areas.

1. Check the engine for any oil, fuel or coolant leakage. Repair as necessary.

2. Check the area around the engine and radiator for any accumulated material and remove as required.

3. Check the hydraulic system components, the hydraulic oil tank, the hoses and the joints for oil leaks and repair as necessary.

5. Check the attachments, cylinders, linkages and hoses for any cracks, wear or looseness and repair as required.

6. Check the guards, steps and handrails for damage, and the capscrews for looseness.

Repair and tighten capscrews as required.

7. Check that the gauges and the instrument panel operate correctly.

4. Check the travel system, such as the crawlers, idlers, and sprockets, for any damage or wear, and the capscrews for looseness.

3-3

3. MACHINE OPERATION 3.1.2

CHECKS BEFORE ENGINE START-UP

The following items should be inspected before starting machine operation: CHECK AND RESTORE ENGINE COOLANT LEVEL

S WARNING NEVER REMOVE RADIATOR CAP WHEN ENGINE IS HOT. WAIT FOR THE ENGINE TO COOL DOWN BEFORE REMOVING THE RADIATOR CAP. The radiator (3) reservoir (4) is located on the right side of the engine compartment.

Check the coolant level with cold engine only.

Open the radiator reservoir. The proper coolant level is between the “FULL” and “LOW” marks visible in the reservoir.

NOTE: engine coolant level is higher than normal when the engine is warm. The coolant level lowers with engine temperature.

Maintain coolant level at full mark when the engine is cold.

Open the cap (1) of the reservoir (4), fill with proper coolant up to the “LOW” mark on the expansion reservoir.

Restore the level of the radiator coolant when it is below the “LOW” mark in the reservoir. Make sure to check the engine cooling system for leakages and repair as needed, before resuming operation.

Remove the radiator cap (2), and check for proper coolant level.

Top up with proper coolant until the approximately reaches the “FULL” mark.

level

Install radiator cap (2) and tighten securely.

S WARNING BE CAUTIOUS OF HOT FLUIDS AND SURFACES. WEAR GOGGLES, SAFETY SHOES, HARD HAT, WORK CLOTHES AND WORK GLOVES TO PERFORM INSPECTION AND MAINTENANCE ON THIS MACHINE.

3-4

3. MACHINE OPERATION CHECK COOLANT LEAKS If the coolant level lowers in the radiator but not in the reservoir, it is possible that the cooling system is leaking. Make sure coolant level is to specifications and pressurize system to check for leakages.

Contact your Dealer for suggestions and/or repairs.

Be sure to repair leakages before resuming operation.

CHECK AND RESTORE ENGINE OIL LEVEL NOTE: make sure the machine is on firm and level ground, when checking oil level.

Always check engine oil level before starting the engine.

Keep the engine switched off for at least 30 minutes after use, to check the engine oil level.

Bring the throttle control lever to minimum speed, stop the engine and remove the starter switch key, then set the safety lock lever to the LOCKED position.

Wait until the machine is cold.

Open the engine guard with the starter key.

Pull out engine oil dipstick (1), clean it with a dry cloth and re-insert it completely. Pull it out again and check the oil level. The level must be between marks (H) and (L).

If the oil is heavily contaminated or deteriorated, change it regardless of periodical schedule.

If the oil level is too low, remove the filler plug (2) and restore level by pouring oil through the filler neck.

Make sure to check the oil level again after refilling.

Clean the plug (2) and reinstall it.

Close the engine guard and lock it with the key.

S WARNING DO NOT TOP UP USING OIL WITH DIFFERENT SPECIFICATIONS FROM THOSE OF OIL ALREADY IN THE HYDRAULIC OIL TANK.

3-5

3. MACHINE OPERATION CHECK AND TOP UP OF OIL LEVEL IN HYDRAULIC SYSTEM

S WARNING NEVER CHANGE OILS OR FILTERS ON A MACHINE THAT HAS JUST FINISHED WORKING. STOP THE MACHINE AND LET IT COOL DOWN BEFORE STARTING ANY INSPECTION: DANGER OF BURNS. RELEASE HYDRAULIC OIL TANK PRESSURE BEFORE ANY INTERVENTION ON THE SYSTEM: DANGER OF PERSONAL INJURIES.

To check the hydraulic oil level, move the machine to a level and firm ground as shown in the right figure.

Bring the throttle control lever to minimum speed, stop the engine and remove the starter switch key, then set the safety lock lever to the LOCKED position.

Wait until the machine is cold.

Check the oil level.

Through the slot in the left side guard (1) it is possible to see the marks on the oil tank.

The level must be between the MIN and MAX marks.

NOTE: avoid overfilling. It causes damages to hydraulic system or oil spilling.

3-6

3. MACHINE OPERATION Remove the left side guard (1).

Remove the cap (2) after the machine has cooled down to touchable with a bare hand. Slowly loosen the cap (2) to release the inside pressure. Remove the cap (2) after all pressure is released.

Check the cap (2) for damages or adhesion of dust.

Clean it and/or replace it if needed.

Securely tighten the cap (3).

Start the engine and run it for 5 to 7 minutes at low idling speed. Operate each cylinder to its full travel and make a complete rotation to remove any air from the hydraulic system.

Stop the engine, check the oil level and top up, if necessary.

Remove the left side guard (1).

CHECK FUEL LEVEL

S WARNING • MAKE SURE TO USE DIESEL FUEL ONLY AND STOP THE ENGINE BEFORE REFUELLING. • BE CAREFUL FUEL DOES NOT OVERFLOW WHEN REFILLING. CLEAN UP ALL SPILLED FUEL TO PREVENT FIRE. • DISPOSE OF HAZARDOUS WASTE ACCORDING TO ENVIRONMENTAL LAWS AND REGULATIONS.

Ensure the machine is parked on a level surface.

Turn the starter switch key (1) to ON, so that the warning lamps on the instrument panel turn on.

Check the fuel level indicator (2). If level is too low, refuel.

3-7

3. MACHINE OPERATION Open the plug (3) with the starter switch key.

Fuel tank capacity: 16 litres (4.20 gal) Do not remove the fuel tank strainer (4) while refuelling to prevent contamination.

After refuelling, install the plug (3) and lock it with the key.

Close the engine guard and lock it with the key.

We recommend refuelling at the end of the working day. In this way condensation will be avoided during overnight pause. Check that the tank does not run out of fuel, because this would cause air seepage in the fuel system and air should then be bled from the fuel tank.

CHECK FUEL LEAKS Check and repair any fuel leakage. Do not operate a machine leaking fuel. Fuel leaks can be caused by a faulty drain plug, by cracks in the hoses or by loose hose clamps.

Make sure to immediately stop the engine after detection of a fuel leak. Repair fuel leak before resuming operation.

INSPECT BELT CONDITION

S WARNING ROTATING PARTS CAN CAUSE PERSONAL INJURY. KEEP AWAY FROM FAN AND BELT WHEN ENGINE IS RUNNING. MAKE SURE TO STOP ENGINE BEFORE SERVICING.

Check the belt (1) for insufficient tension, wear or damage. Insufficient belt tension may cause battery charge failure, engine overheating, or abnormal belt wear. If too much tension is applied to the belt, the bearings or belt may be damaged prematurely.

Apply a force of 98 N to the centre of belt between pulleys, and measure the belt deflection.

A. Belt deflection: 8 ~ 10 mm (0.31 ~ 0.39 in)

3-8

3. MACHINE OPERATION CHECK WARNING LAMPS

S WARNING CARELESS MOVEMENT OF ANY OPERATING LEVER MAY CAUSE SUDDEN MOVEMENT OF THE MACHINE. MAKE SURE TO SET THE SAFETY LOCK LEVER TO THE LOCKED (UP) POSITION BEFORE LEAVING THE CAB. DOZER AND BOOM FUNCTIONS ARE STILL ACTIVE, EVEN WITH THE SAFETY LOCK LEVER IN THE LOCKED (UP) POSITION. Before starting the engine, check if warning lamps turn on correctly: Make sure the safety lock lever is in the LOCKED (up) position.

Make sure all control levers are in NEUTRAL position.

(A) RED: warning lamp (B) YELLOW: indicator lamp

Ensure that manual throttle lever is set at low idle.

When turning the starter switch key to ON, the warning lamps turn on according to the position of the key, as shown in the table aside.

Do not operate machine, if alarm lamps are lit. If necessary, contact your Dealer and make sure that all lamps are working correctly.

Operation key Lamp 1 Glow plug 2 Battery charge lamp 3 Engine oil pressure lamp Engine coolant temperature lamp 5 2nd travel speed lamp

4

OFF → ON ON → START Before start-up Just after start-up

Lamp ON Lamp ON Lamp ON

Lamp OFF Lamp OFF Lamp OFF

Lamp OFF

Lamp OFF

Lamp OFF

Lamp OFF

NOTE: make sure that all warning lamps and indicators operate properly, before starting the machine.

CHECK WORK LIGHT With the starter switch key set to ON, operate the switch of the work light so as to check if it operates correctly.

If light does not turn on, presumably the bulb is burnt out or an electric fault is occurred.

F37288

3-9

3. MACHINE OPERATION 3.1.3

MACHINE WARM UP

S WARNING DO NOT RUN THE ENGINE IDLE FOR MORE THAN 20 MINUTES. EXTENDED PERIODS OF IDLING REDUCE THE LIFE OF THE ENGINE. Set the throttle lever (1) to intermediate position, between low and high idle. Turn the starter key to START to start the engine. Release key as soon as the engine starts. The key will return to ON by itself.

Let the engine run idle for at least 5 minutes.

OIL PRE-HEATING FOR HYDRAULIC SYSTEM The hydraulic oil temperature must be between 50 °C and 80 °C. Avoid machine operation when the hydraulic oil temperature is below 20 °C. Failure to do so will reduce the life of the hydraulic components.

After correct engine warm-up, as previously described, position throttle lever (1) on INTERMEDIATE SPEED. Set the safety lock lever (3) to the UNLOCKED (down) position.

Operate the boom control lever (2) to raise it all the way up.

Operate the bucket control lever to retract it or extend it completely against relief. Hold in this position for one minute, then release lever (2) and wait for another minute before repeating operation.

Repeat this operation for at least 10 times, until the oil temperature in the pilot hydraulic circuit warms up for oil operation.

After hydraulic oil warm up, slowly extend and retract slowly all cylinders several times. Start the travel and rotation motors to complete the warm-up operation.

IMPORTANT: in extremely cold climate it may be necessary to increase the preheating time to ensure proper and safe operation. While operating the machine with cold hydraulic oil, the operator may experience slow or unexpected movements of the functions. Likewise, cold hydraulic oil will not provide adequate lubrication to hydraulic components; thus, reducing the life expectancy of the machine.

3-10

3. MACHINE OPERATION 3.1.4

STARTING THE ENGINE

STARTING THE ENGINE IN NORMAL CONDITIONS Make sure that the safety lock lever (1) is in LOCKED position.

Make sure all control levers are in NEUTRAL position.

Take the throttle control lever to position (2) so that it is approximately at half stroke.

Take the starter switch key (3) to ON and wait for the preheating control lamp to turn off. Turn the starter switch key (3) to START to start the engine.

Release key as soon as the engine starts.

The key will return to ON by itself.

If the engine does not start within 15 seconds, turn the starter key (3) to OFF and wait for 30 seconds.

Then repeat above mentioned operations to start the engine.

S WARNING MAKE SURE THAT THE SLEWING AREA IS CLEAR OF PERSONS AND OBSTACLES BEFORE STARTING THE ENGINE. SOUND THE HORN BEFORE BEGINNING THE WORK. NOTE: do not increase the engine speed (high idling) with cold engine.

3-11

3. MACHINE OPERATION STARTING THE ENGINE AT LOW TEMPERATURES Make sure that the safety lock lever (1) is in LOCKED position.

Make sure all control levers are in NEUTRAL position.

Take the throttle control lever to position (2) totally accelerated.

Take the starter switch key (3) to ON and wait for the preheating control lamp to turn off.

Turn the starter switch key (3) to START to start the engine.

Release key as soon as the engine starts.

The key will return to ON by itself.

If the engine does not start within 15 seconds, turn the starter key (3) to OFF and wait for 30 seconds.

Then repeat above mentioned operations to start the engine.

S WARNING MAKE SURE THAT THE SLEWING AREA IS CLEAR OF PERSONS AND OBSTACLES BEFORE STARTING THE ENGINE. SOUND THE HORN BEFORE BEGINNING THE WORK. NOTE: do not increase the engine speed (high idling) with cold engine.

3-12

3. MACHINE OPERATION EMERGENCY START-UP WITH BOOSTER CABLES Observe the following precautions when using booster cables to start the engine.

S WARNING • BATTERIES GENERATE EXPLOSIVE GAS, EASY FLAMMABLE. DO NOT APPROACH THE CHARGING AREA WITH SPARKS OR NAKED FLAMES TO AVOID FIRES AND AN EXPLOSION. • DO NOT ALLOW THE VEHICLE OR MACHINE USED FOR BOOSTING TO TOUCH METAL TO METAL WITH THE DISABLED MACHINE. • WEAR SAFETY GLASSES OR FACE PROTECTION, GLOVES AND OTHER SAFETY CLOTHING WHEN WORKING WITH BATTERIES. • NEVER ALLOW THE BOOSTER CABLE CLIPS TO COME IN CONTACT WITH EACH OTHER ONCE CONNECTED TO A BATTERY. • THE NEGATIVE CABLE, WHEN CONNECTED TO THE UPPER FRAME OF DISABLED MACHINE, MAY ARC, CAUSING SPARKS. MAKE SURE TO CONNECT THE BOOSTER CABLE TO A GROUND SURFACE IN THE ENGINE COMPARTMENT, AS FAR AS POSSIBLE FROM THE BATTERY. • WHEN THE BATTERY FLUID IS FROZEN, DO NOT START UP THE ENGINE WITH ANOTHER POWER SOURCE. • FOLLOW THE ORDER INDICATED IN THE NEXT PAGE FOR CONNECTING OR DISCONNECTING THE BOOSTER CABLES. NOTE: select booster cables and terminals with suitable sizes, according to batteries dimensions.

Use the booster cables and clips without any signs of damage or corrosion.

3-13

3. MACHINE OPERATION CONNECTING/DISCONNECTING BOOSTER CABLES Turn the starter switch key to OFF before connecting the booster cables. Connect booster cables as per following sequence.

S WARNING • ERRONEOUS CONNECTION OF BOOSTER CABLES MAY CAUSE EXPLOSION OF THE BATTERY. PAY SPECIAL ATTENTION WHEN CONNECTING AND DISCONNECTING THE BOOSTER CABLES. • THE ELECTRICAL SYSTEM OF THIS MACHINE WORKS WITH 12 V DC. Connect the booster cable (red) terminal to the positive (+) terminal on the battery of the disabled machine.

Connect the other terminal of the positive cable (+) (red) to the positive terminal (+) of the battery of the normal vehicle.

Connect the terminal of the booster cable (black) to the negative terminal (-) of the battery of the normal vehicle.

Finally, connect the other terminal of the negative booster cable (-) (black) to the upper frame of the disabled machine, away from the battery.

Start the engine of the normal vehicle, and operate it for around 10 minutes at high idling.

Start the engine of troubled machine.

After starting the engine of the disabled machine, disconnect the booster cables exactly in the reverse order.

Make sure to check and repair the cause of the problem of the charging system on the disabled machine.

A. Booster battery B. Discharged battery C. Red cable D. Black cable E. To the upper frame of the troubled machine Cable connecting order: 1>2>3>4 Cable disconnecting order: 4>3>2>1

3-14

3. MACHINE OPERATION 3.1.5

CHECKS AFTER ENGINE START-UP

After the engine start, check following.

S WARNING • CARELESS CONTACT WITH ANY OPERATING LEVER WILL CAUSE UNEXPECTED SUDDEN MACHINE MOVEMENT. STAND UP OR CHANGE POSITION ONLY AFTER ENGAGING THE SAFETY LOCK LEVER. • MAKE SURE THAT THE SLEWING AREA IS CLEAR OF PERSONS AND OBSTACLES BEFORE STARTING THE ENGINE. ENSURE THE POSITION OF THE TRAVEL MOTORS, BEFORE STARTING TO TRAVEL AND SOUND THE HORN BEFORE BEGINNING THE WORK. CHECK THE INSTRUMENT PANEL Check all instruments and indicators. The lamp (1) turns on when the battery is discharged. The lamp (2) turns on when the engine oil pressure is too low.

Check that the fuel level gauge (3) and engine coolant temperature gauge (4) operate correctly.

SAFETY LOCK LEVER CONTROLS When the engine is running, set the safety lock lever (1) to the LOCKED (up) position.

Move all control levers, except for the control levers of dozer, track width enlargement (only on CX18B models) and swing.

Make sure that all functions, except for the dozer and boom functions, are not active when the safety lock lever is in LOCKED (up) position.

Make sure that the travel control levers are mechanically locked and do not move at all.

NOTE: if a fault is found, immediately stop the engine, take the necessary measures and contact your Dealer for repair.

3-15

3. MACHINE OPERATION SLEWING LOCK PIN CHECK After unlocking the slewing lock pin (1), make sure the screw (2) is fully tightened, in order to unintentionally set the pin while working.

EXHAUST GAS COLOUR, IRREGULAR NOISES AND SMELLS With the engine running, check the following: • Check for anomalous exhaust gas colour.

If the engine exhaust is black, stop the machine immediately. Black exhaust is an indication of an excessively rich fuel/air mixture. Check and service the engine accordingly if this condition is present.

• Stop operation immediately when any abnormal sound is heard during the machine operation.

Check the cause of the abnormal sound, and repair as needed.

• Avoid operation at the speed range with resonance. There may be a certain rotating speed range at which the vibration suddenly becomes large due to resonance. Avoid the operation at such speed range, because some parts may be damaged due to vibration.

• If burning smell or smoke is generated, stop the engine immediately. Check for any abnormalities and repair as needed before resuming operation.

NOTE: if faults are detected after the abovementioned checks, contact your Dealer for repairs.

NOTE: do not apply any heavy load on the new engine for the first 50 hours operation.

Confirm that all lamps turn off.

Carefully listen for any abnormal sound.

Check for oil and water leakages from the engine.

When you start the engine for the first time during the day, let it run idle for about 5 minutes: in this way the engine heats and the oil reaches all its components.

3-16

3. MACHINE OPERATION 3.1.6

STOPPING THE ENGINE

Let the engine run idle for at least 5 minutes before stopping it, to keep it in good conditions.

S CAUTION If the engine stop is abrupt, while it is running at high speed, the engine temperature increases rapidly. As a consequence, the engine oil is overheated and the joints jam.

Before leaving the operator’s seat, make sure that the safety lock lever (1) is in the LOCKED position.

Check that the upper structure slewing lock pin (2) is in LOCKED position.

Bring the throttle control lever (3) to engine low idle.

Let engine run at idle speed for some minutes, in order to ensure gradual cooling.

Turn the starter key (4) to OFF to stop the engine.

Remove the starter key (4).

S WARNING ALWAYS REST THE BUCKET ONTO THE GROUND BEFORE STOPPING THE ENGINE. POSITION THE MACHINE ON A FIRM AND POSSIBLY LEVEL GROUND.

S WARNING NEVER LEAVE THE MACHINE UNATTENDED WHILE THE ENGINE IS RUNNING.

3-17

3. MACHINE OPERATION 3.1.7

MACHINE OPERATION

The following instructions are aimed to provide the operator with the basic functions of each hydraulic control. Following the instructions and putting them into practice will allow the operator to become more skilful in the operation of this equipment. Before operating the machine, carefully read and observe all precautionary measures given in this manual.

TRAVEL

S WARNING MAKE SURE THAT THE SLEWING AREA IS CLEAR OF PERSONS AND OBSTACLES BEFORE STARTING THE ENGINE. ENSURE THE POSITION OF THE TRAVEL MOTORS, BEFORE STARTING TO TRAVEL AND SOUND THE HORN BEFORE BEGINNING THE WORK. IF ANY FAULT OCCURS DURING MACHINE OPERATION, IMMEDIATELY STOP THE ENGINE. MAKE SURE TO REPAIR ANY FAULTY CONDITION BEFORE RESUMING OPERATION. NORMAL POSITIONING OF THE MACHINE, FOR THE PURPOSE OF DETERMINING FRONT, REAR, FORWARD AND REVERSE, IS WITH THE TRAVEL MOTORS LOCATED BEHIND THE OPERATOR’S CAB.

Forward/reverse travel Make sure the safety lock lever (1) is in the UNLOCKED (down) position. Operate the boom, arm, and bucket control levers to raise the attachments from the ground.

Operate the control lever to raise the dozer.

3-18

3. MACHINE OPERATION To move the machine forward, push both (right and left) travel levers forward simultaneously (2). To move the machine in reverse, pull back both travel levers simultaneously (3).

Travel speed changes depending on how far you push or pull the levers.

Right turn Push the left travel lever forward (1) to turn the machine RIGHT.

Left turn Push the right travel lever forward (1) to turn machine LEFT.

Clockwise rotation Push the left travel lever forward (1) and at the same time the right travel lever backward (2).

