Case CX35B CX39B Series 2 Mini Excavator Operator's Manual 47529301 - PDF DOWNLOAD

ORIGINAL INSTRUCTIONS - according to Directive 2006/42/EC, Annex I 1.7.4.1

CX35B CX39B Series 2 Mini Excavator

OPERATOR’S MANUAL

Part number 47529301 1st edition English July 2013

Contents 1 GENERAL INFORMATION Note to the Owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electro-Magnetic Compatibility (EMC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator's Manual storage on the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Machine orientation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Machine components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1 1-4 1-5 1-7 1-7 1-8 1-9

2 SAFETY INFORMATION Signal word definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Hand signals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35 Noise levels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41 Vibration levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42 Towing the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43 Safety signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44

3 CONTROLS/INSTRUMENTS ACCESS TO OPERATOR'S PLATFORM Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

OPERATOR'S SEAT Operator's seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Seat belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

FORWARD CONTROLS Front console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

RIGHT-HAND SIDE CONTROLS Right-hand side controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Instrument cluster panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

EXTERIOR CONTROLS Hoods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

ELECTRICAL EQUIPMENT Work lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

4 OPERATING INSTRUCTIONS COMMISSIONING THE UNIT Daily inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Windscreen washer reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warning lamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Work lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

STARTING THE UNIT Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection after starting the engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine warm up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic oil warm up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-10 4-14 4-16 4-17

STOPPING THE UNIT Stopping the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

PARKING THE UNIT Parking the machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

5 TRANSPORT OPERATIONS ROAD TRANSPORT Transporting on a trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

SHIPPING TRANSPORT Lifting the machine – CX35B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Lifting the machine – CX39B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Load specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

6 WORKING OPERATIONS GENERAL INFORMATION Operating the controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Machine travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Machine operation in water/on soft grounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Getting out of soft ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Swing control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Practices to improve efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Lowering the bucket in emergency situations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Lowering the arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

Caution while using rubber crawlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 Machine operation in adverse weather conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

7 MAINTENANCE GENERAL INFORMATION General safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Maintenance summary decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Maintenance tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Torque specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Fluids and lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Maintenance parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 Releasing pressure in the hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 Bleed air from the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11 Break-in period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

MAINTENANCE CHART Maintenance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

Every 8 hours General check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14 Separator filter draining. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16

Every 50 hours Track tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bucket grease fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-17 7-18 7-19 7-20

Every 250 hours Boom, arm, and attachment grease points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fan belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Separator filter cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Swing bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radiator hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radiator hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-22 7-24 7-25 7-26 7-28 7-29 7-31 7-32 7-33

Every 500 hours Fuel filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35

Every 1000 hours Hydraulic return filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36 Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40

Every 2000 hours Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic oil tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Travel reduction unit oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Idler wheel and rollers change oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning of pilot valve and solenoid valve line filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacement of grease in slewing grease bath . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-41 7-42 7-45 7-46 7-48 7-51

When necessary Rubber track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacement of rubber crawler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Track tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radiator cap cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Work lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuses and relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bucket teeth and side cutters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bucket teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Side cutter replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Buckets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control levers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-52 7-55 7-58 7-62 7-63 7-64 7-65 7-67 7-68 7-69 7-70 7-72

STORAGE Precautions when storing the machine for a long period . . . . . . . . . . . . . . . . . . . . . . . . . . 7-73 Care during storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-74 Removal from storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-74

8 TROUBLESHOOTING FAULT CODE RESOLUTION Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation - Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Travel - Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic systems - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Instrument panel display - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Second auxiliary hydraulic circuit - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1 8-1 8-2 8-3 8-4 8-5 8-6

9 SPECIFICATIONS General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

Operating mass. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7 Digging data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8 Crawler type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14 Buckets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15

10 ACCESSORIES AUX lines for hydraulic PTO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5 Nibbler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11 Additional AUX lines for hydraulic PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15 Load handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20 Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26 Front Guard Protective System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-34 Biodegradable hydraulic oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35

1 - GENERAL INFORMATION

1 - GENERAL INFORMATION###_1_### Note to the Owner This manual is designed as a guide for the correct and safe use of the machinery and for its correct maintenance.

Always following the rules in the manual guarantees the best performance, operating economy and a long life for the machine and also makes it possible to avoid the most common causes of accidents that may occur during work or maintenance operations.

Read the manual carefully, paying special attention to the instructions regarding safety, operation and maintenance to prevent risks or injury during usage or when carrying out maintenance operations on the machine.

Before handing the machine over to an operator, check that: • The operator has been properly trained in the correct and safe use of the machine.

• Also make sure that the operator has read the instructions in this manual and that he has understood them fully.

Always keep this manual in the cab. Make sure that it is always intact and in good condition. Contact the Dealer for further copies or a translation into a different language from the country of use.

The machine has been designed and constructed in accordance with the most rigorous standards of quality and in compliance with current safety regulations. Never use the machine for applications not included in the manual. If the machine needs to be used for work that involves the use of special equipment, accessories or instruments, consult the Dealer to make sure that any adaptations or modifications carried out comply with the technical specifications of the machine and with the safety standards.

Any modification or adaptation that is not approved by the manufacturer may invalidate the original conformity of the machine to the safety requirements and the persons that carry out these unapproved modifications will be held responsible for the consequences.

NOTICE: the engine and fuel system on your machine is designed and built to government emissions standards.

Tampering by dealers, customers, operators and users is strictly prohibited by law. Failure to comply could result in government fines, rework charges, invalid warranty, legal action and possible confiscation of the machine until rework to original condition is completed. Engine service and/or repairs must be done by a certified technician only.

The Dealer can also provide further information, as well as after sales service involving the purchase of genuine spare parts, a guarantee of quality and perfect reliability.

NOTE: each machine is supplied complete with a copy of this Manual. Descriptions and illustrations herein are not binding. The Manufacturer, provided that the basic characteristics of machine types described and shown in this Manual remain the same, reserves the right to change components, parts and accessories supplied without any commitment to timely update this publication; and this any time it deems it convenient for improvement purposes or due to commercial or manufacturing requirements. For exact information, please consult your Dealer or contact the Manufacturer’s Branch Offices.

1-1

1 - GENERAL INFORMATION

PLEASE RECORD THE FOLLOWING INFORMATION Model

________________________________________________________________

Product Identification Number (PIN)

________________________________________________________________

Date Purchased

________________________________________________________________

Engine Model

________________________________________________________________

Engine Pin

________________________________________________________________

1-2

1 - GENERAL INFORMATION

INTRODUCTION 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 dozer for levelling operations.

LELI11E0001AA

1

INTENDED USE WARNING Avoid injury!

Using the machine for purposes other than or beyond the intended use is not allowed; for example: - for the transportation of persons, - as a working platform, - for pulling attached loads, - for pulling or transporting loads without the intended working equipment.

Failure to comply could result in death or serious injury.

W1142B

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 dozer) 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 - 40 °C (-4 - 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.

WARNING Illustrations in this manual may show protective shielding open or removed to better illustrate a particular feature or adjustment.

Replace all shields before operating the machine.

Failure to comply could result in death or serious injury.

W0012A

NOTICE: 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.

1-3

1 - GENERAL INFORMATION

Electro-Magnetic Compatibility (EMC) This machine complies strictly with the European Regulations on electro‐magnetic emissions. However, interference may arise as a result of add‐on equipment which may not necessarily meet the required standards. As such interference can result in serious malfunction of the unit and/or create unsafe situations, you must observe the following: • Ensure that each piece of non‐ CASE CONSTRUCTION equipment fitted to the machine bears the CE mark.

• The maximum power of emission equipment (radio, telephones, etc.) must not exceed the limits imposed by the national authorities of the country where you use the machine.

• The electro‐magnetic field generated by the add‐on system should not exceed 24 V/m at any time and at any location in the proximity of electronic components.

Failure to comply with these rules will render the CASE CONSTRUCTION warranty null and void.

1-4

1 - GENERAL INFORMATION

Product identification Machine identification plate 1. Commercial name 2. Product identification number 3. Operating mass 4. Engine power ( ISO 14396) 5. Year of construction 6. Machine category (Hydraulic excavator <6t)

SMIL13MEX0016AB

1

SMIL13MEX0017AB

2

Engine identification plate 7.

Engine model

8.

Output

9.

Displacement

10. Engine number

Hour counter

LELI11E0004AB

1-5

3

1 - GENERAL INFORMATION

Tip/Roll Over Protective Structure (TOPS/ ROPS) and Falling Object Protective Structure (FOPS) (1) identification plate in the cab (2) identification plate on the canopy

1-6

LELI11E0006BB

4

LELI11E0189AB

5

1 - GENERAL INFORMATION

Operator's Manual storage on the machine 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.

Keep the manual in the storage box provided on the back of seat.

SMIL13MEX0157AB

1

SMIL13MEX0002AB

1

Machine orientation The terms right-hand, left-hand, front, and rear are used in this manual to indicate the sides as they are seen from the operator seat when the travel motors are positioned at the rear and the operator is facing the direction in which the machine advances (forward).

A B C D E

Front of machine Rear of machine Left side of machine Right side of machine Travel motor

1-7

1 - GENERAL INFORMATION

Machine components

TULI12E2B0081GB

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

Engine Oil filter Radiator Reservoir tank Air cleaner Muffler Fuel tank Hydraulic oil tank Hydraulic pumps Slewing motor Swing cylinder Control valve Travel lever

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

1

Safety lever Canopy Operating lever Dozer control lever Throttle lever Gauge cluster Battery Swivel joint Travel motor Slewing ring Idler adjuster Lower roller Upper roller

1-8

27.

28.

29.

30.

31.

32.

33.

34.

35.

36.

37.

Rubber crawler Dozer Dozer cylinder Boom Boom cylinder Arm cylinder Light Arm Link Bucket cylinder Bucket

1 - GENERAL INFORMATION

Declaration of conformity

The original declaration of conformity is supplied with each machine. Keep the original copy in a safe place.

The local authorities may ask for this document to be presented in order to check the conformity of your machine.

2. Point 2 contains all the information required by the Acoustic emission directive 2000/14/EC. Refer to the original copy for specific information on the equipment. Other information relating to the sound power level guaranteed by the equipment ( LWA ) can be found on page 2-41 . This page also contains information relating to the acoustic pressure level in the driver’s seat ( LpA ) which is not the subject of the above mentioned directive and therefore not contained in it.

There is a translation of the declaration on the back of the original copy in the language of the country in which the machine is used.

3. General registration number for this type of equipment. The sequence of letters and numbers may vary depending on the configuration of the equipment.

The page that follows contains a copy of the declaration of conformity. The Manufacturer declares that the machine has been designed and constructed in conformity with European Directives and amendments and the decrees and regulations governed by national laws.

There are some additional notes for greater clarity: 1. The main safety components installed and supplied with the machine are listed in point 1.2. Some of these are supplied as standard, such as the FOPS/TOPS. Others, such as the variant for moving suspended loads or the cab front guard, are available on request by the customer.

4. Registration number of the declaration of conformity.

Refer to this number when information or assistance is requested from the manufacturer about the declaration of conformity.

5. Signature of a person authorized to sign the document on behalf of the company.

1-9

1 - GENERAL INFORMATION

LELI11E0494HB

1-10

1

1 - GENERAL INFORMATION

LELI11E0495HB

1-11

2

1 - GENERAL INFORMATION

1-12

2 - SAFETY INFORMATION

2 - SAFETY INFORMATION###_2_### Signal word definitions Personal safety This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible death or injury.

Throughout this manual you will find the signal words DANGER, WARNING, and CAUTION followed by special instructions. These precautions are intended for the personal safety of you and those working with you.

Read and understand all the safety messages in this manual before you operate or service the machine.

DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury.

WARNING indicates a hazardous situation that, if not avoided, could result in death or serious injury.

CAUTION indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.

FAILURE TO FOLLOW DANGER, WARNING, AND CAUTION MESSAGES COULD RESULT IN DEATH OR SERIOUS INJURY. Machine safety NOTICE: Notice indicates a situation that, if not avoided, could result in machine or property damage.

Throughout this manual you will find the signal word Notice followed by special instructions to prevent machine or property damage. The word Notice is used to address practices not related to personal safety.

Information NOTE: Note indicates additional information that clarifies steps, procedures, or other information in this manual.

Throughout this manual you will find the word Note followed by additional information about a step, procedure, or other information in the manual. The word Note is not intended to address personal safety or property damage.

2-1

2 - SAFETY INFORMATION

Safety rules General safety rules Use caution when you operate the machine on slopes.

Raised equipment, full tanks and other loads will change the center of gravity of the machine. The machine can tip or roll over when near ditches and embankments or uneven surfaces.

Never permit anyone other than the operator to ride on the machine.

Never operate the machine under the influence of alcohol or drugs, or while you are otherwise impaired.

When digging or using ground-engaging attachments, be aware of buried cables. Contact local utilities to determine the locations of services.

Pay attention to overhead power lines and hanging obstacles. High voltage lines may require significant clearance for safety.

Hydraulic oil or diesel fuel leaking under pressure can penetrate the skin, causing serious injury or infection.

• DO NOT use your hand to check for leaks. Use a piece of cardboard or paper.

DO NOT attempt to remove material from any part of the machine while it is being operated or while components are in motion.

Make sure that all guards and shields are in good condition and properly installed before you operate the machine. Never operate the machine with shields removed.

Always close access doors or panels before you operate the machine.

Dirty or slippery steps, ladders, walkways, and platforms can cause falls. Make sure these surfaces remain clean and clear of debris.

A person or pet within the operating area of a machine can be struck or crushed by the machine or its equipment. DO NOT allow anyone to enter the work area.

Raised equipment and/or loads can fall unexpectedly and crush persons underneath. Never allow anyone to enter the area underneath raised equipment during operation.

Never operate the engine in enclosed spaces as harmful exhaust gases may build up.

• Stop the engine, remove the key, and relieve the pressure before you connect or disconnect fluid lines.

Before you start the machine, be sure that all controls are in neutral or park lock position.

• Make sure that all components are in good condition.

Tighten all connections before you start the engine or pressurize the system.