3-19

3. MACHINE OPERATION Counterclockwise rotation Push the right travel lever forward (1) and at the same time pull the left travel lever backward (2).

Shifting from one travel speed to the other (only on 2-speed models) For a HIGH U travel speed (2nd gear), press and release the relevant switch on the grip of the right travel lever. The hare indicator (1) on the instrument panel turns on.

Start the machine by operating the travel levers.

To return to SLOW T travel speed (1st gear), stop travelling, press and release the relevant switch.

NOTE: the travel speed is always reset to SLOW each time the starter key is turned to OFF. STOP TRAVELLING Move the left and right travel control levers to the NEUTRAL position to stop machine travel. Avoid stopping the machine travel suddenly. Stop the machine travel as slowly as possible.

3-20

3. MACHINE OPERATION TRAVEL PRECAUTIONS

S WARNING • USE A FLAGMAN WHEN TRAVELLING ON A ROAD SHOULDER OR IN CONFINED AREAS. • KEEP PEOPLE AWAY FROM LIFTED DEVICES, TO AVOID POSSIBLE INJURIES. Always move with lowered bucket, especially on slopes or during transfers. The bucket, however, should be sufficiently raised from the ground to overcome possible obstacles. Do not use the bucket as a man lift or to carry riders.

Make certain the travel motor (1) location is known before performing any travel operation. Travel with travel motors at the back of the machine for long distance travel.

Travel on flat and firm ground and in straight lines (or large angles) as much as possible. When turning the machine, move forward and backward alternately as much as possible instead of making a sharp turn.

Check the strength of bridges and road shoulders.

Reinforce them if necessary.

Make sure to keep a sufficient distance from bridges and electrical power lines. Prior to digging, check existence and location of electrical lines, gas ducts, water pipes or other public utilities installations. If in doubt, contact local authorities and/or the distributing companies (electric power, gas, telephone, water, telecommunications, etc.).

When travelling on rough ground, use low speed (1st) T (A) to reduce vibrations and make sure that the throttle control lever is in engine low idle (B) position.

Do not allow large or heavy objects to strike against travel motors. Likewise, do not travel over large objects such as boulders, rocks, etc.

On a snowy or icy roads, travel at slow speed. Avoid starting or stopping abruptly and avoid turning the upper structure suddenly.

For loading/unloading at the transport, remove any mud clogged in the crawler shoes to prevent the machine from side skidding on the ramps.

3-21

3. MACHINE OPERATION PRECAUTIONS FOR TRAVELLING ON SLOPES

S WARNING SHOULD IT BE NECESSARY TO OPERATE THE MACHINE ON SLOPES, CAREFULLY OBSERVE THE FOLLOWING PRECAUTIONS. THIS TO PREVENT INJURIES DUE TO ACCIDENTAL MACHINE OVERTURN.

S WARNING ALWAYS STOP THE MACHINE BEFORE SELECTING THE OTHER TRAVEL SPEED MODE. NEVER SHIFT GEARS WHILE TRAVELLING WITH THE MACHINE. AVOID ESPECIALLY SHIFTING TO QUICK TRAVELLING MODE WHILE TRAVELLING ON A SLOPE: IT MAY BE DANGEROUS.

When on slopes avoid as much as possible to travel across them.

Always travel at slow speed.

When travelling, lift the bucket up to 30 ~ 40 cm (0.98 ~ 1.31 ft) from the ground in the travelling direction. Do not travel down a slope in reverse run.

When the machine slips, immediately lower the bucket to the ground and operate the brakes.

Never attempt to rotate the upper structure downhill: the machine could tip over. If this operation is unavoidable, create on the slope a flat working area.

Never attempt to travel up or down a slope with a gradeability of 30° (~ 58%) or more.

3-22

3. MACHINE OPERATION When the engine stops on a slope, immediately lower the bucket to the ground and move all control levers to the NEUTRAL position, then start the engine again.

If it is difficult to climb a slope with the travel motor due to skidding crawlers, etc., the power of the arm can be utilized to pull up the machine with the bucket engaged on the ground.

When the machine is parked on a slope, even for a short time, lower the bucket (1) and the dozer (2) to the ground, return all control levers to the NEUTRAL position, set the safety lock lever to the LOCKED (up) position and block both crawlers by means of wedges (3), as shown in the figure.

NOTE: when the hydraulic oil is not sufficiently warm, the machine may not be able to develop its full performance. Before travelling on a steep slope, pre-heat machine completely.

MACHINE OPERATION IN WATER/ON SOFT GROUNDS NOTE: the slewing bearing of the upper structure, the pinion of the rotation motor and the rotary control valve should never operate in water or mud.

If the machine is operated in water or mud, the slewing bearing and the other components may wear excessively. Immediate replacement of grease or overhaul of the slewing bearing, etc. is required.

Where the river bottom is flat and water flow is slow, the machine may be operated in water, provided that water is not higher than the guide plates of the crawlers (1).

When operating under such condition, use the machine carefully and check condition of river bed.

Never enter deeper waters.

On soft ground, the machine body sinks in some cases gradually. Therefore, pay full attention to the machine at all times during operation.

After travelling in sea water, thoroughly wash up the machine to remove salt.

Make sure to lubricate bucket pins and bushing every 4 hours if working with materials in wet conditions, supply grease with a grease gun until grease oozes out.

3-23

3. MACHINE OPERATION GETTING OUT OF SOFT GROUND If possible, avoid travelling on soft ground. Avoid getting caught in the mud. In the event that the machine gets caught in the mud, get out of it as follows.

One crawler caught in mud When a crawler gets caught in mud, lay logs or boards on the mud to form a base. Operate boom and arm to form an angle between them of about 90°~110°. Push outer side of bucket against the ground to lift the machine body.

Both crawlers caught in mud When both crawlers get caught in mud and the machine does not move because it skids, provide logs and boards, as described in the previous step and anchor the bucket firmly to the ground so that you can help the machine to come out from mud.

If the machine is unable to travel because the crawlers are stuck in mud, sand or gravel, raise each crawler side alternately by pushing the bucket against the ground and scraping off mud, sand or gravel. Gravel and mud may be cleared off by rotating the raised crawler back and forth.

S CAUTION Operate the machine from operator’s seat only. Do not allow any person to come near the machine.

3-24

3. MACHINE OPERATION ROTATION OF THE UPPER STRUCTURE

S WARNING • WHEN YOU WORK ON SLOPES THE MACHINE BECOMES UNSTABLE AND UNBALANCED. • MAKE SURE THE ROTATION AREA IS CLEAR OF PERSONS AND OBSTACLES BEFORE OPERATING THE ENGINE. • WORK UP AND DOWN INCLINES OR SLOPES, NEVER ACROSS. • NEVER SLEW OR TURN MACHINE AROUND ON SLOPES. • OPERATE CONTROL LEVERS CAREFULLY TO PREVENT SUDDEN MOVEMENTS THAT MAY CAUSE THE MACHINE TO SLIP OR TIP OVER. • PREPARE A LEVEL AREA FOR THE MACHINE TO OPERATE. • USE A FLAGMAN TO GUIDE THE OPERATOR.

3-25

3. MACHINE OPERATION TRACK WIDTH ENLARGEMENT (ONLY ON CX18B MODELS) IMPORTANT: change the track width on a level and firm ground without obstacles.

To change the track width, lift the machine body.

Otherwise, the track width adjusting cylinder may be damaged.

Lift the machine body as shown in the figure.

A. Set the dozer/track width enlargement lever to (A) (track width enlargement side).

B.

Extension

Set the track width enlargement lever to (B) to increase the machine’s track width.

C. Retraction Set the track width enlargement lever to (C) to decrease the machine’s track width.

3-26

3. MACHINE OPERATION OPERATING THE DOZER The dozer is used to push the soil back into the ditch or for ground levelling.

If necessary, adjust the height of the dozer by means of the relevant control lever, to prevent overloading the engine.

According to the model, the dozer can be of two different types: A. Fixed dozer (only on CX15B models) B. Extendable dozer (only on CX18B models)

Extendable dozer (only on CX18B models) To extend the dozer, it is necessary to perform the following operations: • remove the pin (1); • take the dozer extension (2) and place it on the outside by aligning the holes; • reassemble the pin (1) to lock the dozer extension (2); • repeat the same operations on the other side of the dozer.

3.1.8

PRACTICE TO IMPROVE EFFICIENCY

S WARNING • SLEWING THE UPPER STRUCTURE ON A SLOPE MAY CAUSE THE MACHINE’S OVERTURNING. ON A SLOPE, IT IS VERY DANGEROUS TO SLEW THE UPPER STRUCTURE DOWNHILL WITH FULL BUCKET. PREPARE A LEVEL AREA FOR THE MACHINE TO OPERATE SAFELY. • MAKE SURE THE ROTATION AREA IS CLEAR OF PERSONS AND OBSTACLES BEFORE OPERATING THE ENGINE. NOTE: the optional attachments offer a wider range of application other than the showed ones.

Refer to 4-35 for changing the bucket.

3-27

3. MACHINE OPERATION DIGGING INSTRUCTIONS Use mainly the mere arm force for digging. Use the full bucket rotation travel to fill it completely. Setting the bucket too deep will decrease the machine’s efficiency.

Maximum digging force position.

The attachment will provide maximum digging force when arm and boom are positioned at 90°~110° from each other. Operate slowly to get maximum digging force.

Bucket teeth direction.

Direct bucket teeth parallel to digging direction. The bucket must be used for shallow diggings, so as to reduce the resistance and avoid damaging the teeth.

Operate boom carefully.

Activate boom operation by moving the control levers carefully. Do not perform sudden starts and stops of the boom as this creates unnecessary stress on the machine and its components.

Clean sand and soil from bucket.

Place the arm in horizontal position and bring the bucket to the dumping position. If sand and soil do not fall out, move the bucket lever right and left a few times to remove soil stuck to the bucket.

3-28

3. MACHINE OPERATION Digging ditches The working efficiency is much improved when the bucket is oriented correctly for digging ditches and parallel to a ditch.

For wide ditch digging, dig the two sides first, then dig the centre portion.

Operating the dozer The dozer is used to push the soil back into an excavated ditch or for ground levelling.

To distribute the earth heaped up on the ground using the dozer, start from the top or from the sides of the heap. If necessary, adjust the height of the dozer by means of the relevant control lever, to prevent overloading the engine.

Offset digging

S WARNING WHEN THE SLEWING RANGE OF THE BOOM IS WIDER, PAY ATTENTION TO THE CONDITIONS OF THE SURROUNDING AREA. By pressing the left and right side of the slewing pedal (1) alternately, the boom (2) slews in left and right direction, thus enabling offset digging in narrow spaces.

By pressing the left side of the slewing pedal, the boom slews leftwards, and by pressing the right side, the boom slews rightwards.

The advantage of this function is that it enables offset digging work as shown in the figure.

3-29

3. MACHINE OPERATION LOAD The working efficiency can increase, if the dump truck collecting the removed earth is parked so that the rotation angle of the arm is minimal. At the same time the operator sight remains the best.

It is recommended that loading be started from the front side of the dump truck body. This will make loading easier and more soil can be loaded than by loading from the side.

POSITION WITH MINIMUM ROTATION ANGLE Extend arm cylinder and bucket cylinder to maximum length, and fold bucket.

Extend boom cylinder to maximum length.

Press the left side of the slewing pedal, and then slew the boom fully to the left.

Operate the control lever for upper structure rotation.

NOTE: avoid interference with the attachment.

3-30

3. MACHINE OPERATION 3.1.9

MACHINE PARKING

S WARNING • ALWAYS PARK THE MACHINE ON A LEVEL AND FIRM GROUND. • WHEN PARKING ON A SLOPE, MAKE SURE THE BUCKET TEETH ARE STUCK IN THE GROUND, LOWER THE DOZER TO THE GROUND AND PROPERLY BLOCK THE CRAWLERS WITH WEDGES. • MAKE SURE TO SET THE SAFETY LOCK LEVER TO THE LOCKED (UP) POSITION BEFORE LEAVING THE CAB. Move both travel control levers (1) to the NEUTRAL position.

Set the throttle lever (2) to LOW IDLING. Lower the bucket to the ground.

Place the dozer on the ground.

Block both crawlers by means of chocks.

Stop the engine by turning the starter key to OFF.

Set the safety lock lever (3) to the LOCKED position.

Set the upper structure slewing lock pin (4) into LOCKED position.

Close the windows.

3-31

3. MACHINE OPERATION 3.1.10

CHECKS AND VERIFICATION AFTER WORK

Regularly check the instrument panel.

If the fuel level in the tank is low, stop the engine and refuel.

If the warning lamps for the coolant temperature (1) and/or engine oil temperature (2) are on, move the machine to a safe place, immediately stop the engine and carry out the necessary repairs before resuming operation.

3.1.11

PRECAUTIONS AFTER OPERATION

Check for any oil or coolant leaks in the machine.

Check the attachment, the machine’s outside and the crawlers. Repair as needed before resuming operation.

Refuelling. Do not overfill fuel tank (up to the top).

With temperature increase the fuel can expand and overflow.

Remove mud from the crawlers.

3-32

3. MACHINE OPERATION 3.1.12

MEASURES AFTER AN EMERGENCY STOP OF ENGINE

Avoid emergency stops of the engine as much as possible.

It should be kept in mind that the engine is to be operated for around 5 minutes with no load, before stopping the engine.

S CAUTION If the engine stops immediately after an high speed operation, the engine temperature increases remarkably.

Even if the engine is not running, keep the safety lock lever engaged.

Set the slewing lock pin into LOCKED position.

When an emergency stop is made and there is no time to lower the bucket to the ground, support it with wood wedges (1) to lock the crawlers.

When the emergency stop is activated on a slope, block both crawlers at their lower sides.

While you are waiting to restart the engine and the machine, free the working area from people and possible obstacles. Set limits around the machine, taking the appropriate measures so that nobody penetrates this area.

In case of emergency stop on a slope, clear the whole area within the slewing circumference of the working attachment with maximum reach.

If the trouble cause is not clear or a repair is required, contact your Dealer.

After an emergency stop, restart the engine only when the coolant is completely cool.

3-33

3. MACHINE OPERATION 3.1.13

EMERGENCY MEASURES FOR SUDDEN FAILURE OF MACHINE

REMOVAL OF TRAVEL MOTOR LOCK While travel motors are at a standstill, they are hydraulically locked by the counter balance valve, and also mechanically locked by the brake system.

When the machine becomes unable to travel due to failure of the travel motors, etc., it is possible to temporarily move it by releasing the lock for the travel motor with one of the following methods.

REMOVE THE TRAVEL MOTOR SPOOL

S WARNING WHEN DISASSEMBLING/REASSEMBLING THE TRAVEL MOTOR, PAY SPECIAL ATTENTION NOT TO ALLOW DUST OR FOREIGN PARTICLES INTO THE TRAVEL MOTOR. Disassemble rubber crawler by slightly opening the grease gun of the crawler idler of one complete turn.

Lift the machine, place wood blocks (1) under the lower frame (travel motor side), lower the machine and stop the engine.

Remove the travel engine cover (3) on the lower frame with loosening three capscrews (2).

Provide a container to receive draining oil under the travel motor, then disconnect the hoses. Since the draining oil comes out from the hoses and oil port, receive it in the container. Put a stopper plug to all openings on the hoses.

NOTE: to avoid erroneous connection of hoses, put a mark, such as the port name, on each hose at their disconnecting.

3-34

3. MACHINE OPERATION Remove the socket capscrews (4) with a wrench to remove the travel engine from the lower frame.

Gradually loosen the capscrews paying attention not to drop off the travel motor.

Remove the plug (5) with a wrench.

Remove the spool (6). If it is difficult to remove, use a plier applying a soft material such as a piece of cloth not to give any damages on the spool. The spring (7) and washer plate (8) will be removed at the same time.

Reassemble the plug (5) to avoid the intrusion of foreign bodies.

Reinstall the travel engine in the lower frame.

For disassembly and reassembly of the other travel engine, follow same procedure.

Reassemble the crawlers.

As the spool is disassembled, the travel motor is not locked any more.

If a towing vehicle is available, tow the machine and take it to a safe place.

NOTE: after moving the machine to a safe place, call up a serviceman to investigate the trouble.

3-35

3. MACHINE OPERATION LOWERING THE BUCKET IN EMERGENCY SITUATIONS

S WARNING • THIS PROCEDURE IS TO BE USED ONLY AS AN EMERGENCY TO LOWER THE POSITION OF THE BUCKET. USE EXTREME CAUTION, SINCE THE WEIGHT OF THE BUCKET WILL TEND TO MOVE THIS ABRUPTLY, WHEN THE HOSES OF THE HYDRAULIC SYSTEM ARE DISCONNECTED. • BE SURE TO BLOCK THE ATTACHMENTS TO AVOID SUDDEN CHANGE OF POSITION. REMOVE THE HOSES OF THE HYDRAULIC SYSTEM SLOWLY, UNTIL OIL PRESSURE IS COMPLETELY RELEASED. THEN CONTROL THE BUCKET MOVEMENT BY SLOWLY REMOVING THE BLOCK. To lower the bucket, proceed as follows: when the bucket is in digging position (A) (bucket cylinder completely extended), disconnect hose (H), conversely, when the bucket is in dump position (B) (bucket cylinder completely retracted), disconnect the hose (R).

S CAUTION Make sure that the hydraulic system or a component of this are not contaminated from polluting agents.

This could cause severe system damages. Contact your Dealer to obtain the proper caps and plugs to be used on this machine.

S CAUTION Clean up all spilled oil. Dispose of collected oil, because polluting, according to the local environments regulations.

3-36

3. MACHINE OPERATION LOWERING THE ARMS

S WARNING • THIS PROCEDURE IS TO BE USED ONLY AS AN EMERGENCY TO LOWER THE POSITION OF THE BUCKET. USE EXTREME CAUTION, SINCE THE WEIGHT OF THE BUCKET WILL TEND TO MOVE THIS ABRUPTLY, WHEN THE HOSES OF THE HYDRAULIC SYSTEM ARE DISCONNECTED. • BE SURE TO BLOCK THE ATTACHMENTS TO AVOID SUDDEN CHANGE OF POSITION. REMOVE THE HOSES OF THE HYDRAULIC SYSTEM SLOWLY, UNTIL OIL PRESSURE IS COMPLETELY RELEASED. THEN CONTROL THE BUCKET MOVEMENT BY SLOWLY REMOVING THE BLOCK. • DO NOT ENTER THE AREA UNDER ATTACHMENTS, WHILE LOWERING THEM. Arm lowering (step 1) Gradually loosen the hose, connected to the arm cylinder, from rod side (R).

Boom lowering (step 2) Gradually loosen the hose, connected to the boom cylinder, from the head side (H).

3-37

3. MACHINE OPERATION

S CAUTION Clean up all spilled oil. Dispose of collected oil, because polluting, according to the local environments regulations.

Keep the attachment at 30 ~ 40 cm from the ground and take the possible movements of the machine into consideration.

Securely retighten the hoses so that the attachment stops lowering.

After moving the machine to a safe place, place the attachment to the ground.

NOTE: if necessary, contact your Dealer for repairs.

3.1.14

CAUTION WHILE USING RUBBER CRAWLERS

PROPER USAGE The rubber crawlers offers excellent features which steel crawlers do not possess.

However, if they are used the same way as the steel crawlers, then their advantages cannot be fully exploited. Operation of the machine varies upon working site and conditions.

Rubber belt

Although the rubber crawler offers many advantages thanks to the properties of its material, it also has disadvantages in terms of strength. As a consequence, it is necessary to be familiar with the characteristics of this kind of crawler.

Less vibration

⊗

Smooth operation

⊗

Low noise

⊗

Harmless for paved road

⊗

Easy handling

⊗

Resistant

Δ

Large traction force

⊗

⊗: Excellent RUBBER CRAWLER WARRANTY The warranty does not cover such damages to the rubber crawlers resulting from improper working or if their tension is inaccurate.

FORBIDDEN OPERATIONS Do not carry out the following operations: Do not travel nor work on following surfaces: gravelmixed land, rugged and solid rock bed, reinforced concrete, steel plate edges.

3-38

Ο: Good

Δ: Normal

3. MACHINE OPERATION Do not operate and/or travel in such places as river beds where there are lots of stones of different sizes. Rocks may get caught into the grooves of the rubber crawlers, thus damaging the crawler or causing it to come off. The life of rubber crawler is shorter, if it skids or rubs against the soil.

Do not let oil, fuel, solvents, etc., come in contact with rubber shoes. If this happens, wipe off crawlers with a cloth immediately.

Do not enter such hot places as an open-air fire, steel plate left in the open sun.

Do not work in asphalt levelling.

When storing the machine for a long period (more than three months), keep it in a closed room where it will not be exposed to direct sunshine or rain.

When the machine travels only on one side of the crawler, and keeps the other side floating, the crawler may come off of the rollers or get damaged.

3-39

3. MACHINE OPERATION PRECAUTIONS FOR USE Use care of the following when working.

Rubber crawlers slip easily on icy surfaces.

Take the necessary safety precautions.

Avoid making a spin turn on concrete surfaces.

Avoid abrupt changes of direction as this will cause an early wear or damage of the rubber crawlers.

Use care so that the bucket does not damage the rubber crawler while working.

Do not move the machine pressing the bucket against a concrete surface or walls.

Lower the machine slowly, if it had previously been lifted by means of the attachment.

If the machine is operated in salty corrosive places, the core metal can detach easily. Do not use the rubber crawler under such circumstances. If the rubber crawlers come in contact with these substances wash them with water.

The rubber crawlers have to be used with a temperature range between -25 °C and +55 °C. NOTE: use the rubber crawlers under proper tension, to prevent them from coming off the rollers.

Operate the rubber crawler carefully even when tensioning is proper.

Avoid changing direction of the machine on places with different level (about 20 cm). To overcome the gap, place the machine perpendicular to the obstacle.

3-40

3. MACHINE OPERATION When climbing on a slope in reverse, avoid changing the machine direction while climbing between the level ground and the slope.

If you travel on a slope with the machine higher at one side, this will risks to damage the rubber crawler. Both machine sides must travel at the same level.

Do not change the direction of the machine with the rubber crawlers positioned on earth heaps, as this could cause the rubber crawler to come off or get damaged.

3-41

3. MACHINE OPERATION 3.1.15

MACHINE OPERATION WITH ADVERSE WEATHER CONDITIONS

OPERATION WITH EXTREME COLD

S CAUTION When the temperature is extremely low, oil flow is reduced due to increased viscosity, making start-up difficult. Coolant may freeze damaging cooler and/ or engine.

FUEL AND OIL Use fuel and oil of high quality and low viscosity for each system.

Coolant In cold climates, the ratio of mixing antifreeze into the cooling system should conform with the lowest predicted ambient temperature. If coolant freezes, the radiator, crankcase and cylinder head may be damaged. To avoid freezing hazard, it is necessary to check that the cooling system is filled with an antifreeze mixture: otherwise, replace the radiator coolant with this mixture.

When shipped from the factory, the machine contains coolant mixed with all-season-type LONG LIFE COOLANT. It is recommended to inspect the coolant to maintain proper viscosity.

NOTE: in extremely frigid climates, covering the radiator is a method to aid the machine warm-up. If necessary to maintain temperatures, cover the outer edges of the radiator, leaving an opening in the centre part of the cover; thus, avoiding fan overloading. Check the instrument panel for warning icons during operation. It may be necessary to use thermal protections for cooling, fuel and engine systems and/or additional power for the battery to help start the engine. Likewise, mix coolant to a protection temperature of 5 °C, lower than the machine will experience during operation, storage or transport.

Battery When the temperature becomes low, the charging power decreases or the battery may freeze. Keep the charging rate as around 100% as possible and cover the battery with insulation material.

NOTE: keep battery terminals free of ice and snow to avoid short circuits. In extremely cold climates, remove the battery and store it overnight at room temperature.

After operation Mud and water adhering to the machine may freeze interfering with proper machine operation. Use the following general guidelines as reference to prevent malfunctions: • Remove water and mud from the machine.

Remove water adhering to the travel system thoroughly and park on dry ground to prevent the travel system from freezing.

• Retract the hydraulic cylinder rods as much as possible to reduce the exposed areas of the rods.

This will prevent mud or water on the rod faces from damaging the seal.

OPERATION ON THE SEASHORE OR IN SALTY ENVIRONMENTS Inspection before start-up Check all plugs, cocks, covers and protections for proper tightness. Torque to proper value to aid in preventing salt from entering the machine systems.

Apply grease to the electrical equipment as required to prevent corrosion.

Precautions after operation Wash the machine thoroughly to remove salt. Apply oil or grease as necessary to prevent corrosion of mechanical pieces.

3-42

3. MACHINE OPERATION CARE FOR ELECTRICAL EQUIPMENT The electrical equipment is especially sensitive to water. Be careful not to expose the electrical equipment to water when washing the machine or when it is raining. The electrical components (relays, fuses, etc.) are installed in the vicinity of the operator’s seat.

Never expose the operator’s seat to water.

OPERATION IN DUSTY AREAS Air filter Clean or replace the filter element at the corresponding intervals. See “Maintenance” section for details.

Radiator Clean the radiator regularly to prevent the radiator core from becoming clogged with dust.

Fuel Be careful not to let contamination in the fuel when refuelling. Inspect the elements and filters at the corresponding interval.

Electrical equipment Clean the starter and generator especially, at the corresponding interval, to prevent dust from accumulating.

3-43

3. MACHINE OPERATION 3.1.16

PRECAUTIONS WHEN STORING THE MACHINE FOR A LONG PERIOD

When storing the machine for more than one month, observe the following points to prevent the machine function from deteriorating.

ITEM

ACTION

CLEAN THE MACHINE

Wash the machine thoroughly.

Check the travel system for any malfunctions and service as required.

Lubricate every required part.

LUBRICATION

Check the lubrication oil to make sure it is at the proper level and for contamination.

If necessary, add oil to the motor. If engine oil is contaminated, discharge it.

• Lubricating oil deteriorates even when the machine is not used.

• Check the oil before operating the machine again.

BATTERY

Remove the battery and store it in a dry protected place. If the battery is not removed, disconnect its negative terminal.

COOLANT

If there is a possibility that the coolant may freeze, add antifreeze in the coolant suitable for the outside temperature.

Normally, long life coolant is mixed in, so it is not necessary to change the coolant.

DUST AND HUMIDITY PREVENTION

Store the machine in a dry and protected place. Should the machine has to be left outside, position it on a wooden table and cover it with a waterproof sheet, placed so as to allow ventilation.

• Retract as far as possible all cylinders rods.

Otherwise, coat the exposed cylinder rods with grease.

• Lower the bucket to the ground and place wedges under the crawlers.

• Lubricate all greasing points.

• Paint parts needing it to prevent rust formation.

3-44

3. MACHINE OPERATION ITEM PERIODICAL LUBRICATION DURING STORAGE

ACTION If the applied oil layer is insufficient, irregular wear may occur during the machine use.

Start the engine, operate the machine and the attachment, etc. once a month to lubricate all of the parts.

• Before starting the engine, check the engine oil and coolant level. Top up, if necessary.

• Remove rust preventing agent covering cylinders and rods.

• Apply rust inhibitors to cylinder rods.

• After starting the engine, warm up the machine completely.

Operate the travel, rotation and digging functions 2 or 3 times to lubricate the sliding surfaces.

• Ensure proper ventilation during warm-up operations.

USING THE MACHINE AFTER PROLONGED STORAGE

Before placing the machine back into operation, proceed as follows before starting up.

• Fully wiped off the rust inhibitors from the cylinders and piston rods.

• Refill fluids to proper levels and lubricate as required.

• Thoroughly check all systems prior to operating the machine at full load.

• Check condition of all hoses and connections.

• Replace engine oil and fuel filters and top up engine oil.

3-45

3. MACHINE OPERATION NOTES:

3-46

4. MAINTENANCE

4-1

4. MAINTENANCE

4-2

4. MAINTENANCE

4.1

GENERAL SAFETY INFORMATION

S WARNING READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS AND PROCEDURES FOUND IN THIS MANUAL BEFORE ATTEMPTING ANY OPERATION, INSPECTION, MAINTENANCE OR REPAIR OF THIS MACHINE, ATTACHMENT OR ANY OF ITS SYSTEMS. NOTE: consult your Dealer to adjust, disassemble and repair the engine, the reduction unit and the electronic devices (controller, etc.).

It is recommended, that an inspection and maintenance schedule be developed and maintained on a regular basis for this machine. Developing and maintaining such a schedule helps to keep the machine in optimum operating condition.

The information contained in this section gives the proper procedures for performing inspection and maintenance functions for this machine. This procedure illustrates all operations one after the other.

The time interval of such operations is indicated in the inspection and maintenance tables.

Basically, lubrication and maintenance intervals are determined by the hourmeter. It is also possible to perform those operations according to calendar time (daily, weekly, monthly, etc.), referring to the service hours displayed. Issues for which a precise service time cannot be specified are explained in chapter “4.13 WHEN NECESSARY”.

NOTE: the inspection and maintenance charts provided in this section give only general time intervals.

If necessary, a special plan with shorter maintenance intervals will have to be prepared, according to the special situation, for difficult working conditions, such as in dusty or humid environments, etc.

Be sure to dispose of all waste materials correctly.

Use only specified oils, fluids, lubricants, filters and replacement parts to keep machine in optimum operating condition. Only use oils and greases with the correct viscosity for the ambient temperature.

Store the containers and cans of lubricating oil, hydraulic oil and grease etc. in closed rooms. Take necessary measures to protect them from dust, water etc.

4-3

4. MAINTENANCE

4.2

GENERAL RULES AND SAFETY PRECAUTIONS

Do not attempt any other inspection or maintenance procedures other than those specified in the manual.

Carry them out after parking the machine in a flat and accessible place.

KEEP MACHINE CLEAN Thoroughly clean machine before performing inspection and maintenance procedures. This facilitates and makes certain the faults detection and the maintenance work. In this way the premature wear of some machine’s components is reduced.

READ THE SERVICE HOURMETER Read the hourmeter daily, and check with the scheduled maintenance book. Proceed with any maintenance as required.

STAY CLEAR OF MOVING PARTS Never attempt any maintenance with engine running. Always stop the engine.

Otherwise, entanglement in moving parts can cause serious injury.

To prevent accidents, care should be taken to ensure that hands, feet, clothing, jewellery and hair do not become entangled when working around moving parts.

4-4

4. MAINTENANCE APPLY NOTICE OF MAINTENANCE IN PROGRESS Before beginning any inspection or maintenance procedure, hang a “Maintenance in progress” tag to the operator’s console or to the cab door, to inform that it is forbidden to operate the machine. This tag will help prevent an accidental starting of the machine.

OBSERVE PRECAUTIONS Start the inspection and maintenance operations only if you fully understand the meaning of the safety decals.

PREVENT BURNS Use caution and wear the proper safety equipment when working around hot areas. Never change oil, engine coolant or filters immediately after a machine has been stopped. Before performing any maintenance procedure, stop the engine and let it and the radiator cool down. Skin contact with hot water or steam jets, can cause severe burns.

Engine oil, gear oil and hydraulic oil also become hot during operation. Wait for the oil and components to cool down before starting any maintenance or repair.

4-5

4. MAINTENANCE AVOID HIGH PRESSURE FLUIDS Escaping fluid under pressure can penetrate the skin causing serious injury. Release the residual pressure from ducts, before disconnecting the hydraulic lines.

PREVENT CONTAMINATION Always cap or plug lines when hydraulic components are removed, to help prevent hydraulic system contamination caused by dirt, dust or foreign bodies entering the system.

S CAUTION Never allow an hydraulic line or component to become contaminated by polluting agents. This could cause severe system damages. Contact your Dealer to obtain spare parts to be used on this machine.

INSPECT WASTE OILS AND FILTERS Check all waste oils and filters for debris and foreign matters.

It is recommended to cut the oil filters to detect possible traces.

4-6

4. MAINTENANCE CAUTION WHILE REFUELLING During the refilling of fuel or oil, avoid to remove possible strainers fitted in the filling ports.

DISPOSE OF WASTE PROPERLY Improperly disposing of waste can threaten the environment. Potentially harmful waste on excavators includes such items as lubricants, fuel, coolant, brake fluid, filters, and batteries.

Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.

Obtain information on the proper way to recycle or dispose of waste from local environmental authorities or recycling centres, or from your Dealer.

SEALS AND O-RINGS After removing the O-ring or gasket, clean the installing face, and replace with a new one.

Always replace O-rings with new ones.

Never reuse a gasket during reassembly of components. Be sure to lubricate all new gaskets with the appropriate oil before installation.

4-7

4. MAINTENANCE SUPPORT MACHINE PROPERLY Never attempt to work on the machine without securing the machine first. Always lower the attachment to the ground before any intervention on the machine. If you must work with the machine or attachment lifted, support them securely.

CAUTION DURING BUCKET REPLACEMENT Never insert your finger into the pin bore.

When aligning the pin bores, never insert your finger, hands or arms into them.

The alignment check must be carried out visually.

4-8

4. MAINTENANCE DUSTY ENVIRONMENT When the machine is operated in dusty environments, take the following precautions.

• Frequently check for the indicator for air filter restriction. Clean the filter element before the end of the specified interval.

• Clean up the radiator before the specified period, to prevent its clogging.

• Replace the filter element before the end of the specified interval.

• Clean the electric equipment, especially starter and generator, to not allow deposit of dust on them.

AVOID PIECES TO FLY OFF Oil in the travel reduction gears and grease in the idler adjusters are under pressure.

As pieces may fly off, be sure to keep body and face away from air release valve and plug to avoid injuries. Reduction gear oil overheats. Wait for it to cool down, then gradually loosen the venting plug to release pressure.

WEAR SAFETY EQUIPMENT Wear a hard hat, safety goggles or face protection, work gloves, safety shoes and well fitting work clothes when performing inspection and maintenance procedures on this machine.

4-9

4. MAINTENANCE CLEANING PARTS Use only approved cleaning solvents and proper equipment to clean parts.

S WARNING NEVER USE GASOLINE, OR OTHER FLAMMABLE SOLVENTS TO CLEAN PARTS. ALWAYS CLEAN PARTS IN A WELL VENTILATED AREA. PRESSURE IN THE HYDRAULIC TANK Always release the internal pressure of the hydraulic tank before performing inspection or maintenance procedures.

Slowly loosen the cap (1) to release pressure from the tank.

S CAUTION Gases from hydraulic tanks may be hot.

Wear safety clothes.

SAFETY DURING WELDING Turn the starter switch key to OFF. Wait 4 seconds for electrical power to disconnect.

Disconnect the negative (-) cable of the battery from the clamp.

Attach welder ground cable with 1 m (3.28 ft) from component being welded.

Do all such work outside or in a well-ventilated area.

Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area. Install temporary fire resistant guards to protect hoses or other materials when engaging in welding, soldering, etc.

4-10

4. MAINTENANCE

4.3

LUBRICANT, FUEL AND COOLANT SPECIFICATIONS

The following table indicates the proper oils, lubricants and fuels to be used with various climates and service conditions.

Components

Technical name

Quantity

Operating range (ambient temperature °C (°F))

Specifications

-20° -10° 0° 10° 20° 30° 40° (-4) (14°) (32°) (50°) (68°) (86°) (104°) Selenia IDRAULICAR AP31 Selenia IDRAULICAR AP46 Hydraulic oil tank

Selenia IDRAULICAR AP51 AKCELA HYDRAULIC EXCAVATOR FLUID

ISO VG 32 Tank: 9 l (2.4 gal) System: 18 l (4.7 gal)

ISO VG 46 * ISO VG 68 ISO VG 46 15 W 40 *

Engine oil pan

AKCELA N. 1 ENGINE OIL

Fuel tank Cooler Travel motor Upper rollers

3.0 l (0.8 gal)

10 W 30

16 l (4.2 gal) AKCELA PREMIUM ORGANIC ANTI-FREEZE

MS 1230

API CH4 ACEA E5 MS 1121 EN590

50% LLC (long life coolant)*

3.7 l (1 gal)

ASTM D 3306 Type 1

0.33 l (0.1 gal) X 2 AKCELA GEAR 135H EP

35 cc (2.14 in3) X 2

Idle wheels

45 cc (2.75 in3) X 2

Attachment and dozer pin

20-places

SAE 80 W-90

API GL5 MS 1316

Swing cylinder pin Slewing bearing

MULTI PURPOSE GREASE 251 H EP

NLGI 2 251 H EP

1 - place

Idler adjuster

2 - place

Operating lever and pedal

When required

Rotation gear

MOLY GREASE

NLGI 2 251 H EP-M

1 - place

(*) The systems are filled with the products indicated with the asterisk.

NOTE: USE OF BIO-DEGRADABLE OILS When you use bio-degradable oil, please refer to following: • there are two types of bio-degradable oil available: vegetable-based and synthetic-based. We recommend using synthetic oils, because vegetable ones have a maximum operating temperature of 80 °C (176 °F).

For this reason, the degradation of vegetable-based oil occurs more rapidly, and they have a reduced service life; • do not mix Bio-oil with original factory-filled mineral oil; in case it is necessary to use Bio-oil, flush the hydraulic system that was filled with bio-oil three times; • if you use Bio-oil, the performance of the rotation brake and that of the parking/travel brake will be reduced, because of the lower friction factor of Bio-oil compared to that of mineral oil; • for further information about the type of bio-degradable lubricant and the relevant specifications for use and maintenance, please refer to chapter 4.20 BIODEGRADABLE HYDRAULIC OIL. USE OF COOLANT • There are two types of coolant depending on the corrosion inhibitors base: ORGANIC-base and INORGANICbase.

• Mini excavators is ORGANIC-base type factory filled.

• Both type can be used, BUT THEY CANNOT BE MIXED. Flush the cooling system before change coolant type.

4-11

4. MAINTENANCE

4.4

MAINTENANCE GENERAL TABLE

PARTS TO BE REPLACED During maintenance, replace parts subjected to wear before expiry, as filters and cartridges. The machine operates more efficiently if worn parts are replaced with new parts.

No. 1

Device Hydraulic oil reservoir

Parts name

Q.ty

Return Filter

1

(O-ring)

Replacement interval After 50 hours (first change) Every 500 hours (from 2nd change) (Breaker specification: every 200 hours)

2

Hydraulic oil reservoir

Suction strainer

3

Air filter

Filter element

4

Engine oil filter

Cartridge

1

Every 2000 hours

(O-ring) When required 1

After 50 hours (first change) Every 250 hours

5

Fuel filter

Cartridge

1

Every 250 hours

1

Every 500 hours

Side cutter (right) (7a)

1

When required

Side cutter (left) (7b)

1

Screw

6

Nut

6

Tooth

3

Safety pin

3

Rubber locking pin

3

(O-ring) 6

Water separator

Cartridge (O-ring)

7

8

Bucket

Bucket

4-12

When required

4. MAINTENANCE

4.5 No. 1

TAG MAINTENANCE IN PROGRESS TOOL NAME

NOTES

Tag maintenance in progress

If tools are lost or damaged, contact your Dealer to order them.

4-13

4. MAINTENANCE

4.6

TORQUE SPECIFICATIONS FOR CAPSCREWS AND NUTS

The following torque specifications are indicated in case the actual torque value of a fastener is unknown.

Check the capscrews and nuts for their looseness and dropping off before the start of daily work and at the periodical maintenance intervals. Retighten the loose screws and nuts, and install new ones to replace the dropped ones. For the new machine, the check and retightening of loose screws and nuts must be carried out after the first 50 hours operation. When replacement is needed, make sure to use genuine parts to the same dimensions. Check the table hereunder for proper torque.

• The table hereunder, is not valid for plastic screws used to fasten hoods, etc.

• For the tightening torque of this kind of screws, contact your Dealer. Over-tightening may cause the damages of the parts to be fixed.

• If this manual specifies a different torque, use such value regardless of the table below.

• Numerical indication on the capscrew head shows the classification (A) strength (e.g.: 8.8). No indication is provided for smaller size of capscrews, M5 or less.

Standard tightening torque values.

Be certain to tighten all capscrews and nuts to proper torque values.