Start the engine only from the operator’s seat. If you bypass the safety start switch, the engine can start with the transmission in gear. Do not connect or short across terminals on the starter solenoid. Attach jumper cables as described in the manual. Starting in gear may cause death or serious injury.

• If hydraulic fluid or diesel fuel penetrates the skin, seek medical attention immediately.

• Continuous long term contact with hydraulic fluid may cause skin cancer. Avoid long term contact and wash the skin promptly with soap and water.

Keep clear of moving parts. Loose clothing, jewelry, watches, long hair, and other loose or hanging items can become entangled in moving parts.

Wear protective equipment when appropriate.

Always keep windows, mirrors, all lighting clean to provide the best possible visibility while you operate the machine.

Operate controls only when seated in the operator’s seat, except for those controls expressly intended for use from other locations.

2-2

2 - SAFETY INFORMATION

Before you leave the machine:

3. Put all controls in neutral position.

1. Park the machine on a firm, level surface.

4. Place the safety lever in LOCK position.

2. Rest the bucket to the ground.

5. Turn off the engine and remove the key.

General maintenance safety Keep the area used for servicing the machine clean and dry. Clean up spilled fluids.

Stop the engine, remove the key, and relieve pressure before you connect or disconnect fluid lines.

Service the machine on a firm, level surface.

Stop the engine and remove the key before you connect or disconnect electrical connections.

Install guards and shields after you service the machine.

Close all access doors and install all panels after servicing the machine.

Do not attempt to clean, lubricate, clear obstructions, or make adjustments to the machine while it is in motion or while the engine is running.

Scalding can result from incorrect removal of coolant caps. Cooling systems operate under pressure. Hot coolant can spray out if you remove a cap while the system is hot. Allow the system to cool before you remove the cap. When you remove the cap, turn it slowly to allow pressure to escape before you completely remove the cap.

Always make sure that working area is clear of tools, parts, other persons and pets before you start operating the machine.

Replace damaged or worn tubes, hoses, electrical wiring, etc.

Unsupported hydraulic cylinders can lose pressure and drop the equipment, causing a crushing hazard. Do not leave equipment in a raised position while parked or during service, unless the equipment is securely supported.

The engine, transmission, exhaust components, and hydraulic lines may become hot during operation. Take care when you service such components. Allow surfaces to cool before you handle or disconnect hot components.

Wear protective equipment when appropriate.

Jack or lift the machine only at jack or lift points indicated in this manual.

Incorrect towing procedures can cause accidents. When you tow a disabled machine follow the procedure in this manual. Use only rigid tow bars.

When welding, follow the instructions in the manual. Always disconnect the battery before you weld on the machine. Always wash your hands after you handle battery components.

General transportation safety When you transport equipment or a machine on a transport trailer, make sure that it is properly secured.

Comply with local laws and regulations.

Use appropriate lighting to meet local regulations.

Use safety chains for trailed equipment when safety chains are provided with machine or equipment.

Be aware of overhead structures or power lines and make sure that the machine and/or attachments can pass safely under.

Lift implements and attachments high enough above ground to prevent accidental contact with road.

Travel speed should be such that you maintain complete control and machine stability at all times.

Fire and explosion prevention Fuel or oil that is leaked or spilled on hot surfaces or electrical components can cause a fire.

Crop materials, trash, debris, bird nests, or flammable material can ignite on hot surfaces.

Always have a fire extinguisher on or near the machine.

Make sure that the fire extinguisher(s) is maintained and serviced according to the manufacturer’s instructions.

At least once each day and at the end of the day, remove all trash and debris from the machine especially around hot components such as the engine, transmission, exhaust, battery, etc. More frequent cleaning of your machine may be necessary depending on the operating environment and conditions.

At least once each day, remove debris accumulation around moving components such as bearings, pulleys, belts, gears, cleaning fans, etc. More frequent cleaning of your machine may be necessary depending on the operating environment and conditions.

2-3

2 - SAFETY INFORMATION

Inspect the electrical system for loose connections and frayed insulation. Repair or replace loose or damaged parts.

Do not store oily rags or other flammable material on the machine.

Do not expose the machine to flames, burning brush, or explosives.

Promptly investigate any unusual smells or odors that may occur during operation of the machine.

Do not weld or flame cut any items that contain flammable material. Clean items thoroughly with non-flammable solvents before welding or flame-cutting.

General battery safety Always wear eye protection when you work with batteries.

Follow the manufacturer’s instructions when you store and handle batteries.

Do not create sparks or have open flame near a battery.

Ventilate the area when you charge a battery or use a battery in an enclosed area.

Disconnect the negative (-) terminal first and reconnect the negative (-) terminal last.

When you weld on the machine, disconnect both terminals of the battery.

Do not weld, grind, or smoke near a battery.

When you use auxiliary batteries or connect jumper cables to start the engine, use the procedure shown in the operator’s manual. Do not short across terminals.

Battery post, terminals, and related accessories contain lead and lead compounds. Wash hands after handling.

Battery acid causes burns. Batteries contain sulfuric acid.

Avoid contact with skin, eyes, or clothing. Antidote (external): Flush with water. Antidote (eyes): flush with water for 15 minutes and seek medical attention immediately.

Antidote (internal): Drink large quantities of water or milk.

Do not induce vomiting. Seek medical attention immediately.

Keep out of reach of children and other unauthorized persons.

Seat belts • Replace belts that have cuts that can make the belt weak.

Seat belts must be worn at all times.

Seat belt inspection and maintenance: • Keep seat belts in good condition.

• Check that bolts are tight on the seat bracket or mounting.

• Keep sharp edges and items than can cause damage away from the belts.

• If the belt is attached to the seat, make sure that the seat or seat brackets are mounted securely.

• Periodically check belts, buckles, retractors, tethers, slack take-up system, and mounting bolts for damage and wear.

• Keep seat belts clean and dry.

• Replace all parts that have damage or wear.

• Clean belts only with soap solution and warm water.

• Do not use bleach or dye on the belts because this can make the belts weak.

2-4

2 - SAFETY INFORMATION

Operator protective structure Your machine is equipped with an operator protective structure, such as: a Roll Over Protective Structure (ROPS), Falling Objects Protective Structure (FOPS), or a cab with a ROPS. A ROPS may be a can frame or a two-posted or four-posted structure used for the protection of the operator to minimize the possibility of serious injury. The mounting structure and fasteners forming the mounting connection with the machine are part of the ROPS. The protective structure is a special safety component of your machine.

DO NOT attach any device to the protective structure for pulling purposes. DO NOT drill holes to 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 and replacement.

After an accident, fire, tip over, or roll over, the following MUST be performed by a qualified technician before returning the machine to field or job-site operations: • The protective structure MUST BE REPLACED. • The mounting or suspension for the protective structure, operator’s seat and suspension, seat belts and mounting components, and wiring 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 OVER, ROLL OVER, COLLISION, OR ACCIDENT. Seat belts are part of your protective system and must be worn at all times. The operator must be held to the seat inside the frame in order for the protective system to work.

Air-conditioning system The air-conditioning system is under high pressure. Do not disconnect any lines. The release of high pressure can cause serious injury.

The air-conditioning system contains gases that are harmful to the environment when released into the atmosphere. Do not attempt to service or repair the system.

Only trained service technicians can service, repair, or recharge the air-conditioning system.

Personal Protective Equipment (PPE) Wear Personal Protective Equipment (PPE) such as hard hat, eye protection, heavy gloves, hearing protection, protective clothing, etc.

Do Not Operate tag Before you start servicing the machine, attach a ‘Do Not Operate’ warning tag to the machine in an area that will be visible.

Hazardous chemicals If you are exposed to or come in contact with hazardous chemicals you can be seriously injured. The fluids, lubricants, paints, adhesives, coolant, etc. required for the function of your machine can be hazardous. They may be attractive and harmful to domestic animals as well as humans.

Material Safety Data Sheets (MSDS) provide information about the chemical substances within a product, safe handling and storage procedures, first aid measures, and

procedures to take in the event of a spill or accidental release. MSDS are available from your dealer.

Before you service your machine check the MSDS for each lubricant, fluid, etc. used in this machine. This information indicates the associated risks and will help you service the machine safely. Follow the information in the MSDS, and on manufacturer containers, as well as the information in this manual, when you service the machine.

2-5

2 - SAFETY INFORMATION

Dispose of all fluids, filters, and containers in an environmentally safe manner according to local laws and regulations. Check with local environmental and recycling centers or your dealer for correct disposal information.

Store fluids and filters in accordance with local laws and regulations. Use only appropriate containers for the storage of chemicals or petrochemical substances.

Keep out of reach or children or other unauthorized persons.

Applied chemicals require additional precautions. Obtain complete information from the manufacturer or distributor of the chemicals before you use them.

Utility safety When digging or using ground-engaging equipment, be aware of buried cables and other services. Contact your local utilities or authorities, as appropriate, to determine the locations of services.

Make sure that the machine has sufficient clearance to pass in all directions. Pay special attention to overhead power lines and hanging obstacles. High voltage lines may require significant clearance for safety. Contact local authorities or utilities to obtain safe clearance distances from high voltage power lines.

Retract raised or extended components, if necessary.

Remove or lower radio antennas or other accessories.

Should a contact between the machine and an electric

power source occur, the following precautions must be taken: • Stop the machine movement immediately.

• Apply the parking brake, stop the engine, and remove the key.

• Check if you can safely leave the cab or your actual position without contact with electrical wires. If not, stay in your position and call for help. If you can leave your position without touching lines, jump clear of the machine to make sure that you do not make contact with the ground and the machine at the same time.

• Do not permit anyone to touch the machine until power has been shut off to the power lines.

Electrical storm safety Do not operate machine during an electrical storm.

If you are on the ground during an electrical storm, stay away from machinery and equipment. Seek shelter in a permanent, protected structure.

If an electrical storm should strike during operation, remain in the cab. Do not leave the cab or operator’s platform. Do not make contact with the ground or objects outside the machine.

Mounting and dismounting Mount and dismount the machine only at designated locations that have handholds, steps, and/or or ladders.

Face the machine when you mount and dismount the machine.

Do not jump off of the machine.

Maintain a three-point contact with steps, ladders, and handholds.

Make sure that steps, ladders, and platforms remain clean and clear of debris and foreign substances. Injury may result from slippery surfaces.

Never mount or dismount from a moving machine.

Working at heights When the normal use and maintenance of the machine requires you to work at heights:

• Do not stand on surfaces that are not designated as steps or platforms.

• Correctly use installed steps, ladders, and railings.

Do not use the machine as a lift, ladder, or platform for working at heights.

• Never use ladders, steps, or railings while the machine is moving.

Lifting and overhead loads Never use loader buckets, forks, etc. or other lifting, handling, or digging equipment to lift persons.

Know the full area of movement of the machine and equipment and do not enter or permit anyone to enter the area of movement while the machine is in operation.

Do not use raised equipment as a work platform.

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Never enter or permit anyone to enter the area underneath raised equipment. Equipment and/or loads can fall unexpectedly and crush persons underneath it.

Load items can fall off the loader bucket or lifting equipment and crush the operator. Care must be taken when lifting a load. Use proper lifting equipment.

Do not leave equipment in raised position while parked or during service, unless securely supported. Hydraulic cylinders must be mechanically locked or supported if they are left in a raised position for service or access.

Do not lift load higher than necessary. Lower loads to transport. Remember to leave appropriate clearance to the ground and other obstacles.

Loader buckets, forks, etc. or other lifting, handling, or digging equipment and its load will change the center of gravity of the machine. This can cause the machine to tip on slopes or uneven ground.

Equipment and associated loads can block visibility and cause an accident. Do not operate with insufficient visibility.

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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.

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Prepare for emergencies Be prepared if a fire starts or an accident occurs.

• Keep the first-aid kit and fire extinguisher on hand.

• Thoroughly read and understand the label attached to the fire extinguisher to use it properly.

• Establish emergency priority procedures to cope with fires and accidents.

• Keep emergency numbers for doctors, ambulance service, hospitals and fire department posted near the telephone.

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Wear protective clothing Wear close fitting safety shoes, hard hat and working clothes. Put on protective glasses, face shields, ear protection and gloves. When necessary, wear reflective vest.

Avoid wearing loose clothing, jewelry, or other items that can catch on control levers or other parts of the machine.

Do not wear headphones while operating the machine.

Work clothing that has come in contact with oil could catch fire. Change clothes immediately.

Protect against noise Prolonged exposure to loud noise can cause impairment or loss of hearing.

• Wear a suitable hearing protection such as earmuffs or earplugs to protect objectionable or uncomfortably loud noise.

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2 - SAFETY INFORMATION

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.

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Inspect the machine 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.

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.

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.

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Engage the safety 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 LOCK position, the controls will be blocked.

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

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Before leaving the machine, lower the bucket to the ground, set the safety levers to the LOCK position, stop the engine and remove the starter key.

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.

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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.

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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.

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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.

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.

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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.

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How to handle life hammer-cab only A life hammer is provided on the right side of cab. In case of emergency, take the life hammer (1), break the cab glass, and escape from the cab. In addition, the life hammer (1) is equipped with a cutter (2) on the lever side to cut the seat belt, etc.

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.

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.

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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.

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Engine start-up Start engine from the operator’s seat. Do not short circuit the starter with the battery to start. This may cause serious injury or damage to the electrical system.

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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.

NOTICE: 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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2 - SAFETY INFORMATION

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. Which may cause injury and/or machine damage.

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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.

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Do not hit the cab with the attachment Check clearance between bucket and machine before operation. Exercise care when operating a bucket near machine.

Slewing 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.

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2 - SAFETY INFORMATION

Travelling on slopes When travelling on slopes, the machine could turn over or slide.

Keep the bucket at a height of 30 - 40 cm (11.81 - 15.75 in) from the ground and always keep the safety belt fastened.

Never make a change of direction on a slope.

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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.

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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.

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.

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2 - SAFETY INFORMATION

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.

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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 0 - 50000 V 50000 - 200000 V 200000 - 350000 V 350000 - 500000 V 500000 - 750000 V 750000 - 1000000 V

Minimum distance ≥ 3 m (9.84 ft) ≥ 4.5 m (14.76 ft) ≥ 6 m (19.69 ft) ≥ 7.5 m (24.61 ft) ≥ 10.5 m (34.45 ft) ≥ 13.5 m (44.29 ft)

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.

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2 - SAFETY INFORMATION

Transport the machine under safe conditions During loading or unloading operations of the machine on a truck or trailer the danger for tipping over is always present.

• Use a truck or trailer appropriate for transporting the machine.

• 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.

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• 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.

• Secure safely the machine to the trailer with appropriate chains or cables. Please refer to the chapter "TRANSPORT OPERATIONS" of this Manual for the safe loading and unloading procedures.

• Make sure that you comply with National and local regulations when transporting the machine on open roads.

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

(A) Overall height (B) Overall length

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) and lower the bucket (2) and the dozer (3) to the ground to prevent an unexpected machine movement.

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.

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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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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.

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2 - SAFETY INFORMATION

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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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.

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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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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 lever to the LOCK position.

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

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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.

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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.

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.

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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 lever to the LOCK position.

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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.

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Read the service hour meter Read the hour meter 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, jewelry and hair do not become entangled when working around moving parts.

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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.

NOTICE: 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.

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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.

Caution while refuelling During the refilling of fuel or oil, avoid to remove possible strainers fitted in the filling ports.

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.

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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.

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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.

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.

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Stopping the engine Before starting any inspection or maintenance operation on the machine, make sure that the engine has been stopped and set the safety lever(s) to the LOCK position.

Failure to stop engine could result in serious bodily injury or death.

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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.

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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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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 Use only approved work lights when performing inspection and maintenance procedures to prevent possible fire or explosion. Certain types of lights cannot be used as there is a risk of some types of liquids or gases inflaming.

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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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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, main 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 on 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.

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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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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.

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• 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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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 h prior to welding.

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• 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.

CAUTION Fire hazard!

Remove all flammable and explosive materials from the area around the welding location.

Shield flammable material that you cannot remove from the immediate area. Always have a fireguard and fire extinguisher available nearby.

Failure to comply could result in minor or moderate injury.

C0062A

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.

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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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Precautions during battery use 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 min 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.

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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. B. C. D. E.

Battery charging Battery discharging Red cable Black cable Upper structure of the stopped machine Cable connecting order: 1>2>3>4 Cable disconnecting order: 4>3>2>1

WARNING Explosion hazard!

Booster batteries or jumper cables must be connected properly to prevent battery explosion and/or damage to the electrical system.

Connect positive to positive and negative to negative.

Failure to comply could result in death or serious injury.

W0343A

Connect booster cables using following procedure: • 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.

2-31

LELI11E0084AB

88

2 - SAFETY INFORMATION

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.

LELI11E0107AB

89

LELI11E0108AA

90

LELI11E0109AA

91

LELI11E0110AA

92

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.

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.

2-32

2 - SAFETY INFORMATION

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.

LELI11E0111AB

93

LELI11E0112AB

94

LELI11E0113AA

95

LELI11E0114AA

96

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.

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.

2-33

2 - SAFETY INFORMATION

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.

LELI11E0115AA

97

LELI11E0116AA

98

LELI11E0117AA

99

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.

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.

2-34

2 - SAFETY INFORMATION

Hand signals Raise load vertically Face machine operator, raise right forearm vertical, with index finger pointing up and move hand in a small circular motion.

NH0081

1

NH0082

2

NH0083

3

NH0084

4

Lower load vertically Face machine operator, extend right arm down, point index finger down and move hand in a small circular motion.

Move load In horizontally Face machine operator, extend right arm toward operator with hand facing operator and move hand in direction of movement required.

Move load Out horizontally Face machine operator, extend right arm toward operator with back of hand facing operator and move hand in direction of movement required.

2-35

2 - SAFETY INFORMATION

Raise boom Face machine operator, extend right arm out horizontally from shoulder, make a fist with thumb up.

NH0085

5

NH0086

6

NH0087

7

NH0088

8

Lower boom Face machine operator, extend right arm out horizontally from shoulder, make a fist with thumb down.

Swing left Face machine operator, extend right arm out horizontally from shoulder, make a fist with index finger pointing in swing direction.

Swing right Face machine operator, extend left arm out horizontally from shoulder, make a fist with index finger pointing in swing direction.

2-36

2 - SAFETY INFORMATION

Arm In Face machine operator, bend at elbows with arms facing operator, make fists and point thumbs in toward each other.

NH0089

9

Arm Out Face machine operator, bend at elbows with arms facing operator, make fists and point thumbs out away from each other.

NH0090

10

NH0091

11

NH0092

12

Counter rotate left Face machine operator, place right hand on top of hard hat, bend left arm at elbow to the right, make a fist with left hand with index finger pointing out and rotate hand in a reverse circular motion.

Counter rotate right Face machine operator, place left hand on top of hard hat, bend right arm at elbow to the left, make a fist with right hand with index finger pointing out and rotate hand in a forward circular motion.

2-37

2 - SAFETY INFORMATION

Travel forward Face machine operator, bend both elbows in, make fists and rotate fists one over the other in a reverse circular motion.

NH0093

13

NH0094

14

NH0095

15

NH0096

16

Travel reverse Face machine operator, bend both elbows in, make fists and rotate fists one over the other in a forward circular motion.

Close bucket Face machine operator, hold left hand in, closed and stationary, hold right hand in, make a fist with index finger pointing toward left hand and move right hand in a small reverse circular motion.

Open bucket Face machine operator, hold left hand in, open and stationary, hold right hand in, make a fist with index finger pointing toward left hand and move right hand in a small forward circular motion.

2-38

2 - SAFETY INFORMATION

Turn left Face machine operator, raise right forearm up, make fist with right hand and hold stationary, bend left arm in, make fist with left hand and rotate left fist in a small reverse circular motion.

NH0097

17

NH0098

18

NH0099

19

NH0100

20

Turn right Face machine operator, raise left forearm up, make fist with left hand and hold stationary, bend right arm in, make fist with right hand and rotate right fist in a small forward circular motion.

Move this much Face machine operator, raise both forearms up, hands open and facing each other , move hands in laterally indicating how far to go.

Move slowly Face machine operator, raise left arm out horizontally toward right shoulder with hand open and facing down, point right index finger up toward open left hand and rotate right hand in a reverse circular motion. (Raise load slowly is illustrated).

2-39

2 - SAFETY INFORMATION

Stop Face machine operator, raise left arm out horizontally from shoulder with hand open and facing down, move arm in a horizontal motion back and forth.

NH0101

21

NH0102

22

NH0103

23

Emergency stop Face machine operator, raise both arms out horizontally from shoulders with hands open and facing down, move arms in a horizontal motion back and forth.

Stop engine Face machine operator, right arm at side, draw left thumb or index finger across throat.

2-40

2 - SAFETY INFORMATION

Noise levels Sound power level Lwa= 94 dB (A) Plate (1) shows the guaranteed sound power level, determined in compliance with European standard 2000/14/ EC.

Level of sound pressure at the operator’s seat Lpa= 80 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.

LELI11E0005BB

2-41

1

2 - SAFETY INFORMATION

Vibration levels The vibration level transmitted to the operator depends mainly upon the conditions of the ground on which operations take place, the mode of operation of the machine and its equipment. The exposure to vibrations can be considerably reduced when the following recommendation are complied with: • use equipment compatible with the machine and the type of work do be done; • adjust and lock the seat in the correct position; also inspect regularly the suspensions of the seat, if provided, and perform the adjustments and repairs as required; • perform regularly the current maintenance operations of the machine at the prescribed intervals;

• when travelling, avoid, as far as possible, particularly rough terrain or the impact against possible obstacles.

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

• The weighted average quadratic acceleration value to which the operator’s arms are subjected does not exceed 2.5 m/s².

• The weighted average quadratic acceleration value to which the operator’s body is subjected does not exceed 0.5 m/s². These results were obtained using an acceleration gauge during the excavation works.

• operate the equipment in a uniform manner, preventing, as far as possible, sharp movements or extreme shocks; NOTE: the Whole-Body exposure value is determined under particular operating and terrain conditions and therefore may not be representative for all the possible operating conditions within the intended use of the machine. Consequently this single Whole-Body 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 working conditions measurement. If this is not feasible use of information provided in the table below from ISO/TR 25398:2006 (*).

Working conditions Digging Use of the hydraulic hammer Transfer movement

Basic emission value Standard deviation aw,eqz 1.4* aw,eqy 1.4* aw,eqx 1.4* Sy 1.4* Sx Sz 0.33 m/s² (1.08 0.21 m/s² (0.69 0.19 m/s² (0.62 0.19 m/s² (0.62 0.12 m/s² (0.39 0.10 m/s² (0.33 ft/s²) ft/s²) ft/s²) ft/s²) ft/s²) ft/s²) 0.49 m/s² (1.61 0.28 m/s² (0.92 0.36 m/s² (1.18 0.20 m/s² (0.66 0.13 m/s² (0.43 0.17 m/s² (0.56 ft/s²) ft/s²) ft/s²) ft/s²) ft/s²) ft/s²) 0.45 m/s (1.48 0.39 m/s² (1.28 0.62 m/s² (2.03 0.17 m/s² (0.56 0.18 m/s² (0.59 0.28 m/s² (0.92 ft/s) ft/s²) ft/s²) ft/s²) ft/s²) ft/s²)

(*) ISO/TR 25398:2006 Mechanical vibrations – Guidelines for assessment of exposure to whole-body vibration of ride-on machine – Use of harmonized data measured by international institutes, organizations and manufacturers.

2-42

2 - SAFETY INFORMATION

Towing the machine WARNING Avoid injury!

When towing, do not enter the area between the machine and towing vehicle. Do not apply a shock load to the wire rope. Keep the wire rope horizontal and perpendicular to the machine frame. Tow in low speed mode.

Failure to comply could result in death or serious injury.

W1193A

Should the machine become stuck in soft soil, it may be necessary to tow it.

SMIL13MEX0148AA

To tow the machine, use towing device as a metal cable or a chain and lay it out on the lower frame as pictured: use a metal cable or chain with sufficient capacity.

Apply pads at the corners of the lower frame to prevent both the towing device and the lower frame from being damaged.

Attach other end of towing device to the vehicle used for towing.

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

NOTICE: Do not use eyes on machine lower frame to tow machine.

NOTE: Do not tow the machine using the brackets welded to the lower plates of the lower frame.

2-43

1

2 - SAFETY INFORMATION

Safety signs WARNING Avoid injury!

Make sure decals are perfectly legible. Clean decals regularly. Replace all damaged, missing, painted over, or illegible decals. See your dealer for replacement decals. When replacing parts bearing decals, be sure to put new decals on each new part.

Failure to comply could result in death or serious injury.

W0229A

SMIL13MEX0125GB

2-44

1

2 - SAFETY INFORMATION

SMIL13MEX0205HB

2-45

2

2 - SAFETY INFORMATION

TULI12E300012HB

2-46

3

2 - SAFETY INFORMATION

Arms movement warning plate Located on seat stand cover.

It warns about danger of contact between machine attachment and operator compartment.

Operator must check clearance between machine attachment and operator compartment.

Using special attachment may increase risk of contact: check attach dimensions before operations.

LELI11E0088BB

4

LELI11E0089AB

5

LELI11E0090AB

6

Hydraulic oil bleeding plate Located on top of radiator duct.

It indicates that air should be bled from the tank, after every hydraulic oil change.

Danger of pump seizure.

Electrical lines safety decal, 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 lever to the LOCKED position. Controls are thereby disconnected and any accidental equipment movement is impossible.

2-47

2 - SAFETY INFORMATION

Hot surface decal Located on hood hinge.

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.

LELI11E0091AB

7

LELI11E0092AB

8

LELI11E0093AB

9

Pressurized fluids and lubricants Located on radiator duct.

Always release pressure from hydraulic reservoir, engine coolant, fuel system and all systems under 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.

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.

Decal, counterweight safe operating area Located on the counterweight.

Make sure that exposed personnel in the area of operation are clear of the machine before moving the machine or its attachments. Sound horn.

LELI11E0094AB

2-48

10

2 - SAFETY INFORMATION

Engine stop decal Located on engine radiator.

It indicates you have to stop the engine before opening the engine guard.

Danger of serious injury because of rotating pieces like fan, pulleys and belts.

LELI11E0095AB

11

LELI11E0096AB

12

LELI11E0097AB

13

LELI11E0098AB

14

Booster cables decal Located on battery box cover.

It warns about the danger of starting the motor with booster cables.

Crawler adjuster decal Located on crawler frame.

It shows that it is obligatory to consult the Operator’s Manual prior to acting on the crawler adjust valve.

Danger of severe injuries.

Keep working area clean Located on both sides of the arm.

Make certain area is clear of obstacles and persons before beginning the operation of 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.

2-49

2 - SAFETY INFORMATION

Lifting point decal Fastening means must be attached here when the machine is to be lifted.

TULI12E300013AB

15

Battery decal Located on battery box cover.

Hydrogen generates in the battery and it is easily flammable. Do not produce sparks and naked flames near a battery, to prevent this from catching fire and explode.

LELI11E0100AB

16

LELI11E0101AB

17

LELI11E0102AB

18

Decal for window lock (cab only) Located inside front window.

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

Front window fall (cab only) Located on front window.

Falling of front window can cause injury.

Always lock securely in place with lock levers on both sides.

When operating the window, use handles and keep the lock lever in release position.

2-50

2 - SAFETY INFORMATION

Cab door decal (cab only) Located inside cab door.

It indicates the danger of injury deriving from incorrect or faulty locking of cab door.

LELI11E0103AB

19

LELI11E0104AB

20

LELI11E0105AB

21

LELI11E0106AB

22

Removing cab (cab only) Located inside the cab right.

Tag maintenance in progress It is compulsory, for maintenance operators, to apply a card warning about incomplete efficiency of the machine and the presence of personnel performing maintenance in unseen positions. This card must be located on the left pilot control or the cab door.

Break the glass to exit (cab only) In case of emergency with the cab door locked, break the glass to exit. Located on inside of front and rear window.

2-51

2 - SAFETY INFORMATION

Lashing point decal Fastening means must be attached here when the machine is to be transported.

SMIL13MEX0124AB

23

SMIL13MEX0208BB

24

Machine overall decal for lifting and lashing points Summary/overview of fastening points (see section 5 for details).

2-52

3 - CONTROLS/INSTRUMENTS

3 - CONTROLS/INSTRUMENTS###_3_### ACCESS TO OPERATOR'S PLATFORM

Cab CAUTION Fall hazard!