Torque value Unit: Nm (lbf·ft) Resistance Class

6.8

8.8

Nominal dimension

10.9

12.9

Tightening torque

M3

P = 0.5

1.19 (0.88)

1.59 (1.17)

2.24 (1.65)

2.69 (1.98)

M4

P = 0.7

2.73 (2.01)

3.64 (2.68)

5.12 (3.78)

6.15 (4.54)

M5

P = 0.8

5.41 (3.99)

7.21 (5.32)

10.14 (7.48)

12.17 (8.98)

M6

P=1

9.29 (6.85)

12.39 (9.14)

17.43 (12.86)

20.91 (15.42)

M7

P=1

15.40 (11.36)

20.54 (15.15)

28.88 (21.30)

34.66 (25.56)

M8

P = 1.25

22.46 (16.57)

29.94 (22.08)

42.10 (31.05)

50.53 (37.27)

M10

P = 1.5

45.10 (33.26)

60.14 (44.36)

84.57 (62.38)

101.49 (74.86)

M12

P = 1.75

77.20 (56.94)

102.94 (75.92)

144.75 (106.76)

173.70 (128.11)

M14

P=2

123.23 (90.89)

164.30 (121.18)

231.05 (170.41)

277.26 (204.50)

M16

P=2

189.51 (139.78)

252.69 (186.37)

355.34 (262.08)

426.41 (314.50)

M18

P = 2.5

261.17 (192.63)

348.22 (256.83)

489.69 (361.18)

587.63 (433.41)

M20

P = 2.5

370.15 (273.01)

493.53 (364.01)

694.02 (511.88)

832.83 (614.26)

M22

P = 2.5

501.62 (369.98)

668.82 (493.30)

940.53 (693.70)

1128.64 (832.44)

M24

P=3

639.61 (471.75)

852.82 (629.01)

1199.27 (884.53) 1439.13 (1061.45)

M27

P=3

943.17 (695.65)

1257.56 (927.53) 1768.45 (1304.34) 2122.14 (1565.21)

M30

P = 3.5

1280.89 (944.08) 1707.86 (1259.65) 2401.67 (1771.38) 2882.01 (2125.66)

4-14

4. MAINTENANCE

4.7

TORQUE SPECIFICATIONS FOR JOINTS AND HYDRAULIC HOSES

SLEEVE-TYPE HOSE FITTINGS Hose dimensions outer diameter x thickness mm (in)

Wrench dimension mm (in)

Tightening torque Nm (lbf·ft)

10 x 1.5 (0.39 x 0.06)

19 (0.75)

44 ± 4.9 (32.45 ± 3.61)

15 x 2.0 (0.59 x 0.08)

27 (1.06)

147 ± 20 (108.42 ± 14.75)

18 x 2.5 (0.71 x 0.10)

32 (1.26)

177 ± 20 (130.55 ± 14.75)

22 x 3.0 (0.87 x 0.12)

36 (1.42)

216 ± 20 (159.31 ± 14.75)

28 x 4.0 (1.10 x 0.16)

41 (1.61)

275 ± 29 (202.83 ± 21.39)

35 x 5.0 (1.38 x 0.20)

55 (2.17)

441 ± 44 (325.26 ± 32.45)

JOINTS FOR PIPINGS (with O-rings) Normal screw dimension (PF)

Wrench dimension mm (in)

Tightening torque Nm (lbf·ft)

1/8

14 (0.55)

17 ± 2 (12.54 ± 1.48)

1/4

19 (0.75)

36 ± 2 (26.55 ± 1.48)

3/8

22 (0.87)

74 ± 5 (54.58 ± 3.69)

1/2

27 (1.06)

108 ± 9.8 (79.66 ± 7.23)

3/4

36 (1.42)

162 ± 9.8 (119.48 ± 7.23)

1

41 (1.61)

255 ± 9.8 (188.08 ± 7.23)

Normal screw dimension (PF)

Wrench dimension mm (in)

Tightening torque Nm (lbf·ft)

1/8

17 (0.67)

15 ± 2.0 (11.06 ± 1.48)

1/4

19 (0.75)

29 ± 4.9 (21.39 ± 3.61)

3/8

22 (0.87)

49 ± 4.9 (36.14 ± 3.61)

1/2

27 (1.06)

78 ± 4.9 (57.53 ± 3.61)

3/4

36 (1.42)

118 ± 9.8 (87.03 ± 7.23)

1

41 (1.61)

137 ± 15 (101.05 ± 11.06)

HYDRAULIC HOSE

NOTE: all above torque values are subject to a dry condition.

4-15

4. MAINTENANCE

4.8

INSTALLING FITTINGS, HYDRAULIC HOSES AND TUBES

METAL FITTING The pressure exerted from the fitting (3) on the flexible (1) ensures the tightness (2). Use cautions to assemble and disassemble both pieces in order not to damage the seat.

FITTING WITH O-RING The O-ring (2), allows to insulate the oil pressure inside of hose (1) and to avoids oil spillages.

The tightening torque of the joint of each hydraulic hose (1) is determined by the diameter of the hose fitting thread. If you notice a fault of operation, repair hose connection or replace it.

When connecting worn parts, pay particular attention to keep sealing surfaces clean from dirt and try not to damage them.

O-ring If the fitting is loose and oil leaks may occur, do not tighten it. It is necessary to install a new O-ring and to check again for tightness.

Never install a damaged and deteriorated O-ring even if it is new one. The use of an O-ring other the specified one, causes oil leakage and short life of hydraulic equipment.

Joint Be careful not to damage hoses, pipes or seal faces, this can impair the tightness.

Keep seal surfaces free from dirt.

Fitting with foreign matter inside causes oil leakage.

Hose Avoid high pressure hoses to twist during connection. Life of twisted hoses is drastically reduced.

Wash pipes and hoses, both inside and outside, with washing fluid and accurately dry them before reconnection.

4-16

4. MAINTENANCE

4.9

RELEASING INTERNAL PRESSURE FROM THE HYDRAULIC SYSTEM

S WARNING HYDRAULIC SYSTEM COMPONENTS AND HOSES CAN REACH VERY HIGH TEMPERATURES DURING OPERATION. THEREFORE STOP THE MACHINE AND LET IT COOL DOWN BEFORE STARTING ANY INSPECTION OR MAINTENANCE. DANGER OF BURNS. THE HYDRAULIC OIL TANK IS UNDER PRESSURE. PRESS THE PRESSURE RELIEVE BUTTON ON THE TANK, TO RELIEVE PRESSURE BEFORE MAINTENANCE. DANGER OF PERSONAL INJURIES. RELEASING HYDRAULIC SYSTEM AND OIL TANK PRESSURE

S WARNING • NEVER CHANGE OILS OR FILTERS ON A MACHINE THAT HAS JUST FINISHED WORKING. ALLOW MACHINE TO COOL FIRST UNTIL OILS AND FLUIDS ARE WARM, NOT HOT. • RELEASE HYDRAULIC TANK PRESSURE, BEFORE WORKING WITH ANY HYDRAULIC COMPONENT, ACCORDING TO THE PROCEDURES PROVIDED BELOW. • WHEN REPLACING ANY HOSE OR SEALS, MAKE SURE THE ATTACHMENTS ARE WELL SECURED TO AVOID SUDDEN MOVEMENT OF ATTACHMENT. SLOWLY REMOVE BOLTS TO RELEASE ANY HYDRAULIC PRESSURE DURING DISASSEMBLY. Park the machine on a level surface as shown in the right figure. Fully retract the arm cylinder and bucket cylinder. Lower the boom to rest the bucket onto the ground, and lower the dozer.

In case of pilot operating lines (boom, arm, bucket, slewing) stop the engine, then operate the control levers to release pressure from each system.

NOTE: the above procedure is the only way to release internal pressure.

4-17

4. MAINTENANCE Set the safety lock lever to the LOCKED position.

Make sure that the hydraulic oil temperature is below 40 °C (104 °F).

Stop the engine, remove the starter switch key and wait for the machine to cool down.

Remove the left side guard (1).

Slowly loosen the cap (2) about half turn to release the inside pressure.

This completes the bleeding of pressure remaining in the hydraulic tank.

4-18

4. MAINTENANCE

4.10

BLEEDING AIR IN FUEL SYSTEM

If air enters the fuel system, the engine may become hard to start or it will malfunction. Proceed with the bleeding of the air that, during the replacement of the pre-cleaner (1), was introduced into the fuel system. This operation is performed in the following way: • park the machine on a level surface; • rest the bucket onto the ground; • stop the engine, remove the starter switch key and set the safety lock lever to the LOCKED position; • wait for the machine to cool down.

BLEEDING AUTOMATICALLY Fill the tank.

Turn the starter switch key to ON. Fuel pump works after 2 minutes, and air is automatically exhausted.

BLEEDING FUEL FILTER (CHANGE COCK TYPE) Deliver fuel by the pump controlled by a solenoid valve (1).

Place the fuel cock to the opened (3) position.

Push and hold the button (4) until the filter cup is filled with fuel.

Stop fuel delivery.

BLEEDING WATER SEPARATOR Loosen the water separator’s air bleed plug (5) at fuel inlet side.

Deliver fuel by solenoid pump.

Tighten air bleed plug (5) at inlet side when the fuel flow the air bleed plug becomes free of bubbles.

Loosen air bleed plug (6) at fuel outlet side.

Tighten air bleed plug (6) at outlet side when the fuel flow from the air bleed plug becomes free of bubbles.

Stop fuel delivery.

4-19

4. MAINTENANCE

4.11

REPLACEMENT OF RUBBER CRAWLER

S WARNING • THIS WORK MUST BE DONE CAREFULLY BY TWO PEOPLE. THE OPERATOR MUST OPERATE THE MACHINE AS INSTRUCTED BY THE SIGNALS OF THE PARTNER. HAVING TO CARRY OUT VISUAL CONTROLS WITH THE CRAWLER IN MOTION, REMAIN ALWAYS AT AN EMERGENCY DISTANCE AND OUTSIDE FROM THE MOVING RANGE OF THE MACHINE. WHATEVER SERVICE TO THE CRAWLERS MUST BE CARRIED OUT WITH THE MACHINE SET UP IN THE FOLLOWING WAY: • THROTTLE LEVER AT IDLE RUN; • ENGINE SHUT DOWN; • STARTER SWITCH KEY REMOVED; • SAFETY LOCK LEVER IN LOCKED POSITION. • GREASE IN THE CRAWLER IDLER ADJUSTER IS UNDER EXTREME PRESSURE AND CAN PENETRATE SKIN CAUSING SEVERE INJURY. KEEP FACE AND BODY AWAY FROM GREASE FITTING AREA. IF GREASE DOES NOT COME OUT AFTER ONE TURN OF THE GREASE NIPPLE, CONSULT YOUR DEALER FOR ASSISTANCE. • BEFORE REMOVING THE RUBBER CRAWLER, CHECK THAT THE GREASE PRESSURE HAS BEEN COMPLETELY RELEASED. • PERSONNEL MUST OBSERVE THE INSTRUCTIONS GIVEN IN PARAGRAPH “REPLACEMENT OF RUBBER CRAWLER”, OTHERWISE THERE IS A RISK OF INJURY.

4-20

4. MAINTENANCE 4.11.1

REPLACEMENT OF RUBBER CRAWLER

Turn the upper structure by 90° and lower the bucket to lift the crawler as shown.

Keep the angle between the boom and the arm to 90° and 110° and position the round part of the bucket on the ground. Place some supports (1) under the frame to support the machine.

Open the grease nipple (2) slowly so as to let grease come out and to relieve the pressure.

One turn, one turn and a half of the grease nipple (2) is sufficient, to loosen the crawler.

Insert some steel pipes (3) in the rubber crawler, then slowly rotate the sprocket backward.

When the rubber crawler leans on the pipes, slide it aside to remove it.

4-21

4. MAINTENANCE 4.11.2

INSTALLING RUBBER CRAWLERS

Turn the upper structure by 90° and lower the bucket to lift the crawler as shown.

Keep the angle between the boom and the arm to 90° and 110° and position the round part of the bucket on the ground. Place some supports (1) under the frame to support the machine.

Engage the crawler into sprocket and engage it into the crawler idler.

Slowly rotate the sprocket backwards and set the rubber crawler into position.

Engage a steel pipe (2) into the rubber crawler, and rotate the sprocket backward again to securely engage the rubber crawler with the idler adjuster.

Stop the sprocket and check whether the rubber crawler (3) is correctly positioned on the crawler idler, on the lower rollers (4) and on the sprocket.

4-22

4. MAINTENANCE 4.11.3

CHECK AND ADJUSTMENT OF TENSION ON RUBBER CRAWLER

An appropriate adjustment of tension on the rubber crawler is vital both for rubber crawler and machine life.

S WARNING SINCE THE ADJUSTMENT CHECK OF THE RUBBER CRAWLER TENSION IS CARRIED OUT WITH THE MACHINE LIFTED, THE SERIOUS DANGER THAT THE MACHINE FALLS IS ALWAYS REAL. NEVER MOVE THE MACHINE WHILE CHECKING AND ADJUSTING IT. WORK HAS TO BE PERFORMED BY TWO PERSONS, AND THE OPERATOR MUST OPERATE THE MACHINE IN ACCORDANCE WITH THE SIGNAL FROM THE PARTNER. RUBBER CRAWLER The friction of the rubber crawler with the soil varies according to working conditions and soil nature. It is therefore necessary to check frequently the crawler tension and wear.

Therefore, frequently check crawlers tension during the first 30 hours of new crawlers service.

Turn the upper structure by 90° and lower the bucket to lift the crawler as shown.

Keep the angle between the boom and the arm to 90° and 110° and position the round part of the bucket on the ground. Place some supports (1) under the frame to support the machine.

4-23

4. MAINTENANCE Measure the clearance (A) between the lower face of crawler frame and the upper face of crawler shoe at the center position of crawler frame.

Correct value (tension) (A): Rubber crawler: 45 ÷ 50 mm (1.77 - 1.96 in) If tension is not within the specified values, loosen or tension the crawler.

NOTE: if the machine is operated with loose rubber crawler, there is the risk that the crawler springs and wears prematurely.

NOTE: check the tension of crawler after accurate removal of possible earth stuck in the crawler, by washing with pressurized water.

NOTE: in case the machine is employed mainly on gravelly, muddy grounds or surfaces with rocky bumps, we recommend checking the crawler tension daily.

Adjustment It is required to adjust the tension on the crawler depending on the working place of the machine.

When working on a place with a lot of gravel or boulder, looser tension (upper limit range of tension) is preferable. With hard grounds, stronger tension (lower limit range of tension) is preferable.

S WARNING • GREASE IN THE CRAWLER IDLER ADJUSTER IS UNDER EXTREME PRESSURE AND CAN PENETRATE SKIN CAUSING SEVERE INJURY. • KEEP FACE AND BODY AWAY FROM GREASE FITTING AREA. IF GREASE DOES NOT COME OUT AFTER ONE TURN OF THE GREASE NIPPLE, CONSULT YOUR DEALER FOR ASSISTANCE.

4-24

4. MAINTENANCE Tension the crawler Provide a grease gun.

Feed grease to the grease nipple (1) with suitable grease gun (2), so that the crawler achieves proper tension.

Move the machine forwards and backwards to equally tension the crawlers on both sides.

Again check for the tension on the crawlers, and repeat the adjustment to obtain the proper tension on both crawlers.

NOTE: if the crawler is still too loose even after grease nipple has been filled, it could be that the cylinder joint or the machine are defective.

Making tension looser

S WARNING • GREASE IN THE CRAWLER IDLER ADJUSTER IS UNDER EXTREME PRESSURE AND CAN PENETRATE SKIN CAUSING SEVERE INJURY. • IF GREASE DOES NOT COME OUT AFTER ONE TURN OF THE GREASE NIPPLE, CONSULT YOUR DEALER FOR ASSISTANCE.

4-25

4. MAINTENANCE To loosen the crawler, open the grease nipple (1) slowly counterclockwise. Grease will ooze out from grease nipple base.

One turn, one turn and a half of the grease nipple (1) is sufficient, to loosen the crawler. If grease does not come out evenly, slowly rotate the raised crawler.

When the expected crawler tension is achieved, turn grease nipple (1) clockwise and tighten it.

Tightening torque: 73.5 ± 14.7 Nm (54.21 ± 10.84 lbf·ft) Move the machine forward and backward to confirm the correct tension on the crawler belts.

Again check the tension, and if it is not correct, adjust it again.

S WARNING WHEN THERE IS MATERIAL (GRAVEL, MUD, ETC.) STUCK BETWEEN THE WHEEL AND THE CRAWLER, REMOVE IT BEFORE LOOSENING THE CRAWLER.

4-26

4. MAINTENANCE

4.12

INSPECTION AND MAINTENANCE TABLE

The following table gives the recommended intervals for regular inspection and maintenance procedures. Perform inspection and maintenance according to the calendar time or operation time shown by the hourmeter, whichever comes first.

See the inspection and maintenance procedure mentioned below for details.

S WARNING READ, UNDERSTAND AND FOLLOW ALL SAFETY INSTRUCTIONS FOUND IN THIS MANUAL BEFORE PERFORMING INSPECTION AND MAINTENANCE. Symbols and their meanings:

T: regular inspection necessary according to the service hourmeter.

O: only perform as a first replacement.

Components

4: inspection and/or maintenance is needed.

Detail

Range

When required

Checking the level Engine oil

Prestart 8h

Every week 50 h

Every 3 months 250 h

Every 6 months 500 h

Every 12 months 1000 h

2000 h

Lubricant etc. (piece to be replaced)

O

3-5

4

Replacement

Page

Engine oil

O

4-48

(1°)

4

Engine oil filter

O

Cartridge

4-52

Element

4-56

(1°) Water separator Fuel filter

Engine

Air filter

Draining/Cleaning

O

4-42

Replacement

O

Replacement

O

Checking / cleaning

O

Replacement

Radiator / coolant

Element

O

Checking the level

O O

Check

4-49 4-55 4-57 3-4

Replacement Fan belt

Cartridge

O

4-59 3-8

Adjustment

O

4-51

Clogged radiator

O

4-30

Radiator cap

O

4-31

Engine cooling system hoses Checking / replacing Check for anomalous colour, noise and odour of the exhaust gas

4-53 4-54

O O

3-16

Valve clearance

O

4-27

4-61

Components

4. MAINTENANCE

Detail

Range

When required

Prestart 8h

Every week 50 h

Every 3 months 250 h

Every 6 months 500 h

Every 12 months 1000 h

Engine

Injection timing Checking / adjusting

Fuel system

Drain water and deposits

Hydraulic system

Suction strainer

3-7 O

4-45

O

Checking the level

3-8

O

3-6 Hydraulic Oil

Replacement

O

Checking / replacing

O

4-62

4

Return Filter

(1°) Checking oil leakage and damage of cylinders, etc.

Filter

O (Breaker 200 h)

O

Element

O

4-58

4-41

In-line filter / cleaning Upper structure

4-69

O

Leakages check

Hydraulic oil reservoir

4-61 O

Fuel Checking / adjusting

Page

4-69

O

Check and adjustments for contact surface of suction and exhaust valve

Hydraulic Oil

Lubricant etc. (piece to be replaced)

O

Starter and generator Checking / adjusting

Fuel tank

2000 h

O

4-64

Slewing bearing lubrication (balls)

O

Grease

4-50

Slewing bearing lubrication (pinion/ slewing bearing)

O

Grease

4-50

Gear oil

4-65

Travel reduction motor

4

Oil change

O

(1°)

Lower frame

Checking / adjusting for tension of rubber crawler Checking wear and damage of rubber shoe Travel motors and rollers

Check

Crawler idler and weel

Oil change

O O

Tool

Greasing of pins

4-37 O

4-42 O

Checking oil leakage and wear of sprocket/travel reduction motor Checking and adjusting the track width enlargement play (only on CX18B models)

4-23

4-67

O

4-42

O

4-32

Bucket

O

Grease

4-44

Boom, arm cylinder and dozer

O

Grease

4-48

Bucket

O

Replacing/Adjusting mount gap

O

Checking wear and damage of the tooth and side cutters

O

4-35 4-33

4-28

Components

4. MAINTENANCE

Detail

Range

Others

Electrical equipment

Check of the electric wiring and fuses

When required

Prestart 8h

Every 3 months 250 h

Every 6 months 500 h

Every 12 months 1000 h

2000 h

Lubricant etc. (piece to be replaced)

O

Page

4-39

Battery Checking the fluid level Measuring the specific gravity

O

Checking the function of warning lamps

O

Checking switches/levers

O

Work light replacement (lamp)

Every week 50 h

Sterile water

4-46

3-9 3-15 12V 55W (Halogen lamp)

O

4-39

Checking abnormal deformation and damage of the machine exterior

O

4-40

Checking looseness and missing of the bolts and nuts

O

4-40

O

3-15

Operating lever

Check Greasing

O

Grease

4-29

4-32

4. MAINTENANCE

4.13

WHEN NECESSARY

Carefully read and understand section “1. SAFETY PRECAUTIONS” before operating or servicing the machine.

CLEAN RADIATOR

S CAUTION Compressed air or pressure water jets will be used to perform this operation. Therefore, suitable clothing must be used to protect the body. In particular, wear glasses with side shields.

Keep people not involved in the maintenance work outside the working area.

Park the machine on a level surface.

Rest the bucket onto the ground.

Bring the throttle control lever to minimum speed, stop the engine and remove the starter switch key, then set the safety lock lever to the LOCKED position.

Remove the left side guard.

Check if radiator fins are clogged with dust or mud.

Clean accurately using compressed air or pressure water, directing the jet from cooler upper part downwards.

Adjust the jet pressure so that the radiator fins are not deformed.

Once cleaning is completed, close the left side guard and the cover under the seat.

4-30

4. MAINTENANCE CLEANING OR REPLACEMENT OF RADIATOR CAP

S WARNING USE EXTREME CARE WHEN REMOVING THE RADIATOR CAP. THE COOLANT IS UNDER HIGH PRESSURE WHEN IT IS HOT. • NEVER REMOVE THE RADIATOR CAP WHEN THE SYSTEM IS HOT. • WAIT UNTIL THE ENGINE HAS COOLED DOWN BEFORE REMOVING THE RADIATOR CAP.

S CAUTION If the cap is not sufficiently tight, there might be the risk of burning, due to the spouting out of hot water or steam during operation.

Remove the radiator cap after the engine has cooled down, so that it can be touched with bare hands.

Slowly loosen the cap to release the inside pressure.

Remove the cap from the radiator after pressure has been relieved.

Check the cap for damages or adhesion of dust.

Clean it and/or replace it if needed.

Securely tighten the cap.

4-31

4. MAINTENANCE LUBRICATION OF CONTROL LEVERS If a control lever malfunctions or operates irregularly, apply a small quantity of grease to the supports (2).

Move the machine to a level and firm ground and set the safety lock lever to the LOCKED position. Stop the engine and remove the starter switch key.

Carefully lift the rubber boot (1) taking care not to damage it.

Apply some grease to the supports (2).

Set back the rubber boot (1) to the original position.