When entering or exiting the cab, never use the control levers as handholds. Always mount and dismount the machine in a safe way.

Maintain a three-point contact with steps, ladders, and/or handholds.

Failure to comply could result in minor or moderate injury.

C0075B

Before getting on the machine: • Keep the access to the machine clear of foreign objects and clean. Remove grease or mud from steps and handrails to minimize the risk of slipping.

• Check that the fasteners of steps and handrails are tightened and undamaged.

• Always face the machine and maintain a three point contact with the steps and handrails.

Locking cab door To lock the door in the open position, slide the door fully open until it locks on the catch (1) located on the rear of the cab.

LELI11E0156AB

1

LELI11E0157AB

2

Unlocking door from inside To unlock the door, pull the lever (1) backward.

3-1

3 - CONTROLS/INSTRUMENTS

(Upper) Front windshield opening The front windshield can be slide on cab ceiling and locked in this position.

NOTICE: Be sure to move the machine to level ground when opening/closing the front windshield, and lock it. Especially, unlocking windshield in forward-inclined position of the machine causes the front windshield to fall down.

Move the machine to a level ground. Engage safety lever and stop the engine.

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

LELI11E0158AB

3

LELI11E0159AB

4

LELI11E0160AB

5

LELI11E0161AB

6

Grab the left/right handle of front windshield. Pull it until the windshield glides backwards the ceiling.

Be sure to lock the front windshield to the ceiling by pulling lever (1).

Close the upper front windshield by following the above steps in the reverse order.

NOTICE: When closing the upper front windshield, take care not to crush your fingers, etc.

To operate the machine with locks not engaged correctly, is quite dangerous. Be sure to lock them properly.

(Lower) Front windshield opening After the upper front windshield has been fastened, the lower front windshield can also be removed. Once it has been removed from the frame guides (1), it is necessary to fix it by means of proper retainers on cab back holders.

NOTICE: Do not start working with lower front windscreen disassembled.

Roof lamp Press relevant switch when required.

ON: the lamp turns on.

OFF: the lamp turns off.

3-2

3 - CONTROLS/INSTRUMENTS

Opening/closing the window on the right side Release retainer (1) and slide the glass.

Close the window by placing the glass to normal position and lock it.

LELI11E0162AB

7

LELI11E0167AB

8

Emergency exit If the cab door cannot be opened (due to an accident occurred while working), the recommended escape route is the following: • Opening of front sliding windshield.

In case the opening of the front windshield is not possible, a life hammer (1) is included to break the front or rear glass.

NOTICE: Before breaking the front windshield, it is necessary to wear suitable gloves and protective glasses. Danger of bodily injuries.

3-3

3 - CONTROLS/INSTRUMENTS

OPERATOR'S SEAT

Operator's seat WARNING Loss of control hazard!

Do not make seat adjustments while the machine is in motion. All seat adjustments should be made with the machine stationary and the safety lever in the LOCK position.

Failure to comply could result in death or serious injury.

W0393A

Before operating the machine, adjust and lock the seat in the correct position to guarantee maximum driving comfort and maximum control accessibility.

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.

LELI11E0168AB

3-4

1

3 - CONTROLS/INSTRUMENTS

Seat belt WARNING Equipment failure could cause accident or injury!

Always fasten seat belt securely before operating the machine. Inspect seat belt parts for wear and/or damage. To ensure operator safety, replace any and all damaged parts of the seat belt prior to operation.

Failure to comply could result in death or serious injury.

W0046A

Check periodically the seat belt and all its securing elements. If you notice that the seat belt and its securing elements are damaged or some of them missing, perform immediately repair or replacement of parts. Seat belts damaged or worn because of an accident, they have to be replaced.

The seat belt buckle must not be clogged, for instance from paper or other objects, otherwise the hooking tongue does not lock. Never fasten your seat belt over hard or fragile objects, such as bunches of keys or glasses inside your pockets. In this way your body could get injured in case of accident. The operator’s seat is fitted with a laptype seat belt. The belt tensioning roller is incorporated on the left side of the seat.

Fasten seat belt 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).

LELI11E0154AB

1

LELI11E0155AB

2

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

3-5

3 - CONTROLS/INSTRUMENTS

FORWARD CONTROLS

Front console

SMIL13MEX0003GB

1

1.

Safety lever

6.

Hydraulic breaker control push-button

2.

Left control lever

7.

Left travel lever

3.

Right control lever

8.

Right travel lever

4.

Horn switch

9.

Travel speed selector switch

5.

Hydraulic nibbler and breaker control slider

10. Swing control pedal

3-6

3 - CONTROLS/INSTRUMENTS

Safety lever WARNING Unexpected machine movement!

When you must leave the operator’s seat, always place the safety lever in the LOCKED position. If the safety lever is unlocked and the control lever is moved unexpectedly, a serious accident could result.

Failure to comply could result in death or serious injury.

W1241A

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 levers, one on each side.

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

NOTE: Never leave the machine unattended with engine running or with safety lever unlocked. Note that, even with the safety lever in LOCKED position, the dozer and boom functions are still enabled.

The safety lever has two positions: A.

LOCK With the safety lever in the LOCKED position, the controls for the attachment and for the rotation of the upper structure are locked.

NOTE: The slewing control is locked by means of the cover on the pedal. The dozer control cannot be locked.

B.

UNLOCK With the safety lever in UNLOCKED position, all functions are enabled again.

3-7

LELI11E0145AB

2

3 - CONTROLS/INSTRUMENTS

Left and right control levers ( ISO configuration) The control levers activate the functions illustrated on the right.

• 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.

2 4

E F G H

Left control lever Arm out Arm in Slewing left Slewing right

1 3

3-8

A B C D

LELI11E0146BB

3

LELI11E0147AA

4

Right control lever Boom down Boom up Bucket in Bucket out

3 - CONTROLS/INSTRUMENTS

Horn switch Depress the symbol of this switch on top of left control lever to sound the horn.

NOTICE: Sound the horn before starting engine, travelling, slewing or operating the attachments.

LELI11E0137AA

5

LELI11E0483AB

6

LELI11E0483AB

7

Hydraulic nibbler and breaker control slider The slider (2) is located on the grip of the right control lever.

It is used to control the opening and closing of hydraulic nibbler by sliding right and left.

NOTICE: Do not touch the breaker push-button (1) when you operate the nibbler.

NOTE: The sliding movement of slider (2) controls hydraulic flow rate to the attachment.

Hydraulic breaker control push-button To operate the breaker, use the push-button (1) located on the grip of the right control lever.

Press the push-button (1) to activate the hydraulic breaker.

Release the push-button (1) to stop the hydraulic breaker.

NOTICE: When the breaker is used, the breaker causes malfunction if the switching of selector valve is wrong, and the operation efficiency and the work speed decrease. It causes not only malfunction but also the machine damage. Switch the selector valve properly.

NOTICE: The breaker can be activated by sliding the slider (2) to the left. But use the breaker push-button (1) as much as possible to operate the breaker.

3-9

3 - CONTROLS/INSTRUMENTS

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.

NOTICE: 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.

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).

LELI11E0148BB

8

LELI11E0136AB

9

Travel speed selector switch 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.

NOTICE: 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.

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.

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

3-10

3 - CONTROLS/INSTRUMENTS

Swing control pedal This pedal operates the swing motion of the boom.

WARNING Unexpected machine movement!

ALWAYS lock the auxiliary pedals when not in use.

Failure to comply could result in death or serious injury.

W0222A

By pushing pedal down and right (A) the right swing is operated.

LELI11E0151AB

By pushing pedal down and left (B) the left swing is operated.

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

3-11

10

3 - CONTROLS/INSTRUMENTS

RIGHT-HAND SIDE CONTROLS

Right-hand side controls

SMIL13MEX0004GC

1

1. Starter switch

6. Throttle control lever

2. Deceleration select switch

7. Dozer control lever

3. Work light switch

8. 12 V socket

4. Heating switch (cab only)

9. Gauge cluster

5. Wiper and washer switch (cab only)

3-12

3 - CONTROLS/INSTRUMENTS

Starter switch The starter switch has four positions: 1. HEAT When starting the engine is difficult due to a cold climate, turn the key to this position to activate the engine preheating. Hold the key in this position for about 15 s to ease up the engine start. Release key after engine start.

2. OFF In this position, the electric system is not powered and the engine is stopped.

3. ON In this position all electrical circuits are powered. Maintain the key in this position while the machine is operating.

LELI11E0135AB

2

LELI11E0138AA

3

LELI11E0139AA

4

4. START To start the engine, turn the key to the start position, then release it so that it automatically returns to ON.

Deceleration select switch Press this switch while the engine rotates to set the same at low speed.

Press this switch again to release deceleration. When you are waiting for the dump truck or the next job, fuel cost and noise can be reduced by this release.

Turn the starter switch from ON to OFF to release deceleration automatically.

Work light switch This switch is used to activate the work lights on boom and canopy.

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3 - CONTROLS/INSTRUMENTS

Heating switch (cab only) This switch is used to warm up the cab interior.

OFF: Stop L: Low speed fan drive H: High speed fan drive NOTE: The heating operates with the engine coolant.

This is the reason why the heating generates warm water only if the coolant is heated.

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5

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6

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7

On the engine has been installed a cock (1) for the cab heating.

Through the cock (1) opening, by means of the hot water flow supplied from the engine, the cab can be heated.

This operation has to be carried out at winter begin and later on when at hot season begin, the cock must be closed.

NOTICE: Before carrying out these operations, stop the engine, ensuring that all its components have cooled down.

Wiper and washer switch (cab 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 s, or without liquid.

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3 - CONTROLS/INSTRUMENTS

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. LO (Low idle) By shifting the lever completely forwards, the engine rpm decreases to the minimum.

B. HI (High idle) By shifting the lever completely rearwards, the engine rpm increases to the maximum.

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8

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Dozer control lever This lever enables to control the dozer (1) up or down functions.

NOTE: Even though the safety lever is set in locked position, the travel lever remains active.

By pulling lever backward (C) dozer lifts, while by pushing lever forward (D) dozer lowers.

12 V socket This socket provides electric power for 12 V electrical appliances (inspection light, etc.).

NOTE: It can not be used as cigarette lighter.

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3-15

10

3 - CONTROLS/INSTRUMENTS

Instrument cluster panel

LELI11E0126EB

Type Gauges Warning lamps

Indicator lamp

No. 1 2 3 4 5 6 7

1

Description Coolant temperature gauge Fuel level gauge Engine oil pressure lamp (red) Coolant temperature lamp (red) Battery charge lamp (red) Low fuel warning lamp (red) High travel speed lamp (yellow)

GAUGES Coolant temperature gauge This indicates the temperature of the engine coolant, and operates when the starter switch is turned to the ON position. The temperature is normal when the indicator needle is in the white range (1). If the needle enters the red range H, let the engine idle until coolant cools down and the needle returns to white range (1).

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2

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3

Fuel level gauge This instrument indicates the amount of fuel in the tank.

Full tank contains about 38 l (10 US gal). This instrument indicates the residual volume of fuel inside the tank.

When the fuel level gauge needle (2) reaches the reference F, the fuel tank is full. Make sure to refuel when the indicator is approaching to reference E. Refill the fuel tank with diesel fuel only. Normally the gauge needle takes some time to move up to the appropriate level after turning the starter key on ON.

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3 - CONTROLS/INSTRUMENTS

WARNING LAMPS NOTICE: When one of these warning lamps turns on, immediately stop working. Then investigate the cause for it, and carry out appropriate inspection and maintenance.

Engine oil pressure lamp (red) The lamp turns On when the starter 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.

NOTICE: The engine may undergo severe damage if the machine is operated while this lamp is On.

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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.

NOTICE: 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.

5

TULI12E2B0081AC

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

NOTICE: 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.

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.

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3-17

6

3 - CONTROLS/INSTRUMENTS

Low fuel warning lamp (red) If the fuel is low, a warning lamp turns On. Stop the engine immediately and refuel.

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INDICATOR LAMP This lamp indicates the working conditions.

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.

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3 - CONTROLS/INSTRUMENTS

EXTERIOR CONTROLS

Hoods NOTICE: Stop the engine when hood or radiator cover are open.

Locking devices are provided for the engine guards. Use the starter key to open and close engine guards.

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Opening Insert the key in the lock (1).

After releasing the lock, remove the key and open the hood.

Fasten hood open with suitable stay (2).

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3 - CONTROLS/INSTRUMENTS

Locking Return the stay to its initial position, and fix it into its holder.

Close the hood.

Insert the key, and turn it counterclockwise to lock the hood. Then remove the key.

NOTE: Be sure to insert the key completely, otherwise it could get damaged.

NOTICE: Always secure hoods with stays to hold them open.

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ELECTRICAL EQUIPMENT

Work lights A work light is provided on the boom and on the canopy to turn on the visual field with poor visibility.

3-20

4 - OPERATING INSTRUCTIONS

4 - OPERATING INSTRUCTIONS###_4_### COMMISSIONING THE UNIT

Daily inspection

TULI12E300101FA

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.

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

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.

4-1

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4 - OPERATING INSTRUCTIONS

Engine coolant level CAUTION Burn hazard!

Hot coolant can spray out if you remove the filler cap while the system is hot. After the system has cooled, turn the filler cap to the first notch and wait for all pressure to release before proceeding.

Failure to comply could result in minor or moderate injury.

C0043A

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 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 level approximately reaches the FULL mark.

Install radiator cap (2) and tighten securely.

NOTICE: 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.

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.

4-2

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4 - OPERATING INSTRUCTIONS

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 min after use, to check the engine oil level.

Bring throttle control lever to minimum speed, stop the engine and remove starter key, then position safety lever on

LOCK position.

Wait for the machine to cool down.

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.

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NOTICE: Do not top up using oil with different specifications from the oil already in the engine.

4-3

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4 - OPERATING INSTRUCTIONS

Hydraulic oil level WARNING Pressurized system!

Never attempt to drain fluids or remove filters when the engine is running. Turn off the engine and relieve all pressure from pressurized systems before servicing the machine.

Failure to comply could result in death or serious injury.

W0905A

NOTICE: Do not top up using oil with different specifications from the oil already in the hydraulic oil tank. If the machine was filled with biodegradable hydraulic oil, do not top up with mineral hydraulic oil, as they cannot be mixed.