CLEARANCE CHECK AND ADJUSTMENT TRACK WIDTH ENLARGEMENT (CX18B) Check and, if necessary, adjust clearance when the operator perceives that clearance has increased so that the operation of the machine is difficult.

Lift up the machine by around 30 cm (0.98 ft) to secure the working space under the machine and set a stable supporting stand at front and rear of the lower frame.

Lower the bucket to the ground.

Reduce the track width to the minimum, then slightly enlarge it (a few cm are sufficient) so that any interference between the adjusting screw and the corresponding slot in the track roller frame is prevented.

Check the clearance of the tubulars and adjust it by tightening the screws (1).

The screws must be hand-tightened until they are in contact with the tubular. Now lock them by tightening the nuts (2).

NOTE: the clearance check must not be performed with the lower frame resting on the ground in order to prevent: • only partially adjusting clearance; • any risk of sticking when reducing/enlarging the track width.

4-32

4. MAINTENANCE CHECK WEAR AND SLACKENING OF THE BUCKET TEETH TIPS AND SIDE CUTTERS Park the machine on a level surface.

Rest the bucket onto the ground.

Bring the throttle control lever to minimum speed, stop the engine and remove the starter switch key, then set the safety lock lever to the LOCKED position.

Their lifetime is not only determined according to the number of operating hours; it is also necessary to consider the working conditions.

Replacement of tooth tips Replace the bucket teeth in the following cases.

• When little holes appear on the teeth tips.

• When the edge lines of the teeth tips are worn.

S WARNING WEAR GOGGLES, SAFETY SHOES, HARD HAT, WORK CLOTHES AND WORK GLOVES TO PERFORM INSPECTION AND MAINTENANCE ON THIS MACHINE. Using a hammer and punching tool, hammer out the locking pin. Be careful not to damage the rubber locking pin (2).

Inspect the safety pin (3) and the rubber pin (2).

Replace them if the locking pin (3) is too short or if the rubber pin (2) is worn.

Clean the surface of the adapter (4) with a putty knife to remove the soil stuck.

Fit the tooth tip (1) onto the adapter (4).

Push the rubber pin (2) into the hole of the adapter (4).

Drive the locking pin (3) until it is aligned with the point face.

4-33

4. MAINTENANCE Replacement of the side cutters

S WARNING WEAR GOGGLES, SAFETY SHOES, HARD HAT, WORK CLOTHES AND WORK GLOVES TO PERFORM INSPECTION AND MAINTENANCE ON THIS MACHINE. Remove completely all sand and soil stuck on the capscrews. Use an acetylene torch to cut off the capscrews, then remove the side cutters (2).

Clean the mounting face and install a new side cutter (2). When replacing the side cutter, also replace the capscrews (3) and nuts (1).

Tightening torque: 115 ± 12 Nm (84.82 ± 8.85 lbf·ft) After tightening the nuts (1), spot-weld them.

4-34

4. MAINTENANCE BUCKET REPLACEMENT

S WARNING • THE BUCKET REPLACEMENT HAS TO BE CARRIED OUT ON A FIRM AND FLAT SURFACE. PAY CLOSE ATTENTION TO SAFETY INSTRUCTIONS. • WHEN ALIGNING THE PIN BORES, DO NOT INSERT YOUR FINGER INTO THE BORES. IT MAY CAUSE SEVERE INJURY. ALWAYS USE SUITABLE TOOLS TO ALIGN HOLES.

Bucket removal Lower the bucket (6) to the ground.

If the bucket leans too heavily on the ground, you will have some problems of movement.

Slightly operate the boom and the arm to remove load from pins (4) and (5) from the weight of the bucket.

Shift the O-rings (1) onto the bucket boss, so as not to damage it.

Disassemble the retainer rings (2) and the safety pins (3). Then extract the pins (4) and (5) with the shims (10). Take off the bucket (6).

NOTE: pay attention not to let any sand or dust stick to the pins removed.

NOTE: pay attention not to damage the dust seals (9) installed on arm ends (7) and on bucket link (8).

4-35

4. MAINTENANCE Bucket assembly Clean each pin and pin hole and grease sufficiently.

Move the bucket cylinder so as to match the pins bores (6) and bucket link bores (8). Then position the pins (4) with the shims (9).

Raise the boom and slightly raise the bucket from the ground.

Align bucket (6) with the bucket bores and arm bores (7). Then position the pins (5) with the shims (9).

Insert the safety pins (3) and snap rings (2) into dowels (4) and (5).

Return the O-ring (1) to normal position.

Apply grease in the grease nipples, until this oozes out from the spaces between pins and bores.

NOTE: replace broken or loose O-rings (1).

S WARNING ALWAYS USE SUITABLE TOOLS TO ALIGN BORES. DO NOT USE HANDS OR FINGERS.

4-36

4. MAINTENANCE INSPECTING RUBBER CRAWLER Repair or replace the rubber crawler under the following conditions.

Contact your Dealer for the repair or the replacement of the rubber crawlers.

Rib height When the height (A) of the ribs (1) wears off, the tractive force decreases. Replace the crawler (2) with a new one if its dimension (A) is lower than 5 mm.

Replace the crawler (2) if the lug (3) is so worn that the steel casing (1) is exposed on two links.

Crack of rubber shoe If a crack (A) about 60 mm long or more is noticed between crawler and lug, repair the rubber crawler.

However, repair the crawler immediately even though the steel cord is exposed, because of a small and short crack (B).

(C) repair not yet required.

NOTE: contact your Dealer for the repair or the replacement of the rubber crawlers.

4-37

4. MAINTENANCE Detachment of the metal core of the rubber crawler According to usage of the rubber crawler (3), there may occasionally be peeling off of metal core (2) (inner side), due to contact (A) with the lower rollers (1) and idler/sprocket, or because of the rubbing, even though there are no external damages or abrasion on the lug (outer side).

NOTE: the metal core can detach easily if the rubber crawler shoe is not used correctly.

Note that the warranty is not valid if rubber crawlers are wrongly used or if their tension is inaccurate.

Replace the rubber crawler on which the metal core (1) detaches itself, even only in one point.

Replace the torn rubber crawler on which the metal core (1) is exposed.

The rubber crawler does not need to be replaced, if the contact surface (1) between metal core and roller is cracked.

NOTE: the metal core can detach easily if the rubber crawler shoe is not used correctly.

4-38

4. MAINTENANCE WORK LIGHT The work light uses a 55 W bulb.

S CAUTION Since the light bulb develops high temperature during use, the service life of it becomes shorter if oil or grease adhere to it.

When replacing the light bulb, hold it at the flange portion without touching its glass portion.

When the work light does not turn on after switch operation, the lamp bulb or the fuse may be blown. If the bulb is in good conditions, check the fuse.

Bulb replacement Lower the bucket to the ground and set the safety lock lever to the LOCKED position, then stop the engine.

Extract the work light from the boom by loosening the nut (4).

Unscrew the connector (5) together with the bulb (2) from the body (3). Never remove the glass (1).

Unscrew the bulb (2) and install a new one.

NOTE: pay attention not to break the light bulb during replacement.

CHECK ELECTRIC WIRING AND FUSES

S WARNING • IF SHORT CIRCUIT TRACES ARE NOTICED ON THE ELECTRIC WIRING, CONTACT YOUR DEALER. • BEFORE CHECKING THE ELECTRICAL SYSTEM, DISCONNECT THE NEGATIVE (-) BATTERY CABLE. • ERRONEOUS CAUSE FIRE.

SHORT

CIRCUITING

MAY

S WARNING ALWAYS MAKE SURE TO INSTALL FUSES OF CORRECT AMPERAGE, TO AVOID OVERLOADING AND DAMAGING THE ELECTRIC SYSTEM.

4-39

4. MAINTENANCE

4.14

PRE-START (EVERY 8 HOURS) INSPECTION AND MAINTENANCE

Carefully read and understand section “1. SAFETY PRECAUTIONS” before operating or servicing the machine. The following inspection and maintenance shall be carried out before and after start up and at the end of work.

Refer to section “3. MACHINE OPERATION”.

Checking the coolant level

3-4

Checking the work light

3-9

Checking the engine oil level

3-5

Checking the warning lamps

3-9

Checking the hydraulic oil level

3-6

Checking all switches and levers

3-15

Checking the fuel level

3-7

Exhaust gas anomalous colour, noise and odour 3-16

Check fuel leaks

3-8

Machine operation

Check belt conditions

3-8

EXTERNAL VISUAL INSPECTION If proper corrective action is taken as soon as the problem is first suspected, machine maintenance costs and down-times may be consistently reduced.

Therefore, we recommend to visually inspect from outside the components daily, before starting the work or at the end of it, to assess their condition.

CHECK FOR DETACHED PIECES OR LOOSE FASTENINGS Check and make sure all capscrews and nuts are properly tight. Likewise, check and make sure that all clamps are properly tightened.

An abnormal sound during operation may cause leakage or fire.

4-40

3-18

4. MAINTENANCE VISUAL CHECK OF HYDRAULIC SYSTEM

S WARNING THE HYDRAULIC OIL TANK IS UNDER PRESSURE. BE SURE TO RELEASE THE PRESSURE IN THE SYSTEM BEFORE STARTING SERVICE AND/OR MAINTENANCE, OR REFILLING. NEVER USE HANDS TO CHECK FOR POSSIBLE LEAKS. HIGH PRESSURE OIL LEAKS CAN PENETRATE THE SKIN AND CAUSE SEVERE INJURY.

Possible hydraulic oil leaks, generate slower machine motion.

Stop the machine on a level surface and position the attachment as shown in the figure.

Bring the throttle control lever to minimum speed, stop the engine and remove the starter switch key, then set the safety lock lever to the LOCKED position.

To locate the leak, wait for the machine to cool down. Be sure to wear protective glasses and gloves for the check.

Open the left side guard (3).

Slowly loosen the cap (2) on the upper surface of hydraulic tank (1) about half turn and release the pressure in the hydraulic tank.

NOTE: if a fault is found, immediately stop working and contact your Dealer for the necessary repairs. If the coolant level becomes too low due to a leakage, a warning lamp turns on to indicate the fault.

4-41

4. MAINTENANCE CHECKING THE TRAVEL MOTORS AND THE ROLLERS Park the machine on a level surface.

Rest the bucket onto the ground.

Bring the throttle control lever to minimum speed, stop the engine and remove the starter switch key, then set the safety lock lever to the LOCKED position.

Wait for the machine to cool down.

Check for possible leakages on lower rollers (3), idlers (4) and travel motor (1).

Check condition of lower rollers (3), idlers (4) and sprockets (2). Check if fastening screws are tight firmly.

Slowly travel the machine and check for any abnormal sound.

DRAIN WATER FROM WATER SEPARATOR

S WARNING WIPE OFF FUEL ON ANY PARTS OF MACHINE. DO NOT USE GASOLINE TO CLEAN FILTER ELEMENTS. DISPOSE OF WASTE FUEL PROMPTLY IN ACCORDANCE WITH GOVERNMENT ENVIRONMENTAL REGULATION. Clean around the water separator.

Place a drip pan under the water separator.

Place the cock (1) to the (A) (closed) position to stop fuel flow.

Remove the ring nut (5) and the body (4).

Drain the cup (4) and clean the element (2) with fuel.

Paying attention to the O-ring (3), install the body (4) with the filter element (2) and secure it with the ring nut (5).

Bleed the water separator.

Place the cock (1) in the (B) (open) position, and operate the engine at idling speed for several minutes.

Check water separator for leakage. If leakage is found, loosen ring nut (5) and check O-ring (3) for damage.

4-42

4. MAINTENANCE

4.15

50-HOUR (WEEKLY) INSPECTION AND MAINTENANCE

Carefully read and understand section “1. SAFETY PRECAUTIONS” before operating or servicing the machine.

Perform together with the daily maintenance operations.

ADJUSTING THE RUBBER CRAWLER TENSION An appropriate adjustment of tension on the rubber crawlers is vital both for the rubber crawler and the machine life.

S WARNING THE CRAWLER TENSION IS CARRIED OUT WITH A MACHINE SIDE LIFTED. THIS CAN GENERATE A FALLING RISK IF THE MACHINE IS HIT ERRONEOUSLY. NEVER OPERATE THE MACHINE DURING THE INSPECTION. BE SURE TO CARRY OUT THE WORK WITH THE HELP OF ANOTHER PERSON. THE OPERATOR MUST OPERATE THE MACHINE AS INSTRUCTED BY THE SIGNALS OF THE PARTNER.

4-43

4. MAINTENANCE GREASING PINS AROUND BUCKET Greasing intervals Generally the greasing is carried out every 50 hours of service.

Move the machine to a level and firm ground. Rest the bucket onto the ground.

Bring the throttle control lever to minimum speed, stop the engine and remove the starter switch key, then set the safety lock lever to the LOCKED position.

Wait for the machine to cool down.

Clean the grease nipples before greasing. Replace if damaged.

Grease the pins using a grease gun as shown on the right (see arrows).

Properly wipe off any grease oozed out around the pin connection.

S CAUTION Dispose of all hazardous waste in accordance with current legislation.

No.

GREASING POINTS

Q’TY

A

Bucket cylinder rod pin

1

B

Idler link/arm connecting pin

1

C

Bucket link pin

1

D

Arm/bucket connecting pin

1

E

Dozer cylinder lower pin

1

F

Dozer lower pins

2

4-44

4. MAINTENANCE DRAIN DEPOSITS FROM FUEL TANK

S WARNING EXTINGUISH ALL SMOKING MATERIALS AND NAKED FLAMES BEFORE CHECKING FUEL LEVEL, REFUELLING, REPLACING FILTERS, OR REMOVING THE CONDENSATE DRAIN PLUG, BECAUSE OF FLAMMABLE VAPOURS. THOROUGHLY WIPE OFF ANY SPILLED FUEL. Park the machine on a level surface with the upper structure turned by 90° in order to make access easier.

Rest the bucket onto the ground.

Bring the throttle control lever to minimum speed, stop the engine and remove the starter switch key, then set the safety lock lever to the LOCKED position.

S WARNING STOP THE ENGINE BEFORE DRAINING FUEL FROM THE FUEL TANK. THOROUGHLY WIPE OFF ANY SPILLED FUEL. Loosen the filler plug of the fuel tank.

Loosen the drain plug to drain the water and deposits in an empty container.

Since the water is deposited during the night, it is effective to drain before starting up the engine in the morning.

Slew the upper structure of the machine so that the drain valve under the fuel tank comes to midway between the left and right crawlers.

Place a empty container under the drain plug to catch the fuel discharged.

Slowly loosen the drain plug to drain water mixed in and deposits together with the fuel.

When pure fuel begins to flow, tighten up the drain plug.

IMPORTANT: check for fuel leakage after tightening up the drain plug. If fuel leaks occur, stop the engine and contact your Dealer.

4-45

4. MAINTENANCE CHECKING THE BATTERY

S WARNING BATTERY GAS MAY EXPLODE. KEEP AWAY SPARKS AND FLAMES. USE A POCKET TORCH TO CHECK ELECTROLYTE LEVEL. SULPHURIC ACID CONTAINED IN THE BATTERY ELECTROLYTE IS POISONOUS. IT CAN BURN THE SKIN, CORRODE CLOTHES AND CAUSE LOSS OF SIGHT IF SPRAYED INTO THE EYES. IF ACID COMES IN TOUCH WITH THE SKIN: • WASH SKIN WITH WATER. • IF ACID HAS REACHED THE EYES, WASH WITH WATER FOR AT LEAST 15 MINUTES. IMMEDIATELY SEEK MEDICAL ATTENTION. Check the warning lamp (A) on the battery; the lamp turns on green when the battery is charged. If the light is red, this means that the battery is discharged.

Park the machine on a level surface with the upper structure turned by 90° in order to make access easier.

Rest the bucket onto the ground.

Bring the throttle control lever to minimum speed, stop the engine and remove the starter switch key, then set the safety lock lever to the LOCKED position.

Keep the terminals and plugs located on top of the battery clean at all times to prevent battery from discharging. Check battery terminals, clamps should not be loose and should not show signs of rust or oxidation. Apply petroleum jelly to the terminals to prevent corrosion.

4-46

4. MAINTENANCE ARMS AND ATTACHMENT LUBRICATION NOTE: under normal conditions, apply grease every 50 working hours or every week. Under particular working conditions, observe following lubrication intervals: • when operating the machine with special attachments, apply grease to each of these devices before starting working.

• for underwater digging, apply grease to the areas immersed in water every day.

Make sure that the machine is parked on a level surface.

Rest the bucket onto the ground and position the boom to obtain easy access to all greasing points shown. If necessary, use only safety ladders during lubrication.

Bring the throttle control lever to minimum speed, stop the engine and remove the starter switch key, then set the safety lock lever to the LOCKED position.Make sure to clean the grease fittings before the greasing. Replace if damaged.

Use table below for lubrication. Inject grease in the grease nipples of the links indicated by the arrows, until grease oozes out.

Completely eliminate the used grease on the outside of the pin.

No. GREASING POINTS Q.ty 1 Dozer cylinder rod pin 1 Dozer cylinder bottom 2 1 pin 3 Dozer fastening pins 1 4 Boom foot pin 1 5 Boom cylinder foot pin 1 6 Boom cylinder rod pin 1 7 Arm cylinder foot pin 1 8 Arm cylinder rod pin 1 Boom/arm connecting 9 2 pin 10 Bucket cylinder foot pin 1 11 Bucket cylinder rod pin 1 12 Slewing cylinder foot pin 1 13 Slewing cylinder rod pin 1 14 Support slewing pin 2

4-47

4. MAINTENANCE

4.16

250-HOUR (3-MONTH) INSPECTION AND MAINTENANCE

Carefully read and understand section “1. SAFETY PRECAUTIONS” before operating or servicing the machine.

ENGINE OIL CHANGE

S WARNING DO NOT CHANGE THE ENGINE OIL IMMEDIATELY AFTER THE ENGINE HAS STOPPED. ALLOW SUFFICIENT TIME FOR THE ENGINE TO COOL DOWN. THE FIRST OIL CHANGE MUST BE CARRIED OUT AT 50 HOURS OPERATION FOR A NEW MACHINE ENGINE.

S CAUTION Avoid prolonged repeated skin contact with exhaust engine oil as skin diseases or other syndromes may result. If this happens, thoroughly wash the area of contact.

Move the machine to a firm, level ground and run engine for 5 minutes if engine has been off for 1 or more hours to warm the oil. Stop the engine.

Under the engine loosen the cover plate bolts and remove the cover (2).

Clean around yellow oil filler cap (4), remove the cap (4).

Slowly loosen drain cap (1) so that the oil does not splash over yourself.

Make sure to contain any oil spillage.

Inspect the drained oil for metal particles or foreign materials. If foreign bodies are found, contact your Dealer.

Securely tighten the drain plug (1).

Fill with the specified engine oil through oil filler port (4) slowly.

Install oil filler cap (4).

Before starting the engine, check the engine oil level using the dipstick (3). The level should be between the (H) and (L) limits as shown in the figure.

Start and run the engine for 5 minutes. Stop the engine and check the oil level after 30 minutes.

If necessary, add oil.

Reassemble the lower plate (2).

4-48

4. MAINTENANCE REPLACEMENT OF FUEL FILTER

S WARNING NEVER USE GASOLINE, SOLVENTS OR OTHER FLAMMABLE FLUIDS TO CLEAN COMPONENTS. ONLY USE APPROVED NON-FLAMMABLE AND NON-TOXIC SOLVENTS.

S CAUTION You are reminded that the engine can reach a high temperature during operation. Protect body and limbs with appropriate clothing and protections, since there is a danger for burns and personal injuries.

Park the machine on a level surface.

Rest the bucket onto the ground.

Bring the throttle control lever to minimum speed, stop the engine and remove the starter switch key, then set the safety lock lever to the LOCKED position.

Wait for the machine to cool down.

Open the engine guard and lock it open.

Clean the area around filter and support (1).

Loosen the cartridge (4) together with the seal (3) by means of a universal tool.

Apply a thin coat of engine oil to the seal (3) of the new cartridge (4). Insert the cartridge and tighten it by hand. Then retighten it of about 2/3 of turn.

Start the engine, and operate it at idling for several minutes to check for any leakage at the installing face.

Close the engine guard.

4-49

4. MAINTENANCE GREASING THE SLEWING BEARING

S WARNING NEVER SLEW THE UPPER STRUCTURE WHILE APPLYING GREASE TO THE SLEWING BEARING.

S WARNING THE LUBRICATION OF THE SLEWING BEARING, OF THE GEAR AND OF THE UPPER STRUCTURE ROTATION SHOULD BE CARRIED OUT BY ONE PERSON ONLY. BEFORE LUBRICATING THE SLEWING BEARING, SEND AWAY PERSONS FROM MACHINE WORKING RANGE. Before leaving the cab, arrange machine and controls as follows: Place the machine on a level surface.

Rest the bucket onto the ground.

Bring the throttle control lever to minimum speed, stop the engine and remove the starter switch key, then set the safety lock lever to the LOCKED position Slewing bearing lubrication (balls) With the upper structure stopped, inject grease through the grease nipple (1).

Start the engine, raise the bucket approximately 20 cm (0.66 ft) from the ground and slew the upper structure by 45° (1/8 of a turn).

Rest the bucket onto the ground.

Repeat the procedure above three times. Always observe the safety indications prescribed.

Grease should be injected until it comes out of the seals. Do not inject grease excessively.

Slewing bearing lubrication (pinion/slewing bearing) With the upper structure stopped, inject grease through the grease nipple (4).

Apply two grease cartridges: - apply the first cartridge positioning the upper structure at 0°.

- apply the second cartridge positioning the upper structure at 180°.

Start the engine, raise the bucket about 20 cm (0.66 ft) above the ground and turn the upper structure four times altogether.

REPLACEMENT OF GREASE IN SLEWING GREASE BATH When the machine works immersed in water up to the upper structure, the grease (2) inside the slewing bearing (3) of the upper structure can deteriorate. Therefore, the pinion of the rotation motor and the internal gears of the slewing bearing may suffer damage. Contact your Dealer to know if grease has to be changed.

S WARNING THE LUBRICATION OF THE SLEWING BEARING, OF THE GEAR AND OF THE UPPER STRUCTURE ROTATION SHOULD BE CARRIED OUT BY ONE PERSON ONLY. BEFORE LUBRICATING THE SLEWING BEARING, SEND AWAY PERSONS FROM MACHINE WORKING RANGE.

4-50

4. MAINTENANCE BELT TENSION ADJUSTMENT

S WARNING DO NOT APPROACH BELTS OR MOVING PARTS WITH YOUR BODY. BE PARTICULARLY CAUTIOUS NEAR FANS (ALTERNATOR AND COOLER FAN).

S CAUTION The engine, when in operation, can reach high temperatures. Therefore, before performing this operation, stop the machine and let it cool down. In the event it is imperative to operate just the same on an hot engine, protect body and limbs with appropriate clothing and protections, since there is a danger of scalds and personal injuries.

Check the fan belt for its tension, wear conditions and damages.

Be sure to adjust tension properly.

Adjusting the fan belt Place the machine on a level surface.

Rest the bucket onto the ground.

Stop the engine, remove the starter switch key and set the safety lock lever to the LOCKED position.

Wait for the machine to cool down.

Slightly loosen the fastening screw (2) and the adjusting screw (3).

Loosen bolt (3) to set the tension of the fan belt.

Tighten the fastening screw (2) and the adjusting screw (3).

After adjustment, rotate engine at low idle for about 5 minutes, then check the tension of belt.

Reinstall cover (1).

4-51

4. MAINTENANCE REPLACEMENT OF ENGINE OIL FILTER

S DANGER Do not run the engine in confined spaces without proper ventilation and/or a suitable system capable to remove harmful exhaust gases.

S WARNING REMEMBER THAT ENGINE AND OIL CAN REACH HIGH WORKING TEMPERATURES; THEREFORE, WHILE CARRYING OUT THIS OPERATION WHEN THE ENGINE IS STILL HOT, PROTECT YOUR BODY WITH SUITABLE CLOTHING AND REPAIRS, SO AS TO AVOID BURNS AND PERSONAL INJURIES.

S CAUTION Avoid prolonged repeated skin contact with exhaust engine oil as skin diseases or other syndromes may result. If this happens, thoroughly wash the area of contact.

NOTE: the oil filter is a cartridge-type filter, that cannot be re-used or cleaned.

On a new machine replace this filter after the first 50 service hours.

The filter wrench provided on the machine is used for the removing.

Stop the engine and open the engine guard to remove the lower cover.

Place the filter wrench (2) on the filter cartridge (1), and turn the wrench with wrench turning counterclockwise to remove it.

Wipe off any dirt on the seal face of filter base, and avoid contamination.

4-52

4. MAINTENANCE Apply a thin coating of engine oil to the seal (3) of the new oil filter. Install and tighten by hand turning about 2/3 of a turn after the seal contacts the engine.

Start and run the engine at low idle for 5 minutes to check for leaks.

Close the engine guard and reinstall the lower cover under the engine.

IMPORTANT: if the machine is operated in very dusty conditions, change the oil filter at a reduced hours interval.

If metal particles or foreign material are noticed in the oil filter, contact your Dealer.

IMPORTANT: dispose of all hazardous waste in accordance with government environmental regulations.

CHECKING RADIATOR HOSES Replacing the hoses before any problems occur is both economical and good maintenance practice.

This will reduce costs and minimize unexpected interruption of working. Replace an old and damaged hose immediately. In this way troubles are avoided. Carefully inspect the sleeves for integrity and sealing (replace if necessary) and tighten possibly loose straps. Check the there are no leakages from the radiator, damages or accumulation of dirt.

4-53

4. MAINTENANCE REPLACING RADIATOR HOSES

S DANGER Do not run the engine in confined spaces without proper ventilation and/or a suitable system capable to remove harmful exhaust gases.

S WARNING LIQUID UNDER PRESSURE; TURN RADIATOR CAP SLOWLY TO RELIEVE PRESSURE. TO AVOID SCALDS DO NOT LOOSEN RADIATOR CAP WITH ENGINE STILL HOT. DO NOT PERFORM THIS OPERATION WHEN THE MACHINE IS STILL HOT. CONTACT WITH ENGINE COOLANT AT WORKING TEMPERATURE MAY CAUSE SCALDS AND PERSONAL INJURIES. Park the machine on a level surface.

Rest the bucket onto the ground.

Bring the throttle control lever to minimum speed, stop the engine and remove the starter switch key, then set the safety lock lever to the LOCKED position.

Wait for the machine to cool down.

Open the door of the radiator compartment and the engine guard and lock them open.

Open radiator plug (1) slowly, so as to relieve pressure.

Remove the under cover located lower position of radiator, and loosen the drain plug (2). Then drain the coolant into a suitable container. When this operation is finished, reinstall plug (2).

Loosen the clamp and remove damaged hose or replace it with a new one.

Fill the radiator (3) and the tank (4) through the plug (1).

After filling, tighten securely the radiator cap (1).

4-54

4. MAINTENANCE CHECKING AND CLEANING THE AIR FILTER

S WARNING OPERATIONS TO BE CARRIED OUT ALSO IF THE RELEVANT LAMP TURNS ON.

S CAUTION Always wear safety glasses with side shields when using compressed air to clean parts to reduce the risk of personal injuries due to projected particles.

Cleaning and replacement of the outer and inner filter element.

• Cleaning: When warning is indicated on multi display.

• Replacement: After cleaning for the 6th time or an interval of 6 months (500 hours).

Cleaning the filter element Park the machine on a level surface.

Rest the bucket onto the ground.

Bring the throttle control lever to minimum speed, stop the engine and remove the starter switch key, then set the safety lock lever to the LOCKED position.

Open the engine guard.

Unhook the clamp (1).

Turn the cover (2) counterclockwise and remove it.

Clean the inside of the air filter body (4).

To clean the element (3), blow compressed air (less than 0.3 MPa) up and down along the folds of the filter element interior to remove clogged dust or other contaminants.

Check that there are no holes or cuts in the filter placing a proper light inside the filter. If the light shows holes or cuts in the element, it must be replaced. In any case, the element must be replaced every year.

Insert the element (3), making sure that it is correctly positioned.

Install the cover (2), locking it by means of the two clamps (1), and direct the “TOP” mark towards the inlet side of the cover.

Close the engine guard.

4-55

4. MAINTENANCE

4.17

500-HOUR (6-MONTH) INSPECTION AND MAINTENANCE

Carefully read and understand section “1. SAFETY PRECAUTIONS” before operating or servicing the machine. Perform this operation at the same time of inspection and maintenance, that have to take place every day and after 500 service hours.

WATER SEPARATOR REPLACEMENT

S WARNING DISPOSE OF WASTE FUEL PROMPTLY IN ACCORDANCE WITH GOVERNMENT ENVIRONMENTAL REGULATION. Clean around the water separator.

Place a drip pan under the water separator.

Place the cock (1) to the (A) (closed) position to stop fuel flow.

Remove the ring nut (5) and the body (4).

Drain the cup (4) and remove the element (2).

Insert the new element (2) into the body (4), replace the O-ring (3) and install the body (4) by tightening the ring nut (5).

Bleed the water separator.

Place the cock (1) in the (B) (open) position, and operate the engine at idling speed for several minutes.

Check water separator for leakage. If leakage is found, loosen ring nut (5) and check O-ring (3) for damage.

4-56

4. MAINTENANCE REPLACEMENT OF THE FILTER ELEMENT OF THE AIR FILTER Replacement must be performed after the 6th cleaning, after six months (500 hours) or in case of damage.

Perform the following operations: Park the machine on a level surface.

Rest the bucket onto the ground.

Bring the throttle control lever to minimum speed, stop the engine and remove the starter switch key, then set the safety lock lever to the LOCKED position.

Open the engine guard.

Unhook the clamp (1).

Turn the cover (2) counterclockwise and remove it.

Remove the old filter element (3).

Clean the inside of the filter body (4).

Insert the new filter element (3), making sure that it is correctly positioned.

Install the cover (2), locking it by means of the two clamps (1), and direct the “TOP” mark towards the inlet side of the cover.

Close the engine guard.

4-57

4. MAINTENANCE REPLACEMENT OF THE OIL RETURN FILTER The return filter keeps the hydraulic oil clean by removing any foreign material that may be in the oil.

This will prevent the hydraulic equipment from becoming damaged and prolong the equipment’s life. Thus, since the return filter is a very important part, treat it with care.

S WARNING HYDRAULIC SYSTEM COMPONENTS AND HOSES CAN REACH VERY HIGH TEMPERATURES DURING OPERATION. THEREFORE STOP THE MACHINE AND LET IT COOL DOWN BEFORE STARTING ANY INSPECTION OR MAINTENANCE. DANGER OF BURNS. THE HYDRAULIC OIL TANK IS UNDER PRESSURE. PRESS THE PRESSURE RELIEVE BUTTON ON THE TANK, TO RELIEVE PRESSURE BEFORE MAINTENANCE. DANGER OF PERSONAL INJURIES. Stop the machine on a level ground and place the attachment as shown in the figure.

Bring the throttle control lever to minimum speed, stop the engine and remove the starter switch key, then set the safety lock lever to the LOCKED position.

Wait for the machine to cool down.

Remove the left side guard (1).

Slowly loosen the cap (2) about half turn to release the inside pressure.

Remove the screws (5) and cover (4) from the side surface of the tank.

Take out the filter (6) from the tank.

Loosen and remove the filter (6) from the hose (7).

Replace the O-ring (3) fitted on the face of the cover (4).

Clean the parts taken out with light oil.

Install element by the reverse procedures.

Install cover (4) by fastening it with the screws (5).

Tightening torque: 23.5 ± 2 Nm (17.33 ± 1.48 lbf·ft) Start and run the engine at idle. Moving the machine controls to remove air from the system. Then position the machine in order to check the oil level.

Stop the engine, check the oil level and top up, if necessary.

Install the left side guard (1).

4-58

4. MAINTENANCE

4.18

1000-HOUR (12-MONTH) INSPECTION AND MAINTENANCE

Carefully read and understand section “1. SAFETY PRECAUTIONS” before operating or servicing the machine.

Perform this operation at the same time of inspection and maintenance, that have to take place every day and after 500 service hours.

REPLACEMENT OF COOLANT

S DANGER Do not run the engine in confined spaces without proper ventilation and/or a suitable system capable to remove harmful exhaust gases.

S CAUTION Liquid under pressure; turn the radiator cap slowly to relieve pressure before removing it.

To prevent scalds, do not loosen the radiator cap with engine still hot.

Do not perform this operation when the machine is still hot. Contact with engine coolant at working temperature may cause scalds and personal injuries.

S WARNING NEVER USE SEALANT ADDITIVES TO STOP LEAKS FROM THE COOLING SYSTEM. FAILURE TO OBSERVE THIS RULE MIGHT CAUSE SYSTEM OBSTRUCTION WITH CONSEQUENT INSUFFICIENT FLOW OF COOLANT, TEMPERATURE INCREASE AND ENGINE OVERHEATING.

4-59

4. MAINTENANCE Park the machine on a level surface.

Rest the bucket onto the ground.

Bring the throttle control lever to minimum speed, stop the engine and remove the starter switch key, then set the safety lock lever to the LOCKED position.

Stop the engine. Open the engine guard. Wait for the system to cool down before servicing.

Loosen the radiator cap (1) slowly. After ensuring that the pressure has been released, push the cap down and hold it down while turning to remove.

Drain the coolant through a hose into an empty container.

After draining, install the drain plug (2). Then fill the cooling system with the mixture of water and system cleaner.

Operate the engine at a speed slightly higher than low idling by means of the lever (5) to raise the coolant temperature up to 80 °C (176 °F), within the white range on the coolant temperature gauge.

Operate the engine for approximately 10 minutes.

Stop the engine. Allow the engine to cool. Loosen the radiator cap slowly. After ensuring that the pressure has been released, push the cap down and hold it down while turning to remove. Loosen the radiator drain plug (2). Flush the radiator (3) with clean water until the water draining becomes clear.

Install the radiator drain plug (2).

The radiator shall be filled up. Start and run the engine for a while to fully release air from the cooling system.

Stop the engine. Allow the engine to cool. Check the coolant level (the level inside the tank (4) must be between the FULL and LOW marks).

Adjust level is to specifications.

Check the system for leaks. Repair all leaks. Close the engine guard.

IMPORTANT: it is recommended that the following service work be done by a qualified service professional. Contact your Dealer to obtain qualified service.

4-60

4. MAINTENANCE CHECKING AND ADJUSTMENT FOR VALVE CLEARANCE This is to correct the time lag at which exhaust and intake valves open and close. If this maintenance operation is ignored, faults may occur.

CHECKING AND ADJUSTMENT FOR STARTER AND GENERATOR There is a possibility of worn-out brushes and/or lack of grease lubrication on bearing.

This is of the adjustment to get good start ability and power generation.

4-61

4. MAINTENANCE

4.19

2000-HOUR SERVICE INSPECTION AND MAINTENANCE

Carefully read and understand section “1. SAFETY PRECAUTIONS” before operating or servicing the machine. Perform this operation at the same time of inspection and maintenance, that have to take place every day and after 1000 service hours.

OIL CHANGE IN HYDRAULIC OIL TANK AND CLEANING OF SUCTION FILTER

S DANGER Do not run the engine in confined spaces without proper ventilation and/or a suitable system capable to remove harmful exhaust gases.

S WARNING HYDRAULIC SYSTEM COMPONENTS AND HOSES CAN REACH VERY HIGH TEMPERATURES DURING OPERATION. THEREFORE STOP THE MACHINE AND LET IT COOL DOWN BEFORE STARTING ANY INSPECTION OR MAINTENANCE. DANGER OF BURNS. THE HYDRAULIC OIL TANK IS UNDER PRESSURE. PRESS THE PRESSURE RELIEVE BUTTON ON THE TANK, TO RELIEVE PRESSURE BEFORE MAINTENANCE. DANGER OF PERSONAL INJURIES. Park the machine on a level surface with the upper structure turned by 90° in order to make access easier.

Bring the throttle control lever to minimum speed, stop the engine and remove the starter switch key, then set the safety lock lever to the LOCKED position.

Wait for the machine to cool down and open the side guard.

Clean the upper side of the hydraulic oil tank to prevent dirt to contaminate the hydraulic system.

Place an oil collection container (4) under the machine beneath the oil tank.

4-62

4. MAINTENANCE Remove the side guard (3).

Release the residual pressure from the hydraulic tank, remove the filler plug (2).

Loosen and remove the plug (1) and drain all oil from the tank.

Once the tank has been drained, reinstall the plug (1).

Loosen and remove the screws (8).

Remove the cover (7) together with the suction filter (5).

Loosen and remove the suction filter (5).

Remove the dirt from the suction filter (5) and wash it with cleaning solvent. If the suction filter (5) is damaged, replace it with a new one.

Check the bottom of the strainer (5) and the O-ring (6) for damage. When it is worn or damaged, replace it with a new one.

Install the suction filter (5) onto the cover (7).

Assemble the cover (7) and fasten it with the screws (8).

Fill the hydraulic oil tank through the hole of the filler plug (2).

Install the right side guard.

Start the engine and let it run for 5 to 7 minutes at low idling speed. Operate each cylinder to its full travel and make a complete rotation to remove any air from the hydraulic system. Return the machine to the hydraulic oil level check position.

Stop the engine, check the oil level and top up, if necessary.

4-63

4. MAINTENANCE PILOT VALVE FILTER AND SOLENOID VALVE FILTER CLEANING

S WARNING HYDRAULIC LINE IS ALWAYS HIGHLY PRESSURIZED. BEFORE INSPECTION AND SERVICING, RELEASE HYDRAULIC SYSTEM PRESSURE. USE DRAIN PANS TO AVOID OIL SPILLS AND FIRE. The port (P) of the right and left pilot valves (for travel operation) and of the solenoid valve are equipped with a connector with filter. Dirt, etc. that adheres on the filter will decrease oil flow. If dirt, etc. enter in the valve it may cause trouble.

Remove and clean filter, periodically.

Move the machine to a level and firm ground, place the attachment in the hydraulic oil check position, then stop the engine.

Carry out the air releasing for the hydraulic line.

Loosen 2 bolts (3) on the operating box to remove the cover.

First of all disconnect the hose (1) connected to port (P) of the pilot valve (4), then remove the connector with the filter (2).

After the removal, put a plug to the bore to prevent entry of foreign matter.

Wear face protection, wash the filter with cleaning solvent. Use compressed air to remove any material.

Check the O-ring (5) for damage, and replace it with a new one, if damaged.

After cleaning, install it to the original position in the reverse order of the above (3) and (4).

Install the floor mat and floor plate. First disconnect the hose (7) connected to port (P) of the pilot valve (8), then remove the fitting (6). After removal, plug the openings to prevent the entry of foreign bodies and carefully clean the various components.

Check the O-ring (9) for damage and replace it with a new one.

After the cleaning, install it to the original position in the reverse order of the above removal.

4-64

4. MAINTENANCE OIL CHANGE FOR TRAVEL REDUCTION UNIT

S WARNING REMEMBER THAT ENGINE AND OIL CAN REACH HIGH WORKING TEMPERATURES; THEREFORE, WHILE CARRYING OUT THIS OPERATION WHEN THE ENGINE IS STILL HOT, PROTECT YOUR BODY WITH SUITABLE CLOTHING AND REPAIRS, SO AS TO AVOID SCALDS AND PERSONAL INJURIES. SLOWLY REMOVE SCREW PLUG FOR OIL FILLING, DRAIN AND LEVEL FROM REDUCTION UNITS. THIS IN ORDER TO DISCHARGE SLOWLY THE PRESSURE ACCUMULATED IN THE REDUCTION UNITS. WHEN YOU CARRY OUT OIL REPLACEMENT, STAY BACK WITH RESPECT TO THE REDUCTION UNIT SIDE AND ALWAYS WEAR PROTECTION GLASSES. THE ALIGNMENT OF FILLING, DRAIN AND LEVEL PLUGS ON REDUCTION UNITS, IS DESCRIBED BELOW AND HAS TO BE CARRIED OUT WITH THE HELP OF ANOTHER PERSON. THIS MUST THOUGH REMAIN STRICTLY OUTSIDE THE MANOEUVRING RANGE OF THE ENGINE. NEVER CARRY OUT MAINTENANCE OR INSPECTION ON TRANSLATION MOTOR CIRCUITS ON SLOPES. THEY ARE HIGHLY PRESSURIZED BECAUSE OF THE MACHINE WEIGHT. With a new machine the first oil change is to carry out after the first 50 service hours.

Park the machine on a level surface. The reduction units should be positioned as to have the plugs (1), (2) as shown. The respect of this position is essential for the accuracy of the maintenance operation.

Rest the bucket onto the ground.

Bring the throttle control lever to minimum speed, stop the engine and remove the starter switch key, then set the safety lock lever to the LOCKED position.

Place a container under the drain port (1) to collect oil.

Slowly remove the filler (2) and level (3) plugs with an Allen wrench.

Then remove the plug of drain port (1) to discharge oil into the container.

Apply a sealing (teflon) tape on the thread of drain plug (1), and securely tighten the plug (1).

Slowly fill with oil through filling port (2), until oil comes out from level port (3). Oil flowing out indicates that the correct level is reached.

4-65

4. MAINTENANCE

Apply sealing (teflon) tape on the threads of the level (3) and filler (2) plugs, then retighten them.

Thoroughly wipe off oil residues.

Travel at low speed and check for oil leaks.

NOTE: check used oil. If metal particles are found, contact your Dealer.

4-66

4. MAINTENANCE OIL CHANGE FOR IDLER AND WHEEL

S WARNING GREASE IN THE CRAWLER IDLER IS UNDER PRESSURE AND CAN PENETRATE THE SKIN, THUS CAUSING SEVERE INJURY. KEEP FACE AND BODY AWAY FROM GREASE FITTING AREA. IF GREASE DOES NOT COME OUT AFTER ONE TURN OF THE GREASE NIPPLE, CONSULT YOUR DEALER FOR ASSISTANCE. Remove lower roller and idler wheel to discharge oil.