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To check the hydraulic oil level, move the machine to a solid soil and flat ground.

Bring throttle control lever to minimum speed, stop the engine and remove starter key, then position safety lever on

LOCK position.

Wait for the machine to cool down.

Open the engine guard (1) with the starter key and fix it by proper stay (2).

Check the oil level through level gauge (3) provided on the side of the hydraulic reservoir. The oil level is correct when set between marks (H) and (L).

Oil level varies according to oil temperature and must be settled between following values: Before starting: (L) level [oil temperature 10 - 30 °C (50 86 °F).

Normal operation: (H) level [oil temperature 50 - 80 °C (122 - 176 °F).

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

4-4

4 - OPERATING INSTRUCTIONS

If hydraulic oil level is low, top up as suggested.

Release the internal pressure in the reservoir.

Once ensured that hydraulic tank inner pressure is null, loosen screws (4) and remove plug (5). Fill tank with recommended hydraulic oil through filler, up to restore correct level.

Check the O-ring (6) of the cover, and if worn or damaged, replace it.

Install the cover (5) and fasten with the capscrews to the specified torque.

Tightening torque: 21.7 - 25.5 N·m (16.0 - 18.8 lb ft).

Start the engine. Activate 5-10 times the cylinder at no-load. Return the machine in oil check position.

Stop the engine and check the oil level. If necessary, top up with other oil.

Remove stay and close engine guard.

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4-5

4

4 - OPERATING INSTRUCTIONS

Fuel level WARNING Fuel vapors are explosive and flammable.

Do not smoke while handling fuel. Keep fuel away from flames or sparks. Shut off engine and remove key before servicing. Always work in a well-ventilated area. Clean up spilled fuel immediately.

Failure to comply could result in death or serious injury.

W0904A

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Turn the starter 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.

Park the machine on a level surface.

Rest the bucket to the ground.

Bring throttle control lever to minimum speed, stop the engine and remove starter key, then position safety lever on

LOCK position.

Open the plug (3) with the starter key.

Fuel tank capacity: 38 l (10 US gal).

Do not remove the fuel tank filter (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.

4-6

4 - OPERATING INSTRUCTIONS

Belt tension WARNING Rotating parts!

The engine is running. Keep clear of rotating fans and belts.

Failure to comply could result in death or serious injury.

W0275A

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1

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 (22 lb) to the centre of belt between pulleys, and measure the belt deflection.

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

2

TUIL12E2B0020AB

Windscreen washer reservoir The washer reservoir is installed on the left rear of cab.

Check the washer reservoir (1) for liquid level.

When the liquid level is low, remove cap (2) and restore washer liquid level.

NOTICE: During winter use all seasons washing liquid.

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4-7

1

4 - OPERATING INSTRUCTIONS

Warning lamps WARNING Unexpected machine movement!

When you must leave the operator’s seat, always place the safety lever in the LOCKED position. If the safety lever is unlocked and the control lever is moved unexpectedly, a serious accident could result.

Failure to comply could result in death or serious injury.

W1241A

Before starting the engine, check if warning lamps turn on correctly.

LELI11E0184AB

Make sure the safety lever is in the

1

LOCK position.

Make sure all control levers are in the neutral position.

Ensure that manual throttle lever is set at low idle.

Turn starter key into ON position and check warning lamps turn on, according to the key position, as shown in the table below.

Do not operate machine, if alarm lamps are lit. If necessary address to authorized Dealer and make sure that all lamps work correctly.

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

RED: warning lamp YELLOW: indicator lamp Lamp 1 2 3

4 5

Operation key from HEAT to OFF Preheating Engine oil Lamp OFF Pressure lamp Battery charge Lamp OFF Lamp Engine coolant Lamp OFF Temperature warning light Insufficient fuel Lamp OFF Warning lamp 2nd speed Lamp OFF Travel lamp

4-8

from OFF to ON Before startup Lamp ON

from START to ON Just after startup Lamp OFF

Lamp ON

Lamp OFF

Lamp OFF

Lamp OFF

Lamp OFF

Lamp OFF

Lamp OFF

Lamp OFF

4 - OPERATING INSTRUCTIONS

Work lights With the starter key in ON position, turn on the work light switch 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.

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4-9

1

4 - OPERATING INSTRUCTIONS

STARTING THE UNIT

Starting the engine WARNING Inhalation hazard!

Make sure there is proper ventilation before starting the engine.

Failure to comply could result in death or serious injury.

W0928A

Starting the engine in normal conditions 1. Securely fasten the seat belt.

2. Make sure that safety lever is in

LOCK position.

3. Make sure that all control levers are in neutral position.

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4. Make sure that throttle control lever (2) is set to engine low idle speed.

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

Release key as soon as the engine starts. The key will return to ON by itself.

6. If the engine does not start within 15 s, turn the starter key (3) to OFF and wait for 30 s. Then repeat above mentioned operations to start the engine.

NOTICE: 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.

NOTE: Do not increase the engine speed (high idling) with cold engine.

4-10

4 - OPERATING INSTRUCTIONS

Starting the engine in cold conditions With cold weather, due to the increase of oil viscosity and the decrease of battery charge, starting the engine may be difficult. Use the pre-heater to start the engine easily under these conditions.

1. Perform the starting procedure in normal conditions.

2. Turn the starter key (1) to HEAT and keep it in this position for 15 s so that the engine warms up.

3. Turn key to START position to start the engine.

4. Release key immediately after the engine start. The key will return to ON by itself.

5. If the engine does not start within 15 s, turn the starter key (1) to HEAT and wait for 10 s. Then repeat above mentioned operations to start the engine.

NOTICE: Do not hold the starter key to START for more than 15 s. If the engine does not start, return the starter key to OFF, wait for 30 s and then try again.

4-11

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4

4 - OPERATING INSTRUCTIONS

Starting the engine with booster batteries WARNING Explosive gas!

Batteries emit explosive hydrogen gas and other fumes while charging. Ventilate the charging area. Keep the battery away from sparks, open flames, and other ignition sources. Never charge a frozen battery.

Failure to comply could result in death or serious injury.

W0005A

WARNING Explosion hazard!

Booster batteries or jumper cables must be connected properly to prevent battery explosion and/or damage to the electrical system.

Connect positive to positive and negative to negative.

Failure to comply could result in death or serious injury.

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W0343A

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.

4-12

4 - OPERATING INSTRUCTIONS

Connecting booster batteries 1. Make sure that the starter key is in OFF position and the safety lever in LOCK position.

2. Remove left hood (1). Then open the cover (2) under the operator’s seat.

NOTICE: 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.

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8

3. Connect one terminal of the red cable (C) to the positive (+) pole of the discharged battery (B).

4. Connect the other terminal of the red cable (C) to the positive (+) pole of the booster battery (A).

5. Connect one terminal of the black cable (D) to the negative (-) pole of the booster battery (A).

6. Connect the other terminal of the black cable (D) to the upper frame (E) of the machine (ground).

Cables connecting order: 1 --> 2 --> 3 --> 4 A. B. C. D. E.

Booster battery Discharged battery Red cable Black cable To the upper frame of the troubled machine

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9

Disconnecting booster batteries 1. Disconnect the terminal of the black cable (D) from the upper frame (E) of the machine (ground).

2. Disconnect other terminal of the black cable (D) from the negative (-) pole of the booster battery (A).

3. Disconnect the terminal of the red cable (C) from the positive (+) pole of the booster battery (A).

4. Disconnect one other terminal of red cable (C) from the positive (+) pole of the machine battery (B).

Cables disconnecting order: 4 --> 3 --> 2 --> 1

4-13

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10

4 - OPERATING INSTRUCTIONS

Inspection after starting the engine NOTICE: Careless contact with any operating lever will cause unexpected sudden machine movement. Stand up or change position only after engaging the safety lever.

NOTICE: 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.

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.

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1

Safety lever WARNING Avoid injury!

If the machine responds to the controls with the safety lever in the LOCK position, stop the engine immediately and contact your dealer.

Failure to comply could result in death or serious injury.

W0937A

With the engine running and the safety lever (1) in LOCK position: • Move all control levers, except for the dozer and slewing control levers.

• Make sure that all functions, except for the dozer and boom functions, are not active.

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

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

4-14

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2

4 - OPERATING INSTRUCTIONS

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 above-mentioned checks, contact your Dealer for repairs.

NOTE: Do not apply any heavy load on the new engine for the first 50 h 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 min, in this way the engine heats and the oil reaches all its components.

4-15

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4 - OPERATING INSTRUCTIONS

Engine warm up NOTICE: Do not run the engine idle for more than 20 min.

Extended periods of idling reduce the life of the engine.

To warm up the engine, proceed as follows: • 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 min.

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1

4 - OPERATING INSTRUCTIONS

Hydraulic oil warm up NOTICE: do not start working prior to completing a correct hydraulic oil warm up, since the hydraulic functions would be slowed down and unexpected movements of the machine could occur. Also, some hydraulic components could be damaged by insufficient lubrication.

The hydraulic oil temperature must be between 50 °C (122 °F) and 80 °C (176 °F).

Avoid machine operation when the hydraulic oil temperature is below 20 °C (68 °F).

To warm up the hydraulic oil, proceed as follows: • Make sure to perform the engine warm up.

LELI11E0187AB

1

• Place the safety lever (3) in UNLOCK position and the engine throttle lever (1) on INTERMEDIATE SPEED 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 1 min, 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.

NOTICE: 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.

4-17

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2

4 - OPERATING INSTRUCTIONS

STOPPING THE UNIT

Stopping the engine NOTICE: 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.

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

1. Normally, the attachment should be placed on the ground, before stopping the engine (except for particular situations).

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

3. Bring the throttle control lever (2) to engine low idle.

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

5. Turn the starter key (3) to OFF to stop the engine.

6. Remove the starter key (3).

NOTICE: Always rest the bucket onto the ground before stopping the engine. Position the machine on a firm and possibly level ground. Never leave the machine unattended while the engine is running.

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4 - OPERATING INSTRUCTIONS

PARKING THE UNIT

Parking the machine • Always park the machine on a level and firm ground.

• Avoid parking on a slope.

When parking on a slope is unavoidable, make sure the bucket teeth are stuck in the ground, lower the dozer to the ground and properly block the crawlers with wedges.

• Stopping the engine.

• Turn the starter key to off and remove it.

• Make sure that the safety lever is in locked position to prevent any unexpected machine movement.

NOTICE: Do not shut off the engine when running at full speed, but let it run idle for some minutes to cool it down.

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• 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. NOTICE: Do not shut off the engine when running at full speed, but let it run idle for some minutes to cool it down.

• Set the safety lever (3) to the LOCK position (A).

• Close all windows.

4-19

4 - OPERATING INSTRUCTIONS

Lock with key (4) the access door of the cab and the engine guards, cooler and fuel filler covers.

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4

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5

Parking the machine 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 min with no load, before stopping the engine.

NOTICE: If the engine stops immediately after an high speed operation, the engine temperature increases remarkably. As a consequence, the engine oil is overheated and the joints jam, etc.

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

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4-20

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4 - OPERATING INSTRUCTIONS

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.

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4-21

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4 - OPERATING INSTRUCTIONS

4-22

5 - TRANSPORT OPERATIONS

5 - TRANSPORT OPERATIONS###_5_### ROAD TRANSPORT

Transporting on a trailer MACHINE PREPARATION • Know the total weight, length, width and height of the machine to be transported. Refer to the chapter SPECIFICATIONS. • Use only a trailer with a rated capacity sufficient to transport the machine.

NOTE: reference information for transport (for different machine configuration, see page 9-7 ) Models

Versions

CX35B CX35B CX39B CX39B

Canopy Cab Canopy Cab

Operating mass ISO 6016 3360 kg (7408 lb) 3500 kg (7716 lb) 3760 kg (8289 lb) 3900 kg (8598 lb)

• Make sure trailer has ramps or a ramp is available for loading the machine. Use ramps which have sufficient width, length, thickness and strength. The ramp slope should be 15 ° or less.

• Investigate beforehand the conditions of the road to be traveled, weight and size limits, and special local traffic regulations.

• Obtain any permits required from proper government agencies for machine transportation.

• Position the trailer on firm and level ground. Put blocks to the tires of trailer to prevent machine from moving.

• Accurately clean the machine undercarriage and tracks to prevent mud or debris from skidding during transport.

NOTE: if the machine is equipped with the steel crawlers, rubber stripes must be used between trailer and steel crawlers.

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 °.

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5-1

1

5 - TRANSPORT OPERATIONS

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 LELI11E0420AB

2

LOADING THE MACHINE • Always select the slow travel speed mode with extreme care and attention.

, proceed

• 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.

• In order to load the machine with the attachment fitted, travel on the ramp slowly at forward run, keeping the attachment and the dozer positioned ahead.

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• After arriving to the required position, lower the dozer and turn the upper structure 180 ° slowly.

• 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 and by securing the bucket to the flatbed with wire ropes.

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.

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5 - TRANSPORT OPERATIONS

SECURING THE MACHINE • After loading the machine, stop the engine and set the safety lever from the UNLOCK (B) to the LOCK position (A).

• Deactivate all switches and remove the starter key.

• Lock all covers and the cab door (cab version).

• Position blocks at the front and rear of the tracks in order to prevent the machine from moving during transport.

• Secure the machine to flatbed laying out the securing tools as per following prescriptions.

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5

1 — Cross tie-down 1. Tie-down the machine across its lower frame using two securing tools (1) as pictured.

2. Protect the securing tools (1) against edges with pads (2).

3. Apply force (F) of 700 daN (1574 lbf) using appropriate securing tools (1) of minimum Standard Tension Force of 1400 daN (3147 lbf).

Models CX35B CX39B

Tie-down width A MIN MAX 2100 mm (83 in) 2200 mm (87 in) 2100 mm (83 in) 2200 mm (87 in)

5-3

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5 - TRANSPORT OPERATIONS

2 — Front and rear fastening 1. Install two securing tools (1) to the installation holes at the top ends of blade (3). See lashing points decals on the blade.

2. Protect the securing tools (1) against edges with pads (2).

3. Use securing tools (1) having a Lashing Capacity of at least 1200 daN (2698 lbf) ( CX35B ) / 1500 daN (3372 lbf) ( CX39B ).