The procedures for removal, installation and change of gear oil are described hereunder.

Crawler idler For oil discharge, remove rubber crawler according to relevant side.

S WARNING THE INSPECTION OF THE CRAWLER TENSION IS CARRIED OUT WITH ONE SIDE OF MACHINE RAISED. THIS CAN GENERATE A FALLING RISK IF THE MACHINE IS HIT ERRONEOUSLY. NEVER OPERATE THE MACHINE EXCEPT THE RUBBER CRAWLERS DURING SUCH WORK. Turn the upper structure by 90° and lower the bucket to lift the crawler as shown.

Keep the angle between the boom and the arm to 90° and 110° and position the round part of the bucket on the ground.

Place some supports (1) under the frame to support the machine.

4-67

4. MAINTENANCE Pull off the idler wheel (1) and adjuster (2) from the crawler frame.

Weight of the idler wheel: 22 kg (48.50 lb) Loosen the cap (3) and let the oil drain into a container.

Fill gear oil through the plug hole (3).

Apply a sealing (teflon) tape on the thread of the plug (3), then tighten the plug. Dry oil residues.

Apply grease to the sliding surface (A) of the piston (4), of the cylinder (5) and of the crawler idler (2).

Install the idler so that the plug (3) and the grease nipple (6) of the crawler idler are facing outwards.

Tension the rubber crawler.

After confirmation of rubber crawler engagement with the idler and the conditions for tension, lower the machine to the ground, removing the safety support, etc.

4-68

4. MAINTENANCE CHECKING AND ADJUSTMENT FOR FUEL INJECTION TIMING This is to adjust the fuel injection timing to optimise the engine performance.

CHECK AND ADJUSTMENT OF THE CONTACT SURFACE OF THE SUCTION AND DRAIN VALVE This is to ensure the gas-tightness on the exhaust and suction valves to optimise the engine performance.

NOTE: the following procedures require professional skill, because they are for the inspection and maintenance inside the engine. Since the adjustment requires special knowledge, contact your Dealer.

4-69

4. MAINTENANCE

4.20

BIODEGRADABLE HYDRAULIC OIL

Specifications Recommended oils PANOLIN AG. - HLP SYNTH 46 AKCELA HYDRAULIC EXCAVATORS FLUID BIO. Operating range Ambient temperature: from -20 °C (-4 °F) to +40 °C (104 °F).

Instructions for use IMPORTANT: biodegradable hydraulic oil must not be mixed with mineral hydraulic oil.

Oil change

Oil sampling for analysis

Every 2000 hours

Every 500 hours

Oil samples to be analysed should be taken every 500 hours of operation using the sampling kit and related instructions supplied by the Dealer.

The samples should be sent by the Customer to the Oil Manufacturer, who will carry out the necessary checks. The Dealer will inform the customer if the oil features necessary for use have changed.

IMPORTANT: if special equipments (hydraulic breaker, etc.) are used, oil sampling for analysis should be done every 250 hours.

IMPORTANT: if the Dealer informs the customer that the oil has exceeded the service limits, proceed to its replacement. Failure to observe this measure will invalidate the warranty and may cause damages to the machine.

To change the biodegradable hydraulic oil, please proceed as indicated in the preceding pages.

Replacing mineral hydraulic biodegradable hydraulic oil

oil

with

IMPORTANT: when buying a machine filled with mineral hydraulic oil and wanting to replace it wit biodegradable oil (optional), it is necessary to have the replacement operation carried out by the Dealer. This because an accurate drainage of mineral oil and a complete wash of the hydraulic system is necessary. Remember that mineral hydraulic oil must not be mixed with biodegradable hydraulic oil.

4-70

5. TRANSPORTATION

5-1

5. TRANSPORTATION

5-2

5. TRANSPORTATION

5.1

WHEN PREPARING TRANSPORTATION PLANS

Before preparing the machine for transport, refer to section “6. SPECIFICATIONS” and following parameters: total weight, height, width and total length, speed and pressure on soil, etc.

When transporting the machine on a trailer on public roads, you must know and observe all the Norms of the Highway Law as well as all provisions released by the different Agencies owning the roads (Municipality, Province, Region, State).

Before transporting the machine on a trailer, check width, height, length and weight of the trailer with the machine loaded.

NOTE: the dimensions and weight may differ according to the type of tyres and/or front attachment installed.

LOADING AND UNLOADING THE MACHINE

S WARNING ALWAYS SELECT THE SLOW TRAVEL SPEED MODE T, PROCEED WITH EXTREME CARE AND ATTENTION. AVOID STEERING WHILE DRIVING THE MACHINE ONTO THE RAMP: DANGER OF MACHINE OVERTURN. SHOULD CORRECTIVE STEERING BE NECESSARY, MOVE BACK TO GROUND OR TRAILER SURFACE, CHANGE TRAVEL DIRECTION AND RESUME DRIVING. THE RAMP END (LINK SPOT WITH THE TRAILER) CAUSES A SUDDEN BUMP; TRAVEL OVER THE BUMP WITH EXTREME CARE AND INCREASE MACHINE STABILITY USING THE FRONT ATTACHMENT.

5-3

5. TRANSPORTATION USE OF A RAMP The loading and unloading ramp should be of sufficient width, length, and strength; also ensure that ramp angle is lower than 15°.

Make the ramp strong enough so that the machine does not turn over during the loading/unloading operations and the slope sides do not break. If necessary, provide some supporting posts to reinforce both side of the banking.

The height of the platform or ramp must correspond to that of the base of the truck/trailer.

1. Wedges 2. Blocks 3. Ramps

In order to load the machine with the attachment fitted, travel on the ramp slowly at forward run, keeping the attachment positioned ahead.

5-4

5. TRANSPORTATION TRANSPORT IN SAFETY CONDITIONS After the machine is loaded and positioned, immobilize it as follows: Lower the dozer.

Fully extend the bucket and arm cylinders. Then slowly lower the boom.

Make sure to block the involuntary rotation of the upper structure by resting the bucket on the ground.

NOTE: to prevent the bucket cylinder from damages during transport, apply a wooden block to the edge of bucket link in order not to get down it to the floor.

Pull up the safety lock lever and set it to the LOCKED position (A).

Bring the slewing lock pin (2) from the UNLOCKED (B) to the LOCKED (A) position.

Deactivate all switches and remove the starter key.

Close all covers and the cab door (cab version).

Place some wedges under the front and the rear of the crawlers. Fix them with a wire rope (1) of sufficient strength. This will prevent the machine from moving forward/backward or rolling due to vibration from the truck/trailer.

5-5

5. TRANSPORTATION

5.2

LIFTING PROCEDURES OF COMPLETE MACHINE

S DANGER Metal cables or chains may break causing severe injuries. Carefully inspect metal cables and/or chains prior to use and check for damages or wear. Always wear suitable protection gloves when handling metal cables or chains. Use metal cables or chains of appropriate size according to the load to be raised.

Arrange the lifting sling with the utmost care to avoid any possible movement of the machine while it is being raised. Crane the machine very slowly. Ensure no one is under or near the machine while this is being raised: danger of death.

Fully extend the arm and bucket drive cylinders and tuck in the front attachment.

Lower the boom and gently rest the bucket onto the ground.

Pull up the safety lock lever and set it to the LOCKED position.

Stop the engine, then remove the key from the starter switch.

Hook the steel cables at both dozer ends (A).

Hook wire cable at (B) point of the boom.

Arrange carefully some protections, where the steel cables are in direct contact with the machine, so as to avoid possible damages during lifting.

Slightly lift the machine to ensure its balance. Then lift up the machine.

Machine total weight Canopy version: 1580 kg (3263 lb) (CX15B) 1660 kg (3439 lb) (CX18B) Cab version: 1700 kg (3748 lb) (CX15B) 1780 kg (3924 lb) (CX18B)

5-6

6. SPECIFICATIONS

6-1

6. SPECIFICATIONS

6-2

6. SPECIFICATIONS

6.1

MAINTENANCE OPERATIONS SUMMARY DECAL

Under the operator’s seat there is a summary plate (1) indicating the main lubrication and replacement operations to be carried out periodically.

Greasing

Replacement of engine oil filters

Replace reduction gear oil, axle oil and transmission oil

Replacement of engine coolant

Replacement of hydraulic system oil

Replacement of engine oil

Replacement of hydraulic system return oil filter

Replacement of air filter

Replacement of fuel filters

Grease slewing ring

6-3

6. SPECIFICATIONS

6.2

DIMENSIONS

6.2.1

CAB DIMENSIONS

A

B

C

D

E

F

G

H

I

L

M

N

O

P

Q

R

S

T

16 3606 1055 2350 444 1213 1566 1155 773 2212 245 1202 760 990 230 414 442 1065 233 Rmc (141.7) (41.5) (92.5) (17.5) (47.8) (61.7) (45.5) (30.4) (87.1) (9.6) (47.3) (30.0) (39.0) (9.0) (16.3) (17.4) (41.9) (9.2)

1020 mm (40.16 18 3606 1055 2350 444 1213 1566 1155 773 2212 245 1202 in) Rmc (141.7) (41.5) (92.5) (17.5) (47.8) (61.7) (45.5) (30.4) (87.1) (9.6) (47.3) 16 3621 1220 mm Rmc (142.6) (48.03 18 3621 in) Rmc (142.6)

-

-

230 414 442 1065 233 (9.0) (16.3) (17.4) (41.9) (9.2)

U

V

V’

Z

Z’

70 (2.8)

-

-

-

-

70 773 1103 1003 1333 (2.8) (30.4) (43.4) (39.5) (52.5)

1055 2350 444 1213 1566 1155 773 2212 245 1202 760 990 230 414 442 1065 233 (41.5) (92.5) (17.5) (47.8) (61.7) (45.5) (30.4) (87.1) (9.6) (47.3) (30.0) (39.0) (9.0) (16.3) (17.4) (41.9) (9.2)

70 (2.8)

1055 2350 444 1213 1566 1155 773 2212 245 1202 (41.5) (92.5) (17.5) (47.8) (61.7) (45.5) (30.4) (87.1) (9.6) (47.3)

70 773 1103 1003 1333 (2.8) (30.4) (43.4) (39.5) (52.5)

6-4

-

-

230 414 442 1065 233 (9.0) (16.3) (17.4) (41.9) (9.2)

-

-

-

-

6. SPECIFICATIONS 6.2.2

CANOPY DIMENSIONS

A

B

C

D

E

F

G

H

I

L

M

N

O

P

Q

R

S

T

U

V

V’

Z

Z’

-

-

-

-

16 3606 1020 mm Rmc (141.7) (40.16 18 3606 in) Rmc (141.7)

1055 2342 444 1213 1566 1155 773 2212 245 890 760 990 230 414 442 1065 233 (41.5) (92.2) (17.5) (47.8) (61.7) (45.5) (30.4) (87.1) (9.6) (35.0) (30.0) (39.0) (9.0) (16.3) (17.4) (41.9) (9.2)

70 (2.8)

1055 2342 444 1213 1566 1155 773 2212 245 890 (41.5) (92.2) (17.5) (47.8) (61.7) (45.5) (30.4) (87.1) (9.6) (35.0)

70 773 1103 1003 1333 (2.8) (30.4) (43.4) (39.5) (52.5)

16 3621 1220 mm Rmc (142.6) (48.03 18 3621 in) Rmc (142.6)

1055 2342 444 1213 1566 1155 773 2212 245 890 760 990 230 414 442 1065 233 (41.5) (92.2) (17.5) (47.8) (61.7) (45.5) (30.4) (87.1) (9.6) (35.0) (30.0) (39.0) (9.0) (16.3) (17.4) (41.9) (9.2)

70 (2.8)

1055 2342 444 1213 1566 1155 773 2212 245 890 (41.5) (92.2) (17.5) (47.8) (61.7) (45.5) (30.4) (87.1) (9.6) (35.0)

70 773 1103 1003 1333 (2.8) (30.4) (43.4) (39.5) (52.5)

6-5

-

-

-

-

230 414 442 1065 233 (9.0) (16.3) (17.4) (41.9) (9.2)

230 414 442 1065 233 (9.0) (16.3) (17.4) (41.9) (9.2)

-

-

-

-

6. SPECIFICATIONS

6.3

GENERAL SPECIFICATIONS

SPEED AND GRADEABILITY Detail

Rubber belt

Rotation speed Travel Speed

9.5 rpm (CX15B); 9 rpm (CX18B) Low (1st)

High (2nd)

2.0 km/h (1.24 mph)

3.5 km/h (2.17 mph)

Gradient

58% (30°)

ENGINE Model

MITSUBISHI L3E-31KBSA

Type

Water-cooled, 4-stroke with direct injection, diesel engine

Number of cylinders-Bore x stroke

3 - 76 x 70 mm (3 - 2.99 x 2.76 in)

Total displacement

952 ml (0.30 gal)

Power

11.2 kW / 2100 rpm

Maximum torque

53.5 Nm (39.46 lbf·ft) / 1800 rpm

Starter

12 V / 1.7 kW

Generator

12 V / 40 A

HYDRAULIC COMPONENTS (CX15B - single speed) Hydraulic pump

2 variable displacement pumps with axial pistons + 1 pilot gear pump

Rotation gearmotor

Fixed displacement with axial pistons

Travel gearmotor

Fixed displacement with 1-speed axial pistons

Control valve

11-spool multiple control valve

Cylinder

Double-acting cylinder

(Boom, arm, slewing, bucket, dozer) HYDRAULIC COMPONENTS (CX15B - two-speed) Hydraulic pump

2 variable displacement pumps with axial pistons + 1 pilot gear pump

Rotation gearmotor Travel gearmotor

Fixed displacement with axial pistons Fixed displacement with 2-speed axial pistons

Control valve

11-spool multiple control valve

Cylinder

Double-acting cylinder

(Boom, arm, slewing, bucket, dozer)

6-6

6. SPECIFICATIONS HYDRAULIC COMPONENTS (CX18B) 2 variable displacement pumps with axial pistons + 2 rotation and pilot gear pumps

Hydraulic pump Rotation gearmotor

Fixed displacement with axial pistons

Travel gearmotor

Variable displacement with 2-speed axial pistons

Control valve

11-spool multiple control valve

Cylinder Double-acting cylinder

(Boom, arm, slewing, bucket, dozer, track width enlargement) OFFSET DIGGING AND DOZER Type

Boom slewing by hydraulic cylinder

Boom slewing angle Dozer stroke (up/down)

Right

45°

Left

80°

mm (in)

280 / 270 (11.2 / 10.63)

RUBBER CRAWLER

Type

Wheel base between driving wheel and free wheel mm (in)

Width mm (in)

Basic pressure kPa

230 (9.06)

27

STANDARD BUCKET Heaped Capacities m3 (ft3)

0.047 (1.66)

Outer thickness mm (in) with side cutter

without side cutter

488 (19.21)

450 (17.72)

6-7

Number of teeth

Weight kg (lb)

3

36 (79)

6. SPECIFICATIONS

6.4

DIGGING PERFORMANCE

Unit: mm (in) ARM

1020 (40.16)

1220 (48.03)

A

3802 (149.68)

3993 (157.20)

A’

3706 (145.90)

3902 (153.62)

B

2200 (86.61)

2400 (94.49)

C

3550 (139.76)

3674 (144.65)

D

2471 (97.28)

2595 (102.17)

E

830 (32.68)

632 (24.88)

F

2062 (81.18)

2260 (88.98)

G

1524 (60)

1555 (61.22)

H

2635 (103.74)

2635 (103.74)

K

1702 (67.01)

1974 (77.72)

L

1112 (43.78)

1033 (40.67)

X

208 (8.19)

208 (8.19)

Y

309 (12.17)

309 (12.17)

6-8

6. SPECIFICATIONS

6.5

LIFTING LOADS

6.5.1

LIFTING LOADS (CX15B)

CAB

Range m (ft)

Lifting loads kg (lb)

Arm l = 1020 mm (40.16 in)

Z2

Arm l = 1220 mm (48.03 in)

Z2

1.0 (3.28)

1.5 (4.92)

2.0 (6.56)

2.5 (8.20)

3.0 (9.84)

-

-

-

253 (558)

-

Z1

754 (1662) 523 (1153)

330 (728)

247 (545)

191 (421)

Z3

1023 (2255) 374 (825)

344 (758)

251 (553)

-

-

210 (463)

204 (450)

-

-

Z1

652 (1437) 515 (1135)

335 (739)

242 (534)

185 (408)

Z3

825 (1819) 492 (1085)

328 (723)

243 (536)

-

The table contains the values of the maximum lifting loads kg (lb) to roll-over limit (Standard ISO 10567).

• boom l = 1750 mm (5.74 ft) • 76 kg (168 lb) counterweight • relief valve adjustment pressure = 206 bar (2987 psi)

The values refer to a machine outfit including: • 0.044 m3 (1.55 ft3) standard bucket

6-9

6. SPECIFICATIONS CANOPY

Range m (ft)

Lifting loads kg (lb)

1.0 (3.28)

1.5 (4.92)

2.0 (6.56)

2.5 (8.20)

3.0 (9.84)

Arm l = 1020 mm (40.16 in)

Z2

-

-

-

243 (536)

-

Z1

754 (1662)

453 (993)

293 (646)

211 (465)

162 (357)

Z3

929 (2048)

374 (825)

297 (655)

215 (474)

-

Arm l = 1220 mm (48.03 in)

Z2

-

-

-

210 (463)

175 (386)

Z1

652 (1437)

445 (981)

287 (633)

206 (454)

156 (344)

Z3

825 (1819)

450 (992)

289 (637)

207 (456)

-

The table contains the values of the maximum lifting loads kg (lb) to roll-over limit (Standard ISO 10567).

The values refer to a machine outfit including: • 0.044 m3 (1.55 ft3) standard bucket

6-10

• boom l = 1750 mm (5.74 ft) • 76 kg (168 lb) counterweight • relief valve adjustment pressure = 206 bar (2987 psi)

6. SPECIFICATIONS 6.5.2

LIFTING LOADS (CX18B)

CAB

Range m (ft)

Lifting loads kg (lb)

Arm l = 1020 mm (40.16 in)

Z2

Arm l = 1220 mm (48.03 in)

Z2

1.0 (3.28)

1.5 (4.92)

2.0 (6.56)

2.5 (8.20)

3.0 (9.84)

-

-

-

269 (593)

-

Z1

792 (1746) 560 (1235)

350 (772)

266 (586)

205 (452)

Z3

1086 (2394) 399 (880)

396 (873)

269 (593)

-

-

223 (492)

218 (481)

Z1

686 (1512) 553 (1219)

-

-

359 (792)

260 (573)

200 (441)

Z3

878 (1936) 524 (1155)

351 (774)

262 (578)

-

The table contains the values of the maximum lifting loads kg (lb) to roll-over limit (Standard ISO 10567).

• boom l = 1750 mm (5.74 ft) • 76 kg (168 lb) counterweight • relief valve adjustment pressure = 216 bar (3132 psi)

The values refer to a machine outfit including: • 0.044 m3 (1.55 ft3) standard bucket

6-11

6. SPECIFICATIONS CANOPY

Range m (ft)

Lifting loads kg (lb)

Arm l = 1020 mm (40.16 in)

Z2

Arm l = 1220 mm (48.03 in)

Z2

1.0 (3.28)

1.5 (4.92)

2.0 (6.56)

2.5 (8.20)

3.0 (9.84)

-

-

-

261 (575)

-

Z1

792 (1746) 491 (1083)

318 (701)

230 (507)

177 (390)

Z3

1006 (2218) 399 (880)

322 (710)

234 (516)

-

-

223 (492)

190 (419)

Z1

686 (1512) 483 (1065)

-

-

312 (688)

225 (496)

171 (377)

Z3

878 (1936) 488 (1076)

314 (692)

226 (498)

-

The table contains the values of the maximum lifting loads (kg) to roll-over limit (Standard ISO 10567).

The values refer to a machine outfit including: • 0.044 m3 (1.55 ft3) standard bucket

6-12

• boom l = 1750 mm (5.74 ft) • 76 kg (168 lb) counterweight • relief valve adjustment pressure = 216 bar (3132 psi)

7. OPTIONAL ATTACHMENT

7-1

7. OPTIONAL ATTACHMENT

7-2

7. OPTIONAL ATTACHMENT

7.1

OPTIONAL ATTACHMENT PEDAL (HYDRAULIC BREAKER AND NIBBLER)

7.1.1

SELECTION OF HYDRAULIC BREAKER AND NIBBLER

During the fitting of the hydraulic breaker on the excavator, it is necessary to choose a model satisfying the required features as to stability, hydraulic pressure, and oil quantity of the hydraulic system. In order to choose the most suitable hydraulic breaker for the machine specifications, contact your Dealer.

7.1.2

BEFORE OPERATING HYDRAULIC BREAKER AND NIBBLER

Contact your Dealer for pipings, for the installation of the hydraulic breaker and nibbler, and for the replacement of the hydraulic oil return filter, according to the maintenance schedule enclosed. Thoroughly read the hydraulic breaker operation manual and the safety instructions described in this manual to prevent damaging the machine or the hydraulic breaker during operation. When the hydraulic breaker is used, the excavator is subjected to working conditions more critical than usual, that speed up hydraulic oil deterioration and contamination. To avoid damaging the hydraulic system of the excavator and of the hydraulic breaker, follow maintenance procedures observing the time schedule indicated in this manual.

7.1.3

PREVENTION OF HYDRAULIC OIL CONTAMINATION

When the hydraulic breaker is not installed on the machine, apply blanking plugs on the tube ends of arm and hydraulic breaker, to prevent the penetration of foreign bodies.

Before starting operation, check the fixing clamps for looseness, and the tubes and hoses fittings for leakage.

7-3

7. OPTIONAL ATTACHMENT 7.1.4

ATTACHMENT OPERATION

S CAUTION Before using the machine, carefully read the safety instructions and the instructions for use given in this manual; make sure to understand and observe them.

Push the safety lock lever downwards (B) and set it to the UNLOCKED position.

Set the throttle lever to HIGH IDLING. Lower slowly the attachment until it rests on the surface to be hit.

Lift the locking device (2) to allow access to the pedal (1).

Make certain breaker or nibbler is in desired position and against material to be broken.

Place the left foot on the pedal (1) and press to activate the hydraulic breaker.

Operate the breaker for 30 seconds, then release the pedal.

S WARNING • TO OPERATE BREAKER OR NIBBLER LONGER THAN 30 SECONDS, COULD CAUSE PREMATURE WEAR OR DAMAGE TO THE MACHINE ATTACHMENT. IF MATERIAL IS NOT BREAKING, REPOSITION BREAKER OR NIBBLER AND REPEAT OPERATION AT 30 SECONDS INTERVALS. • NEVER LEAVE THE OPERATOR CAB WITH ENGINE RUNNING.

7-4

7. OPTIONAL ATTACHMENT ATTACHMENT PEDAL CONTROL The installed attachments are controlled by pedal (1) located left of the operator’s seat.

S CAUTION • Precaution during pedal operation.

The operation varies in the specifications, so before operating, read the operator’s manual carefully.

• Never place your foot on the pedal. If you place your foot on the pedal and press it by error, the machine can suddenly move. This can cause serious accidents.

Breaker Foot pedal depressing section

Operating condition

Left side (A)

Breaker stops operating

Right side (B)

Breaker starts operation

Crusher Foot pedal depressing section

Operating condition

Left side (A)

Nibbler closes

Right side (B)

Nibbler opens

S WARNING NEVER LEAVE THE OPERATOR CAB WITH ENGINE RUNNING.

7-5

7. OPTIONAL ATTACHMENT 7.1.5

SETTING SELECTOR VALVE

Machines equipped with a nibbler breaker attachment the hydraulic system must have the selector valve (1) set to the correct position for breaker or nibbler operation.

NOTE: wrong switching of the selector valve, may decrease the work efficiency and operating speed of the machine and also damage it.

Switch selector valve anyway.

Be sure to switch selector valve one or twice a month.

B.

Breaker

N. Hydraulic nibbler

7-6

7. OPTIONAL ATTACHMENT

7.2

SAFETY INSTRUCTIONS

The following safety precautions should be used in conjunction with all other safety precautions found in this MANUAL.

S WARNING READ, UNDERSTAND AND FOLLOW ALL SAFETY INSTRUCTIONS AND OPERATING PROCEDURES FOUND IN THIS MANUAL BEFORE OPERATING THE MACHINE OR ANY ATTACHMENT. PASSENGERS This equipment is not intended or designed for the transportation of persons. Nobody is allowed on the machine except for the driver. Serious injury or death can result from allowing passengers on or in the machine.

PROTECTIVE EQUIPMENT If there is the risk of rocks falling down, assemble the protective grid and close all windows in order to protect the driver. Also the operator and all personnel in the vicinity of the machine should wear protective clothing such as safety shoes, hard hat, gloves and face shield or goggles.

USE FOR INTENDED PURPOSE Use the attachment only for its intended purpose. If not used in accordance with the Manufacturer’s instructions, the excessive pressure exerted on the boom, arm and frame structure of the machine will cause premature failure of the components.

7-7

7. OPTIONAL ATTACHMENT CYLINDERS Avoid operating with the excavator cylinders at stroke end (maximum extension or maximum retraction) in order not to damage the attachment structure and the cylinders.

AVOID CONTINUOUS OPERATION Operate the breaker with intervals of 30 seconds.

A prolonged attachment use can cause a temperature increase and the risk of serious damages to the pressure accumulators, to the cylinder seals and to the pump.

HOSE SWELLING Should the hydraulic hoses begin swelling or vibrating during the operation of the hydraulic breaker, immediately stop working and consult your Dealer.

This inconvenient is often due to pressure accumulators being damaged.

DO NOT USE THE FORCE OF GRAVITY Do not use the force of gravity by letting the attachment drop onto the material. This will cause extensive damage to the attachment and machine structure.

7-8

7. OPTIONAL ATTACHMENT DO NOT USE THE ROTATION / SWING FORCE Do not use the rotation/swing force of the machine for pushing objects. This will cause premature failure of the attachment and other machine components.

DO NOT PRY WITH HYDRAULIC BREAKER Do not use the breaker to pry open and break rocks or concrete. This may damage the hydraulic breaker, and also boom, arm and cylinder.

ARM IN VERTICAL POSITION Do not operate with arm set perpendicular to soil.

The piston rod joint and the same piston can get damaged.

DO NOT LIFT Never use an optional attachment to lift or transport objects or material. Failure to observe this instruction can cause extensive damage to the attachment and to the machine structures and cause injury or death.

7-9

7. OPTIONAL ATTACHMENT WORKING RANGE

S WARNING NEVER OPERATE AN OPTIONAL ATTACHMENT OVER THE SIDES OF THE MACHINE. OPERATE THE ATTACHMENT ONLY OVER THE FRONT OR REAR OF THE MACHINE. Do not operate the breaker to the side of the machine. The machine may become unstable and the components of the lower frame would wear off more rapidly.

NOTE: • Refer to this SECTION also for other attachments fitted on the machine, further to the hydraulic breaker.

• When working with hydraulic breaker, etc. use reinforced arm. If you use the standard arm, you can damage it.

7-10

7. OPTIONAL ATTACHMENT

7.3

REGULAR INSPECTION AND MAINTENANCE

REPLACEMENT INTERVAL Contamination and deterioration of hydraulic oil may develop malfunctioning of control valves, early wear and seizure of hydraulic pump. Operation of the breaker hastens deterioration of hydraulic oil, if compared with normal operation with bucket.

Replace hydraulic oil return filters, referring to the following table: REPLACEMENT INTERVAL

INSPECTION AND MAINTENANCE TABLE

LOCATION

HYDRAULIC OIL RETURN FILTER

FIRST

2nd REPLACEMENT

REGULAR

Hydraulic oil reservoir

-

-

Every 600 hours

Hydraulic oil reservoir

50 hours

200 hours

Every 200 hours

MAINTENANCE RECORD SHEET (EXAMPLE) DATE

HOURS

FILTER REPLACEMENT

7-11

HYDRAULIC OIL CHANGE

7. OPTIONAL ATTACHMENT NOTES:

7-12

8. TROUBLESHOOTING

8-1

8. TROUBLESHOOTING

8-2

8. TROUBLESHOOTING

8.1

GENERAL TROUBLESHOOTING

This troubleshooting information covers the components and systems as described in this MANUAL. Should in-depth troubleshooting, repair or replacement of certain components, or valve adjustment become necessary, contact your Dealer.

PROBLEM All operating speeds are slow or power is lost.

POSSIBLE CAUSE Low hydraulic oil level.

Fill oil to specified level.

Air in the suction pipe.

Tighten suction pipe hose clamp or replace hose.

Hydraulic pump is damaged.

Repair or replace.

Pilot gear pump is damaged.

Repair or replace.

Main relief valve not adjusted correctly.

Adjust or replace.

Relief valve of pilot circuit not adjusted correctly.

Adjust or replace.

OPERATION

A specific cylinder Cylinder seal is scored. functions improperly or Defective control valve or overload valve or loses power. presence of air in the cylinder.

The cylinder position will not hold with operating lever in neutral.

Repair or replace / remove air from cylinder.

Repair or replace.

Pilot valve piping is loose.

Tighten.

Cylinder seal is scored.

Repair or replace.

The control valve or overload valve is damaged.

Repair or replace.

Overload valve is not operating.

Repair or replace.

Pilot valve is damaged.

Repair or replace.

Slewing bearing is damaged.

Anomalous noise during rotation.

Repair or replace.

Pilot valve is damaged.

Machine does not slew. The hydraulic motor (rotation) is not working or the rotation gear is damaged.

The rotation speed is slow.

REMEDY

Repair or replace.

Repair or replace.

Pilot valve is not working.

Repair or replace.

The rotation gear is damaged.

Repair or replace.

Solenoid valve is not working.

Repair or replace.

The control valve is not working.

Repair or replace.

Lock solenoid valve is not working.

Repair or replace.

The control valve is not working.

Repair or replace.

The hydraulic motor (rotation) is not working.

Repair or replace.

Hydraulic pump is not working.

Repair or replace.

Pilot valve is not working.

Repair or replace.

Insufficient lubrication of upper structure slewing ring and bearings.

Grease.

Pilot valve is not working.

Repair or replace.

The control valve is not working.

Repair or replace.

8-3

8. TROUBLESHOOTING PROBLEM

TRAVEL

Machine does not travel smoothly.

TRAVEL

Travelling power is insufficient.

POSSIBLE CAUSE Too much crawler tension.

Adjust crawler tension.

Dirty or clogged crawlers.

Clean crawlers.

Brake valve is not working.

Repair or replace.

Travel reduction unit is damaged.

Repair or replace.

The control valve is not working.

Repair or replace.

Travel motor damaged.

Repair or replace.

Main relief valve pressure is set incorrectly.

Adjust or replace.

Damaged swivel joint.

Repair or replace.

Hydraulic pump is damaged.

Repair or replace.

Poor engine performance.

Repair or replace.

Main relief valve pressure is set incorrectly.

Adjust or replace.

Low hydraulic oil level.

Fill to proper level.

The hydraulic motor (travel) is not working.

Repair or replace.

Brake valve is not working.

Repair or replace.

Seal in swivel joint is scored or oil is leaking.

Repair or replace.

Machine does not Unequal tensions on crawlers. travel in a straight line. Set pressures of main relief valves unbalanced.

Adjust tension.

Adjusting.

One of the travel motors loses power.

Repair or replace.

Unbalanced oil flow from the control valve.

Repair or replace.

Unbalanced discharge from hydraulic pump.

Repair or replace.

Unbalanced flow from brake valve.

Repair or replace.

Unbalanced flow between right swivel joints.

HYDRAULIC SYSTEM

REMEDY

Temperature rise of the Oil cooler core clogged. hydraulic oil.

Engine fan belt slipping.

Repair or replace.

Cleaning.

Adjust or replace.

Low hydraulic oil level.

Fill oil to specified level.

Wrong type hydraulic oil used.

Replace with correct oil.

Hydraulic pump is not working.

Repair or replace.

8-4

8. TROUBLESHOOTING PROBLEM

INSTRUMENT PANEL DISPLAY

Engine oil pressure low.

Abnormal rise in the coolant temperature.

Battery charge.

POSSIBLE CAUSE Engine oil level low.

Fill oil to specified level.

Oil leaking.

Repair and fill as recommended.

Wrong oil viscosity.

Replace with proper oil.

Insufficient coolant.

Fill to proper level.

Coolant leaking.

Repair and fill as recommended.

Loose radiator cap.

Tighten.

Clogged radiator.

Clean the cooling system.

V-belt loose or damaged.

Tighten to proper tension.

Rust or scale in coolant.

Flush system / fill to level.

Faulty thermostat.

Replacing.

Battery terminals disconnected, loose or corroded.

Clean and connect.

Low battery electrolyte level.

Refill.

V-belt loose or damaged.

Adjust or replace.

Battery service life has run down.

The starter does not Battery disconnected. turn or turns too slowly Battery discharged. to start the engine.

Battery terminals disconnected, loose or corroded.

ENGINE

The starter turns but the engine does not start.

Replacing.

Connect.

Charge.

Clean and connect.

Ground cable disconnected.

Connect.

Engine oil viscosity too thick (Cold Weather).

Replace with correct oil.

Insufficient fuel.

Refill.

Improper starting procedure.

Refer to section “1.

SAFETY PRECAUTIONS”.

Air in fuel line.

Bleed air.

Fuel filter clogged.

Replace element.

Clogged air filter.

Replace elements.

Air heater circuit malfunctioning.

Check circuit.

Engine tends to stop at Low idling rpm. low speed.

Fuel filter clogged.

No power.

REMEDY

Serviceman.

Replace element.

Clogged air filter.

Replace elements.

Improper valve clearance.

Serviceman.

Fuel filter clogged.

Replace element.

Clogged air filter.

Replace element.

Improper valve clearance.

Serviceman.

Loose clamps on the air inlet hose.

Tighten clamps.

Cracked air inlet hose.

Replace.

8-5

8. TROUBLESHOOTING PROBLEM

ENGINE

Engine overheats.

POSSIBLE CAUSE

REMEDY

Insufficient coolant.

Top up coolant.

Clogged radiator.

Clean the cooling system.

V-belt loose or damaged.

Adjust or replace belt.

Faulty thermostat.

Replacing.

Engine exhaust is black.

Clogged air filter.

Replace elements.

Improper valve clearance.

Serviceman.

Excessive fuel consumption.

Fuel leak.

Serviceman.

Clogged air filter.

Replace elements.

Loose clamps on the air inlet hose.

Tighten clamps.

Excessive oil consumption.

Cracked air inlet hose.

Replace with new hose.

Engine oil level is too high.

Reduce to specified level.

Improper oil.

Replace with correct oil.

Oil leaking.

Serviceman.

Improper oil replacement intervals.

Change at correct interval.

Improper preheating.

Refer to 3-12.

The engine oil pressure Oil level too low. does not rise.

Oil leaking.

Battery dies often.

Fill oil to specified level.

Serviceman.

Improper oil viscosity.

Replace with proper oil.

Battery terminals disconnected, loose or corroded.

Clean and tighten terminals.

Low battery electrolyte level.

Fill cells with distilled water.

V-belt loose or damaged.

Adjust or replace belt.

Defective battery.

Replace batteries.

8-6

9. ELECTRICAL SYSTEM

9-1

9. ELECTRICAL SYSTEM

9-2

9. ELECTRICAL SYSTEM

9.1

GENERALITIES

S WARNING

IMPORTANT: • The electrical system of this machine operates with 24 V and is powered by two batteries connected in series.

• EXCLUSIVELY USE GROUNDED ELECTRICAL POWER SOURCES FOR HEATERS, BATTERY CHARGERS, PUMPS AND SIMILAR DEVICES, SO AS TO MINIMISE ELECTRICAL SHOCK HAZARDS.

• The machine is equipped with complex electric and electronic components which can be handled exclusively by qualified personnel.

• MAKE SURE TO CONNECT THE CABLES TO THE CORRECT POLES (+ TO +) AND (- TO -) AT BOTH ENDS.

• Do not run the engine with the alternator threaded terminal disconnected.

• DO NOT SHORT-CIRCUIT THE TERMINALS.

• If the batteries have been recharged using an external equipment, they should then be reinstalled onto the machine paying attention to match terminals of same sign (+ to + and - to -).

• IF BATTERIES ARE TO BE RECHARGED OR IF BOOSTER CABLES ARE NEEDED FOR STARTING, REMOVE BATTERY CELL PLUGS.

• This norm should be observed also when the engine is to be started using slave batteries.

• FLAMMABLE VAPOURS. EXTINGUISH ALL SMOKING MATERIALS AND NAKED FLAMES BEFORE CHECKING, FILLING OR CHARGING THE BATTERIES.

• If repair using electrical welders is required on the machine, it is good practice to disconnect the batteries and alternator, and ground the welder as near as possible to the welding point.

• AVOID CAUSING SPARKS WHILE TESTING BATTERIES. IMPORTANT: • Improper radio-communications equipment and associated parts and/or improper assembly of radio-communications equipment affects machine electronic components with consequent unexpected machine movement. Consult an authorized Dealer when installing radio-communication equipment or any additional electronic component or when replacing an electric part.

• Do not disassemble or change electric or electronic components.

• If a replacement or change of such components is required, consult an authorized Dealer.

9-3

9. ELECTRICAL SYSTEM

9.2

BATTERIES

INSPECTION

S WARNING • BATTERY GAS MAY EXPLODE. KEEP AWAY SPARKS AND FLAMES. • TO AVOID DANGERS: WHEN STARTING THE MACHINE WITH BOOSTER BATTERIES, OBSERVE THE PROCEDURES DETAILED IN CHAPTER “MEASURES AFTER AN EMERGENCY STOP OF ENGINE”. MAKE SURE TO CONNECT THE CABLES TO THE CORRECT POLES (+ TO +) AND (- TO -) AT BOTH ENDS. DO NOT SHORTCIRCUIT THE TERMINALS. The battery installed to this type of machine are maintenance-free, therefore is do not require topups with distilled water.

S CAUTION Always disconnect the negative (-) ground terminal first and reconnect it last.

Open the engine guard (1).

Check the areas around the battery to assess possible electrolyte leaks. Otherwise clean accurately to avoid metal parts corrosion.

Unscrew and remove the wing nuts (6). Remove the plate (5) and the rubber protection (4).

Remove the battery (2).

Keep the terminals and plugs located on top of the battery clean at all times to prevent battery from discharging. Check battery terminals, clamps should not be loose and should not show signs of rust or oxidation. Apply petroleum jelly to the terminals to prevent corrosion.

It is better not to stop the engine in case of short stops; let the engine idle, as each start-up requires considerable power supply from the batteries.

9-4

9. ELECTRICAL SYSTEM Observe the following norms to preserve battery efficiency: • with the engine stopped, remove the starter switch key to prevent a progressive battery discharge; • do not keep the lights switched on for a long time with the engine stopped or idling.

Close the cooler bay access panel.

NOTE: handle and dispose of batteries according to current legislation. Only use authorised disposal procedures; in case of doubt, contact the authorities concerned.

9-5

9. ELECTRICAL SYSTEM

9.3

FUSE BOX (MAIN)

S CAUTION Stop the machine before replacing the fuses (starter switch key set to OFF).

The fuses protect the electrical system from excessive current. If operation is irregular, a fuse may be blown. Replace blown or faulty fuses with the spare fuses as follows.

Replace any fuse generating white powder on it or in case that some looseness exists between the fuse and fuse holder.

NOTE: • When replacing a fuse, replace it with one of the same capacity.

• The spare fuses are stored in the back side of fuse box cover.

1. Heater, wiper - 30A

6. Battery relay, engine stop solenoid - 10A

2. Two-speed - 20A (on 2-speed machines)

7. Available - 30A

3. Work light - 30A

8. Available - 20A

4. Horn, boom light - 10A

9. Available - 10A

5. Engine stop - 30A

10. Available - 20A 11. Available - 30A

9.3.1

VARIOUS FUSES

Other fuses are located to the sides of the main fuse box.

1. Main fuse - 50A 2. Generator fuse - 50A

9-6

9. ELECTRICAL SYSTEM

9.4

RELAY BOX

S WARNING Stop the machine before replacing the relays (starter switch key set to OFF).

If operation is irregular, a relay may be damaged.

Replace any defective relay.

NOTE: when replacing a relay, replace it with one of the same capacity.

1. Safety relay 2. Starter relay 3. Battery relay 4. Charge indicator relay 5. Preheating relay

9-7

9. ELECTRICAL SYSTEM NOTES:

9-8

ATTACHMENT 1 - “EC” DECLARATION OF CONFORMITY On the following pages, a facsimile copy of the “EC” Declaration of Conformity (EC DoC) is provided.

The EC DoC is the manufacturer’s declaration about equipment compliance to relevant EU provisions.

Please keep the original document in a safe place.

Local authorities may require you to show this document in order to assure compliance of your equipment.

IMPORTANT: an original of this “EC” declaration is supplied with each machine and must be kept carefully by the owner.

IMPORTANT: the official documents supplied with the machine must be kept by the owner so as to be able to present them to any inspecting authority which may request them.

1. Under point 1.2 those options or variants are listed which have safety related functions. Some of them are standard provided, like FOPS or TOPS (please refer to page 0-6 for other detail).

Others, like object handling kit required to lift loose objects, are available upon Customer request.

Please address to your Dealer to know the availability of variants/optionals provided for your machine.

2. Under point 2 all information required by EU “Outdoor Noise” Directive 2000/14/EC is given.

Please refer to your own original EC DoC for specific machine information. Other information about equipment guaranteed sound power level (LWA) can be found on page 0-4. On the same page, information about operator’s station noise level (LpA) is given, which is not matter of above-mentioned EU Directive and therefore not indicated on it.

3. Generic serial number for this machine type.

The sequence of letters and numbers may vary depending on machine configuration.

4. EC DoC serial number. Please make reference to this number when requiring information or support to CASE about EC DoC. 5. Signature of a person authorised to sign the document on behalf of the company.

Attachment-1

Reduced scale. Original is A4 format.

Reduced scale. Original is A4 format.

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