Models CX35B CX39B

Fastening distance A Fastening distance C MIN MAX MIN MAX 2100 mm 2200 mm 550 mm 1150 mm (83 in) (87 in) (22 in) (45 in) 2100 mm 2200 mm 530 mm 1130 mm (83 in) (87 in) (21 in) (44 in)

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5-4

8

5 - TRANSPORT OPERATIONS

4. Install two securing tools (1) to the installation holes on bottom rear part of the lower frame (4). See lashing points decals close to the holes.

5. Protect the securing tools (1) against edges with pads (2).

6. Use securing tools (1) having a Lashing Capacity of at least 1200 daN (2698 lbf) ( CX35B ) / 1500 daN (3372 lbf) ( CX39B ).

Models CX35B CX39B

Fastening distance A Fastening distance B MIN MAX MIN MAX 2100 mm 2200 mm 1380 mm 1980 mm (83 in) (87 in) (54 in) (78 in) 2100 mm 2200 mm 1360 mm 1960 mm (83 in) (87 in) (54 in) (77 in)

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9

5 - TRANSPORT OPERATIONS

UNLOADING THE MACHINE NOTICE: Before unloading the machine, make sure all tie-down chains are removed and the trailer wheels blocked.

• Position the trailer on firm and level ground. Put blocks to the tires of trailer to prevent machine from moving.

• Remove chains or wire ropes used to secure the machine.

• Start engine and move the safety lever to UNLOCK position.

• Raise attachment and dozer blade and travel slowly in reverse along the flatbed.

• Set arm and boom to angle between 90 - 110 ° and travel down slowly from trailer to ramps.

• Travel down on ramps slowly while operating boom and arm softly until the machine passes through the ramps completely.

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5 - TRANSPORT OPERATIONS

SHIPPING TRANSPORT

Lifting the machine – CX35B WARNING Crushing hazard!

The lifting systems must be operated by qualified personnel who are aware of the correct procedures to follow. Make sure all lifting equipment is in good condition, and all hooks are equipped with safety latches.

Failure to comply could result in death or serious injury.

W0256A

NOTICE: 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.

5-7

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5 - TRANSPORT OPERATIONS

Lift the machine from firm level ground as follows: • 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 lever and set it to the LOCK 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.

NOTE: reference information for transport (for different machine configuration, see page 9-7 ) Versions Canopy Cab

Operating mass ISO 6016 3360 kg (7408 lb) 3500 kg (7716 lb)

5-8

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5 - TRANSPORT OPERATIONS

Lifting the machine – CX39B WARNING Crushing hazard!

The lifting systems must be operated by qualified personnel who are aware of the correct procedures to follow. Make sure all lifting equipment is in good condition, and all hooks are equipped with safety latches.

Failure to comply could result in death or serious injury.

W0256A

NOTICE: 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.

5-9

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5 - TRANSPORT OPERATIONS

Lift the machine from firm level ground as follows: • 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 lever and set it to the LOCK 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.

NOTE: reference information for transport (for different machine configuration, see page 9-7 ) Versions Canopy Cab

Operating mass ISO 6016 3760 kg (8289 lb) 3900 kg (8598 lb)

5-10

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5 - TRANSPORT OPERATIONS

Load specifications Boom with arm cylinder ( CX35B) 2390 mm (94.09 in) x 870 mm (34.25 in) x 320 mm (12.6 in) 163 kg (359 lb)

LxHxW Weight

Boom with arm cylinder ( CX39B) LxHxW Weight

2590 mm (101.97 in) x 810 mm (31.89 in) x 320 mm (12.60 in) 184 kg (406 lb)

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Arm and standard bucket ( CX35B) 2190 mm (86.22 in) x 450 mm (17.72 in) x 500 mm (19.69 in) 198 kg (437 lb)

LxHxW Weight

Arm and standard bucket ( CX39B) 2360 mm (92.91 in) x 450 mm (17.72 in) x 600 mm (23.62 in) 219 kg (483 lb)

LxHxW Weight

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5 - TRANSPORT OPERATIONS

Arm ( CX35B) 1520 mm (59.84 in) x 430 mm (16.93 in) x 280 mm (11.02 in) 101 kg (223 lb)

LxHxW Weight

Arm ( CX39B) 1690 mm (66.54 in) x 430 mm (16.93 in) x 280 mm (11.02 in) 123 kg (271 lb)

LxHxW Weight

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Standard bucket ( CX35B) Capacity

0.09 m³ (3.18 ft³) 670 mm (26.38 in) x 620 mm (24.41 in) x 500 mm (19.69 in) 72 kg (159 lb)

LxHxW Weight

Standard bucket ( CX39B) Capacity

0.11 m³ (3.88 ft³) 670 mm (26.38 in) x 620 mm (24.41 in) x 600 mm (23.62 in) 78 kg (172 lb)

LxHxW Weight

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5 - TRANSPORT OPERATIONS

Dozer ( CX35B) LxHxW Weight

1230 mm (48.43 in) x 346 mm (13.62 in) x 1550 mm (61.02 in) 142 kg (313 lb)

Dozer ( CX39B) LxHxW Weight

1280 mm (50.39 in) x 345 mm (13.58 in) x 1700 mm (66.93 in) 150 kg (331 lb)

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5 - TRANSPORT OPERATIONS

5-14

6 - WORKING OPERATIONS

6 - WORKING OPERATIONS###_6_### GENERAL INFORMATION

Operating the controls The instructions to follow have the purpose of informing the operator about the basic function of each hydraulic control. Learning these instructions and practising on the machine make the operator more efficient in operating the machine. Each operator must read carefully, learn and implement the safety rules described in this manual and on the machine prior to operating it.

NOTICE: 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.

6-1

6 - WORKING OPERATIONS

Machine travel Forward/reverse travel • Make sure the safety lever (1) is in the UNLOCK position.

• Operate the boom, arm, and bucket control levers to raise the attachments from the ground.

• Operate the control lever to raise the dozer.

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• 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.

6-2

6 - WORKING OPERATIONS

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

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Anti-clockwise 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 travel speed (2nd gear), press and re• For a HIGH lease 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. travel speed (1st gear), stop • To return to SLOW 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.

6-3

6 - WORKING OPERATIONS

Travel precautions NOTICE: 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.

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9

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).

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When travelling on rough ground, use low speed (1st) (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.

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6 - WORKING OPERATIONS

Precautions for travelling on slopes NOTICE: Should it be necessary to operate the machine on slopes, carefully observe the following precautions.

This to prevent injuries due to accidental machine overturn.

NOTICE: 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.

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Always travel at slow speed.

When travelling, lift the bucket up to 30 - 40 cm (11.8 15.7 in) 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.

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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 lever to the LOCK position and block both crawlers by means of wedges (3).

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, preheat machine completely.

6-5

6 - WORKING OPERATIONS

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.

1

TUIL12E2B0023AB

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 h if working with materials in wet conditions, supply grease with a grease gun until grease oozes out.

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6-6

2

6 - WORKING OPERATIONS

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.

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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.

NOTICE: Operate the machine from operator’s seat only.

Do not allow any person to come near the machine.

6-7

6 - WORKING OPERATIONS

Swing control Rotation of the upper structure • 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.

LELI11E0227AB

The turret swings when the left control lever is moved rightward or leftward. The swinging speed is determined by the stroke of the lever.

• When moving the left control lever leftward, the turret swings leftward.

• When moving the left control lever rightward, the turret swings rightward.

• When returning the left control lever centrally (neutral position) the turret stops moving.

6-8

1

6 - WORKING OPERATIONS

Practices to improve efficiency • 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.

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 LELI11E0228AB

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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.

6-9

6 - WORKING OPERATIONS

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.

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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 NOTICE: 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.

6-10

6 - WORKING OPERATIONS

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.

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7

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.

Minimum slewing radius Boom With swing Without swing Boom With swing Without swing

CX35B Canopy 1590 mm (62.60 in) (left 70 °) 1920 mm (75.59 in)

Cab 2100 mm (82.68 in) (left 70 °) 2480 mm (97.64 in) CX39B

Canopy 1690 mm (66.54 in) (left 70 °) 2040 mm (80.31 in)

6-11

Cab 2170 mm (85.43 in) (left 70 °) 2560 mm (100.79 in)

6 - WORKING OPERATIONS

Lowering the bucket in emergency situations NOTICE: 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 the hose (H);

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• when the bucket is in dump position (B) (bucket cylinder completely retracted), disconnect the hose (R).

NOTICE: 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.

NOTE: Clean up all spilled oil. Dispose of collected oil, because polluting, according to the local environments.

6-12

6 - WORKING OPERATIONS

Lowering the arms NOTICE: This procedure is to be used only as an emergency to lower the arms. Use extreme caution, since the weight of the arms 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.

Do not enter the area under attachments, while lowering them.

Arm lowering (1) • Gradually loosen the hose, connected to the arm cylinder, from rod side (R).

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

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

Keep the attachment at 30 - 40 cm (11.8 - 15.7 in) 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.

6-13

6 - WORKING OPERATIONS

Caution while using rubber crawlers Proper usage

Rubber belt

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.

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 Large traction force : Excellent : Good

: Normal

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.

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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.

6-14

6 - WORKING OPERATIONS

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

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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.

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.

6-15

6 - WORKING OPERATIONS

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.

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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 (-13 °F) and +55 °C (131 °F).

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 (7.87 in)). To overcome the gap, place the machine perpendicular to the obstacle.

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

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10

6 - WORKING OPERATIONS

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.

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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.

6-17

6 - WORKING OPERATIONS

Machine operation in adverse weather conditions Operation in extreme cold

low dirt and debris to accumulate in the radiator fins, oil cooler fins or debris screen.

• Follow procedures on page (Starting the engine in cold conditions) as starting engine may be difficult due to extremely cold temperatures.

• Use an engine oil, hydraulic oil and diesel fuel designed for use in cold climates.

• Keep batteries fully charged.

• During the engine WARM-UP phase do not increase the engine rpm to prevent premature wear or damage to pumps, motors and other components.

NOTICE: in extremely frigid climates, covering the radiator is a method to aid the machine warm-up. If necessary to maintain operating temperatures, cover the outer edges of the radiator, leaving an opening in the center part of the cover - thus avoiding fan overloading. Keep a close watch on the instrument cluster for warning icons during operation. It may be necessary to use a coolant heater, fuel heater, engine heater jacket, and/or additional battery power to aid engine starting.

• Keep batteries terminals free of ice and snow. Ice and snow could cause the terminals to short circuit and cause extensive damage to the machine systems.

Check the batteries electrolyte (acid) level frequently and fill as necessary with distilled water. If the machine will be left outside overnight, it is recommended to remove the batteries and store in a warm area.

• Make certain that the engine coolant mixture is sufficient to keep the machine safe. Take into consideration wind chill factors when mixing coolant ratios.

NOTICE: mix coolant to a protection temperature of 5 °C lower than the machine will experience during operation, storage or transport.

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

• Keep all belts properly tensioned.

• Make certain that the engine coolant mixture is sufficient to keep the machine safe.

• If the machine becomes overheated, idle the machine to help cool the engine, turn the engine off and check coolant level. After filling to proper level the machine continues to over heat, stop engine, allow to cool, drain and flush entire cooling system and refill with the proper mixture of fresh, clean coolant.

• Check the batteries electrolyte (acid) level frequently and fill as necessary with distilled water.

• Keep a close watch on the instrument cluster for warning icons during operation. Avoid unnecessary low speed running of the engine during operation. During slow, or no work periods, place throttle control lever to LO position.

Operation in high altitudes • Due to low atmospheric pressure at high altitudes, a decrease in engine power will be experienced. Be aware of this fact when placing machine under heavy load in high altitude climates.

• Keep close watch on the coolant temperature meter to avoid overheating of the engine.

Operation in sandy and dusty areas Air filter • Check the engine air filter element frequently in sandy or dusty conditions. Clean or replace the filter element at the corresponding intervals Radiator • Clean the radiator regularly to prevent the radiator core from becoming clogged with dust.

• 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 in extreme heat

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.

Operation at seashore or salty climate

• Use an engine oil, hydraulic oil and fuel oil designed for use in hot climates.

• Keep batteries fully charged.

• Thoroughly wash machine daily to help avoid corrosion of machined areas, electrical components and cylinder rods.

• Clean radiator, oil cooler and debris screen often to prevent damage or overheating of the machine. Do not al6-18

6 - WORKING OPERATIONS

• Frequently check all mounting hardware for proper tightness. Torque to proper value to aid in preventing salt from entering the machine systems.

Operation in Humid Climate • In climates with high humidity, thoroughly wash the machine daily and coat all bare surfaces with an oil based lubricant to help prevent corrosion.

6-19

6 - WORKING OPERATIONS

6-20

7 - MAINTENANCE

7 - MAINTENANCE###_7_### GENERAL INFORMATION

General safety information WARNING Avoid injury!

Carefully read and observe all the precautionary advice contained in this manual.

Failure to comply could result in death or serious injury.

W0044A

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 “WHEN NECESSARY” .

LEPH11E0272AA

1

LELI11E0273AA

2

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.

7-1

7 - MAINTENANCE

Maintenance 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.

LELI11E0435AB

LELI11E0436FA

1

2

Greasing

Replacement of engine oil filters

Replace reduction gear oil, axle oil and transmission oil Replacement of hydraulic system oil

Replacement of engine coolant

Replacement of hydraulic system return oil filter Replacement of fuel filters

Replacement of air filter

Replacement of engine oil

Grease slewing ring

7-2

7 - MAINTENANCE

Maintenance tool No.

Tool name

1.

Tag maintenance in progress

2.

Tool case

3.

Wrench for engine oil filter

4.

Wrench for fuel filter

5.

Pipe wrench for grease nipple of idler adjuster

Notes

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

7-3

7 - MAINTENANCE

Torque specifications 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 h 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 cap screw head shows the classification (A) strength (e.g.: 8.8). No indication is provided for smaller size of cap screws, M5 or less.

Standard tightening torque values.

LELI11E0296AB

1

Be certain to tighten all cap screws and nuts to proper torque values.

Resistance class Nominal dimension M3

P = 0.5

M4

P = 0.7

M5

P = 0.8

M6

P=1

M7

P=1

M8

P = 1.25

M10

P = 1.5

M12

P = 1.75

M14

P=2

M16

P=2

M18

P = 2.5

M20

P = 2.5

M22

P = 2.5

6.8 1.19 N·m (0.88 lb ft) 2.73 N·m (2.01 lb ft) 5.41 N·m (3.99 lb ft) 9.29 N·m (6.85 lb ft) 15.40 N·m (11.36 lb ft) 22.46 N·m (16.57 lb ft) 45.10 N·m (33.26 lb ft) 77.20 N·m (56.94 lb ft) 123.23 N·m (90.89 lb ft) 189.51 N·m (139.78 lb ft) 261.17 N·m (192.63 lb ft) 370.15 N·m (273.01 lb ft) 501.62 N·m (369.98 lb ft)

8.8

10.9 Tightening torque 1.59 N·m 2.24 N·m (1.17 lb ft) (1.65 lb ft) 3.64 N·m 5.12 N·m (2.68 lb ft) (3.78 lb ft) 7.21 N·m 10.14 N·m (5.32 lb ft) (7.48 lb ft) 12.39 N·m 17.43 N·m (9.14 lb ft) (12.86 lb ft) 20.54 N·m 28.88 N·m (15.15 lb ft) (21.30 lb ft) 29.94 N·m 42.10 N·m (22.08 lb ft) (31.05 lb ft) 60.14 N·m 84.57 N·m (44.36 lb ft) (62.38 lb ft) 102.94 N·m 144.75 N·m (75.92 lb ft) (106.76 lb ft) 164.30 N·m (121.18 231.05 N·m (170.41 lb ft) lb ft) 252.69 N·m (186.37 355.34 N·m (262.09 lb ft) lb ft) 348.22 N·m (256.83 489.69 N·m (361.18 lb ft) lb ft) 493.53 N·m (364.01 694.02 N·m (511.88 lb ft) lb ft) 668.82 N·m (493.30 940.53 N·m (693.70 lb ft) lb ft)

7-4

12.9 2.69 N·m (1.98 lb ft) 6.15 N·m (4.54 lb ft) 12.17 N·m (8.98 lb ft) 20.91 N·m (15.42 lb ft) 34.66 N·m (25.56 lb ft) 50.53 N·m (37.27 lb ft) 101.49 N·m (74.86 lb ft) 173.70 N·m (128.11 lb ft) 277.26 N·m (204.50 lb ft) 426.41 N·m (314.50 lb ft) 587.63 N·m (433.41 lb ft) 832.83 N·m (614.26 lb ft) 1128.64 N·m (832.44 lb ft)

7 - MAINTENANCE

Resistance class M24

P=3

M27

P=3

M30

P = 3.5

6.8 8.8 639.61 N·m (471.75 852.82 N·m (629.01 lb ft) lb ft) 1257.56 N·m 943.17 N·m (695.65 (927.53 lb ft) lb ft) 1280.89 N·m 1707.86 N·m (944.74 lb ft) (1259.65 lb ft)

10.9 1199.27 N·m (884.54 lb ft) 1768.45 N·m (1304.34 lb ft) 2401.67 N·m (1771.38 lb ft)

Torque specifications for joints and hydraulic hoses Sleeve-type hose fittings Hose dimensions outer diameter x thickness

Wrench dimension

10 - 1.5 mm (0.39 - 0.06 in)

19 mm

15 - 2.0 mm (0.59 - 0.08 in)

27 mm

18 - 2.5 mm (0.71 - 0.10 in)

32 mm

22 - 3.0 mm (0.87 - 0.12 in)

36 mm

28 - 4.0 mm (1.10 - 0.16 in)

41 mm

35 - 5.0 mm (1.38 - 0.20 in)

55 mm

Tightening torque 39.1 - 48.9 N·m (28.84 - 36.07 lb ft) 127 - 167 N·m (93.67 - 123.17 lb ft) 157 - 197 N·m (115.80 - 145.30 lb ft) 196 - 236 N·m (144.56 - 174.06 lb ft) 246 - 304 N·m (181.44 - 224.22 lb ft) 397 - 485 N·m (292.81 - 357.72 lb ft)

Joints for pipings (with O-rings) Normal screw dimension

Wrench dimension)

1/8 in

14 mm

1/4 in

19 mm

3/8 in

22 mm

1/2 in

27 mm

3/4 in

36 mm

1 in

41 mm

Tightening torque 15 - 19 N·m (11.06 - 14.01 lb ft) 34 - 38 N·m (25.08 - 28.03 lb ft) 69 - 79 N·m (50.89 - 58.27 lb ft) 98.2 - 117.8 N·m (72.43 - 86.88 lb ft) 152.2 - 171.8 N·m (112.26 - 126.71 lb ft) 245.8 - 264.8 N·m (181.29 - 195.31 lb ft)

Hydraulic hose Normal screw dimension

Wrench dimension

1/8 in

17 mm

1/4 in

19 mm

3/8 in

22 mm

1/2 in

27 mm

3/4 in

36 mm

1 in

41 mm

Tightening torque 13.0 - 17.0 N·m (9.59 - 12.54 lb ft) 24.1 - 33.9 N·m (17.78 - 25.00 lb ft) 44.1 - 53.9 N·m (32.53 - 39.75 lb ft) 73.1 - 82.9 N·m (53.92 - 61.14 lb ft) 108.2 - 127.8 N·m (79.80 - 94.26 lb ft) 122 - 152 N·m (89.98 - 112.11 lb ft)

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

7-5

12.9 1439.13 N·m (1061.45 lb ft) 2122.14 N·m (1565.21 lb ft) 2882.01 N·m (2125.66 lb ft)

7 - MAINTENANCE

Installation Metal fitting The pressure exerted by the fitting (3) on the hose (1) ensures tightness (2). Use caution to assemble and disassemble both pieces in order not to damage the seat.

LELI11E0297AB

1

LELI11E0298AB

2

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.

7-6

7 - MAINTENANCE

Fluids and lubricants Component to be filled

Engine oil pan

Travel motor Upper rollers Idler wheels Radiator (1) Fuel tank Hydraulic oil tank (2) Attachment and dozer pin Swing cylinder pin Slewing bearing Idler adjuster Operating lever and pedal Rotation gear Air conditioning Compressor

Quantity

Consumable

2.8 - 6.7 l (0.74 - 1.77 US gal)

CASE AKCELA NO. 1™ ENGINE OIL SAE 10W-30 CASE AKCELA NO. 1™ ENGINE OIL SAE 15W-40

0.7 l (0.18 US gal) 45 cm³ CASE AKCELA GEAR (2.75 in³) 135 H EP 80W-90 80 cm³ (4.88 in³) 1.6 l (0.42 CASE AKCELA PREMIUM US gal) ORGANIC ANTI-FREEZE 38 l (10 US — gal) 38 l (10 US AKCELA HYDRAULIC gal) EXCAVATOR FLUID

Manufacturer specifications

International specifications

MS 1121 API CI 4/CH-4 ACEA E7/E5 MS 1121

MS 1316

API GL 5

—

ASTM D 3306

—

EN 590

MS 1230

—

AKCELA Multi purpose grease

251 H EP

NLGI 2

AKCELA Moly grease

251 H EP-M

NLGI 2

R134A

—

—

SANDEN SP-10 LUBRICANT

—

—

20 places 1 place 2 place — 1 place 0.7 kg (1.54 lb) 120 cm³ (7.32 in³)

NOTE: (1) Coolant to be mixed with water at 50 %. Cooling system total volume: ~ 4.6 l (1.22 US gal) NOTICE: (2) Hydraulic system total volume: ~ 54.4 l (14.37 US gal). If the machine was filled with biodegradable hydraulic oil PANOLIN HLP SYNTH 46 (option), take note that this oil cannot be mixed with mineral hydraulic oil.

Temperature operating ranges

Engine Travel motor, upper rollers and idler wheels Hydraulic system

Consumable CASE AKCELA NO. 1™ ENGINE OIL CASE AKCELA GEAR 135 H EP 80W-90 AKCELA HYDRAULIC EXCAVATOR FLUID

7-7

Viscosity SAE 10W-30 SAE 15W-40

Temperature operating range -25 °C - +25 °C -15 °C - +40 °C

SAE 80W-90

-25 °C - +45 °C

ISO VG 46

-20 °C - +50 °C

7 - MAINTENANCE

Use of biodegradable oils When you use biodegradable oil, please refer to following: • There are two types of biodegradable 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 biodegradable lubricant and the relevant specifications for use and maintenance, please refer to chapter ACCESSORIES.

Use of coolant • There are two types of coolant depending on the corrosion inhibitors base: ORGANIC-base and INORGANIC base.

• 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.

7-8

7 - MAINTENANCE

Maintenance parts 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.

TULI12E300043EB

No.

Device

1.

Hydraulic oil tank

2.

Hydraulic oil tank

Parts name

Qty.

Return filter (O-ring)

1

Suction strainer (O-ring) Element (outer) (3a) Element (inner) (3b)

1

1

3.

Air filter

4.

Engine oil filter

Cartridge

1

5.

6.

Fuel filter Water separator

7.

Bucket

8.

Bucket

Cartridge Cartridge Side cutter (right) (7a) Side cutter (left) (7b) Screw Nut Tooth Safety pin Rubber locking pin

1 1 1 1 6 6 4 4 4

7-9

1

Replacement interval After 50 h (first change) Every 1000 h(from 2nd change) (Breaker specification: Every 250 h) Every 2000 h After 6th time cleaning or maintenance interval For machines equipped with W (double) element and inner element. Don’t fail to replace the inner element with a new one After 50 h (first change) Every 250 h Every 500 h When required When required

When required

7 - MAINTENANCE

Releasing pressure in the hydraulic system WARNING Pressurized system!

System is still under pressure. Release pressure according to instructions in this manual.

Failure to comply could result in death or serious injury.

W1044A

WARNING Pressurized hydraulic fluid can penetrate the skin and cause severe injuries.

Hydraulic fluid is under extreme pressure.

Rest the bucket or attachment on the ground.

Shut the engine off, turn the key on, and move the hydraulic control lever through all movements several times to relieve residual pressure in the system.

Failure to comply could result in death or serious injury.

TULI12E300044AA

1

TULI12E300045AB

2

W0161A

WARNING Hot surface possible!

Wait for all components to cool before performing any operation.

Failure to comply could result in death or serious injury.

W0251A

Park the machine on a level surface. 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: This procedure is the only way to release internal pressure.

To release the internal pressure from the hydraulic system, proceed as follows: • Bring the throttle lever to low idle. Set the safety lever to LOCKED position.

• Stop the engine, remove the starter key and wait until the machine is cold.

• Clean the hydraulic oil tank upper side to prevent dirt contamination in the hydraulic system.

• Open hydraulic tank cover (1) to relieve the pressure inside.

• Press the rubber cap (2) on the upper surface of hydraulic reservoir several times (5 to 7 times).

• This completes the bleeding of pressure remaining in the hydraulic tank.

• Check and service the hydraulic system.

7-10

7 - MAINTENANCE

Bleed air from the fuel system If air contaminates the fuel system, the engine may become hard to start or it may malfunction. Proceed with the bleeding of the air that, during the replacement of the prefilter (1), was introduced into the fuel system.

Perform this operation as follows: • Park the machine on a level surface.

• Rest the bucket to the ground.

• Shut down the engine, pull out the starter key and set the safety lever on LOCK position.

• Wait until the machine is cold.

• Open engine guard and lock it in this position.

TULI12E300032A

1

• Confirm that the handle (2) of water separator is set on “OPEN”.

• Loosen breather screw (3), placed on upper side of filter, so as to allow air to come out.

• Turn starter on for engine cranking. Continue this operation until a minimum amount of fuel, free from bubbles, comes out from the loose breather screw (3), then tighten the screw.

LELI11E0302BB

7-11

2

7 - MAINTENANCE

Break-in period Within the first 8 hours Within the first 8 hours it is necessary to perform the following operations: • Lubricate the bucket links every 8 hours: to lubricate the bucket links perform the operations described on page 7-18.

• Lubricate boom and arms every 8 hours: to lubricate the boom and arms perform the operations described on page 7-22.

Within the first 30 hours Within the first 30 hours it is necessary to perform the following operation: • Check the track tension at 30 hours: to check and adjust the track tension perform the operations described on page 7-58 .

Within the first 50 hours Within the first 50 hours it is necessary to perform the following operations: • Replace the engine oil at 50 hours: to replace the engine oil perform the operations described on page 7-24.

• Replace the engine oil filter at 50 hours: to replace the engine oil filter perform the operations described on page 7-26.

• Replace the hydraulic oil return filter at 50 hours: to replace the hydraulic oil return filter perform the operations described on page 7-36.

• Adjust the fan belt tension at 50 hours: to adjust the fan belt tension perform the operations described on page 7-25.

Within the first 500 hours Within the first 500 hours it is necessary to perform the following operation: • Replace the travel reduction units oil at 500 hours: to replace the travel reduction units oil perform the operations described on page 7-45.

7-12

7 - MAINTENANCE

MAINTENANCE CHART

Maintenance Chart

Interval

Every 8 hours

Page no.

7-14 7-16 Every 50 hours 7-17 7-18 7-19 7-20 Every 250 hours 7-22 7-24 7-25 7-26 7-28 7-29 7-31 7-32 7-33 Every 500 hours 7-34 7-35 Every 1000 hours 7-36 7-38 7-40 Every 2000 hours 7-41 7-42 7-45 7-46 7-48 7-51 When necessary 7-52 7-55 7-58 7-62 7-63 7-64 7-65 7-67 7-68 7-69 7-70 7-72

Maintenance action

General check Separator filter draining Track tension Bucket grease fittings Fuel tank Battery Boom, arm, and attachment grease points Engine oil Fan belt Engine oil filter Separator filter cleaning Air filter Swing bearing Radiator hoses Radiator hoses Fuel filter Air filter Hydraulic return filter Radiator Engine Engine Hydraulic oil tank Travel reduction unit oil Idler wheel and rollers change oil Cleaning of pilot valve and solenoid valve line filters Replacement of grease in slewing grease bath Rubber track Replacement of rubber crawler Track tension Radiator Radiator cap cleaning Work lights Fuses and relays Bucket teeth and side cutters Bucket teeth Side cutter replacement Buckets Control levers

7-13

Cleaning Replace Adjust Change fluid Grease Drain fluid Check No. of pts.

X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X

7 - MAINTENANCE

Every 8 hours

General check 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.

TULI12E300047AA

1

LELI11E0348AA

2

TULI12E300048AA

3

Check for detached pieces or loose fastenings Check and make sure all cap screws 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.

Visual check of hydraulic system CAUTION Escaping fluid!

Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or performing work on the hydraulic system. Before applying pressure, make sure all connections are tight and all components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately.

Failure to comply could result in minor or moderate injury.

C0104A

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 key, then set the safety 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 side guard, check the hydraulic oil tank level through the level indicator (3) located on the hydraulic oil tank. Assess possible leaks in the system.

7-14

7 - MAINTENANCE

Open hydraulic tank cover (1) to relieve the pressure inside.

Press the rubber cap (2) on the upper surface of hydraulic tank several times (5 to 7). This completes the release of the hydraulic tank remaining pressure.

Once carried out these operations, ask the help of an authorized Dealer for repair.

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.

TULI12E300050AB

4

LELI11E0351AB

5

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 key, then set the safety lever to the LOCKED position.

Wait for the machine to cool down.

Check for possible leakages on lower rollers (3), idler adjuster (4) and travel motor (1).

Check condition of lower rollers (3), idler adjuster (4) and sprockets (2). Check if fastening screws are tight firmly.

Slowly travel the machine and check for any abnormal sound.

7-15

7 - MAINTENANCE

Separator filter draining If red float (5) lowers to cup bottom (8), water is drained. If float (5) floats, there is water in the cup and this must be drained as follows: NOTICE: Pay attention, during the removal phase, to avoid spilling the fuel in the filter: danger of fire.

Shut down the engine, pull out the starter key and set the safety lever on LOCK position.

Wait until the machine is cold.

Open engine guard and lock it in this position.

Turn the knob (1) of separator filter in (A) to close it.

Loosen ring (2) and disassemble the cup (8). Drain water into a container NOTE: Pay attention not to lose the red float (5) and spring (6).

LELI11E0356BB

7-16

1

7 - MAINTENANCE

Every 50 hours

Track tension Checking and tensioning the rubber crawler An appropriate adjustment of tension on the rubber crawlers is vital both for the rubber crawler and the machine life.

NOTICE: 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.

7-17

LELI11E0352AA

1

LELI11E0353AA

2

7 - MAINTENANCE

Bucket grease fittings Greasing intervals.

Generally the greasing is carried out every 50 h 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 key, then set the safety lever to the LOCKED position.

Wait for the machine to cool down.

TULI12E300051AA

1

LELI11E0355AB

2

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.

NOTICE: Dispose of all hazardous waste in accordance with current legislation.

No. A. B. C. D.

Greasing points Bucket cylinder rod pin Idler link/arm connecting pin Bucket link pin Arm/bucket connecting pin

7-18

Qty. 1 1 1 1

7 - MAINTENANCE

Fuel tank WARNING Avoid injury and/or machine damage!

Always have a fire extinguisher on or near the machine. Keep the fire extinguisher in good condition through routine maintenance and service according to the manufacturer's instructions.

Failure to comply could result in death or serious injury.

W1160A

WARNING Fuel vapors are explosive and flammable.

Do not smoke while handling fuel. Keep fuel away from flames or sparks. Shut off engine and remove key before servicing. Always work in a well-ventilated area. Clean up spilled fuel immediately.

Failure to comply could result in death or serious injury.

TULI12E300047AA

1

LELI11E0360AB

2

LELI11E0361AB

3

W0904A

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 key, then set the safety lever to the LOCKED position.

Reach the upper structure underneath and loosen the lateral protection from its seat.

Loosen filling plug (1).

Slowly open the cock (2) and let condensate and deposits discharge into a suitable container, until only clean fuel comes out.

NOTE: Check for fuel leakage after tightening up the drain plug.

If fuel is leaking, stop the engine and address to an authorized Dealer.

After draining, tighten the cock (2), fit the protection and close filling plug (1).

NOTE: Dispose of the water mixed with fuel according to current legislation. Use only authorized disposal procedures. For any doubt, apply to authorities concerned.

7-19

7 - MAINTENANCE

Battery WARNING Hazardous chemicals!

Battery electrolyte contains sulfuric acid. Contact with skin and eyes could result in severe irritation and burns. Always wear splash-proof goggles and protective clothing (gloves and aprons). Wash hands after handling.

Failure to comply could result in death or serious injury.

W0006A

WARNING Battery acid causes burns. Batteries contain sulfuric acid.

Avoid contact with skin, eyes or clothing. Antidote (external): Flush with water. Antidote (eyes): flush with water for 15 minutes and seek medical attention immediately. Antidote (internal): Drink large quantities of water or milk. Do not induce vomiting. Seek medical attention immediately.

Failure to comply could result in death or serious injury.

LELI11E0362AA

1

LELI11E0478AB

2

W0111A

The battery is maintenance-free, therefore is not required top up with the distilled water.

NOTICE: If short circuit traces are noticed on the wiring harness, contact your dealer.

Before checking the electrical system, disconnect the negative (-) battery cable.

Erroneous short circuit may cause fire.

NOTE: Always disconnect the negative (-) ground terminal first and reconnect it last.

Open the engine guard (1).

Check inside the battery bay (2) to assess possible electrolyte leaks. Otherwise clean accurately to avoid metal parts corrosion.

7-20

7 - MAINTENANCE

Remove the cover (3).

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.

LELI11E0479AB

3

LELI11E0363AB

4

LELI11E0480AA

5

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.

Observe the following norms to preserve battery efficiency: •

With the engine stopped, remove the starter 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 authorized disposal procedures; in case of doubt, contact the authorities concerned.

7-21

7 - MAINTENANCE

Every 250 hours

Boom, arm, and attachment grease points Under normal conditions, apply grease every 50 h working 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.

TULI12E300047AA

1

LELI11E0366AB

2

LELI11E0367AB

3

LELI11E0368AB

4

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 key, then set the safety 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.

7-22

7 - MAINTENANCE

No. 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

Greasing points Dozer cylinder rod pin Dozer cylinder bottom pin Dozer fastening pins Boom foot pin Boom cylinder foot pin Boom cylinder rod pin Arm cylinder foot pin Arm cylinder rod pin Boom/arm connecting pin Bucket cylinder foot pin Bucket cylinder rod pin Swing cylinder foot pin Swing cylinder rod pin Swing pin

7-23

Qty. 1 1 1 1 1 1 1 1 2 1 1 1 1 1

7 - MAINTENANCE

Engine oil NOTICE: Do not change the engine oil immediately after the engine has stopped. Allow sufficient time for the engine to cool down.

NOTE: The first oil change must be carried out at 50 h operation for a new machine engine.

NOTICE: 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.

LELI11E0369AA

1

LELI11E0370BB

2

Park the machine on a level surface.

Rest the bucket to the ground.

Bring throttle control lever to minimum speed, stop the engine and remove starter key, then position safety lever on LOCK position.

Wait until the machine is cold. Open engine guard and lock it in this position.

Remove plug (1) and slide out the level dipstick (2). These two actions allow faster draining of the oil from the sump.

Reach upper structure underneath, loosen the retaining screws of protection (3) and remove it from its seat.

Loosen plug (4), to allow waste oil to flow into a suitable container.

Once the draining is finished, reinstall plug (4) and protection (3).

Start up the engine, operate it for several minutes idle, and then stop it. Check the oil level with proper dipstick (2), it should be set between marks “H” and “L”.

7-24

7 - MAINTENANCE

Fan belt WARNING Rotating parts!

The engine is running. Keep clear of rotating fans and belts.

Failure to comply could result in death or serious injury.

W0275A

WARNING Hot surface possible!

Wait for all components to cool before performing any operation.

Failure to comply could result in death or serious injury.

LELI11E0372AA

1

TULI12E300054AB

2

W0251A

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 key and set the safety lever to the LOCKED position.

Wait for the machine to cool down.

Loosen mounting bolt (1) and adjusting bolt (2) slightly.

Loosen adjusting bolt (3) to set the tension of the fan belt.

Tighten fastening screw (1) and adjusting bolt (2).

After adjustment, rotate engine at low idle for about 5 min, then check the tension of belt.

7-25

7 - MAINTENANCE

Engine oil filter WARNING Burn hazard!

Do not handle any service fluid (engine coolant, engine oil, hydraulic oil, etc.) at temperatures that exceed 49 °C (120 °F). Allow fluids to cool before proceeding.

Failure to comply could result in death or serious injury.

W0330B

WARNING Inhalation hazard! Risk to operators and bystanders.

Avoid running the engine in confined areas.

Make sure there is adequate ventilation at all times.

Failure to comply could result in death or serious injury.

LELI11E0374AA

1

LELI11E0375AB

2

W0156A

NOTICE: 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 reused or cleaned.

On a new machine replace this filter after the first 50 h service.

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.

Park the machine on a level surface.

Rest the bucket to the ground.

Bring throttle control lever to minimum speed, stop the engine and remove starter key, then position safety lever on LOCK position.

7-26

7 - MAINTENANCE

Wait until the machine is cold.

Open engine guard and lock it in this position.

Remove the support area and the area around the filter.

Loosen filter (1) using a universal tool (2).

Lubricate the seal (3) of the new filter with engine oil.

Tighten the filter by hand until the seals touch the support.

Tighten further by 2/3 of a turn using a universal tool (2).

Start engine and let it run idle for several minutes. Recheck if fitting surface shows leaks.

Close engine guard.

NOTICE: 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.

NOTICE: Dispose of all hazardous waste in accordance with government environmental regulations.

7-27

LELI11E0376AB

3

7 - MAINTENANCE

Separator filter cleaning NOTICE: Dispose of all hazardous waste in accordance with environmental regulation.

Check the water drained for its contamination. And when it is dirty, clean up the filter element (4) and inside the case (8).

LELI11E0357AB

1

LELI11E0358AA

2

Remove the filter element (4), and clean it with diesel fuel.

Replace the O-ring (7).

Install the filter element (4) on the water separator body.

Place the O-ring (7) on the case (8), then tighten it up with ring (2).

Push the handle (1) in “OPEN” position (B).

After draining the water, bleed the air from the supply system.

NOTE: Do not clean up the element with petrol.

7-28

7 - MAINTENANCE

Air filter WARNING Eye injury hazard!

Wear full coverage safety glasses with side panels when using compressed air. Limit air pressure to 200 kPa (29 psi).

Failure to comply could result in death or serious injury.

W0162A

NOTICE: Operations to be carried out also if the relevant lamp turns On. 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 h).

LELI11E0379BA

1

LELI11E0380AB

2

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 key, then set the safety 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.

7-29

7 - MAINTENANCE

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 orient the “TOP” mark of the cover, tilting it by 15°.

Close the engine guard.

LELI11E0381AA

3

LELI11E0382AA

4

If the display shows the icon of clogged filter after the 6th cleaning, outer element has to be replaced with a new one.

7-30

7 - MAINTENANCE

Swing bearing NOTICE: Never slew the upper structure while applying grease to the slewing bearing.

NOTICE: The lubrication of the balls must be carried out by one person only. Before lubricating the slewing bearing, keep people away from the machine’s 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 key, then set the safety lever to the LOCKED position.

•

With the upper structure stopped, inject grease through the grease nipple (1).

•

Start the engine, raise the bucket approximately 20 cm (7.87 in) 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.

7-31

LELI11E0371AB

1

7 - MAINTENANCE

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.

LELI11E0377AA

7-32

1

7 - MAINTENANCE

Radiator hoses WARNING Inhalation hazard! Risk to operators and bystanders.

Avoid running the engine in confined areas.

Make sure there is adequate ventilation at all times.

Failure to comply could result in death or serious injury.

W0156A

WARNING Burn hazard!

Hot coolant can spray and scald if you remove the radiator or deaeration tank cap while the system is hot. To remove the cap: allow the system to cool, turn the cap to the first notch, and wait for all pressure to release. Remove the cap only after all pressure has released.

Failure to comply could result in death or serious injury.

W0367A

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 key, then set the safety 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).

7-33

LELI11E0378BB

1

7 - MAINTENANCE

Every 500 hours

Fuel filter CAUTION Hazardous chemicals!

Never clean with gasoline, naphtha, or any other volatile materials. These materials are toxic and/or flammable.

Failure to comply could result in minor or moderate injury.

C0061A

NOTICE: 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.

LELI11E0385AA

1

LELI11E0386AB

2

LELI11E0387AB

3

NOTICE: Pay attention, during the removal phase, to avoid spilling the fuel in the filter: danger of fire.

Park the machine on a level surface.

Rest the bucket to the ground.

Bring throttle control lever to minimum speed, stop the engine and remove starter key, then position safety lever on LOCK position.

Wait until the machine is cold.

Open engine guard and lock it in this position.

Clean the area around filter (1) and support (2).

Loosen filter (1) using a universal tool (3).

Replace cartridge (1) and O-ring (4) with new pieces.

The reassembly is carried out according to the inverse procedure of the described one.

7-34

7 - MAINTENANCE

Air filter NOTICE: when the engine is operated in dusty conditions, clean the element more frequently. Do not run the engine with removed air cleaner or element, as this may cause foreign material to enter and damage the engine.

Park the machine on a level surface.

Rest the bucket to the ground.

Bring throttle control lever to minimum speed, stop the engine and remove starter key, then position safety lever on LOCK position.

Press on tongue (1).

Turn the cover (2) counterclockwise and remove it.

Check that dust ejection valve (3) is clean.

Insert inside housing new inner (5) and outer elements (4).

Fit cover (2) and turn it clockwise.

Close engine guard.

7-35

LELI11E0383AB

1

LELI11E0384AA

2

7 - MAINTENANCE

Every 1000 hours

Hydraulic return filter WARNING Burn hazard!

Allow the oil to cool down below 49 °C (120 °F) before checking.

Failure to comply could result in death or serious injury.

W1127A

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.

LELI11E0385AA

1

TULI12E300055AA

2

NOTICE: 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 flat ground and place the attachment as shown in the figure.

Bring throttle control lever to minimum speed, stop the engine and remove starter key, then position safety lever on LOCK position.

Wait until the machine is cold.

7-36

7 - MAINTENANCE

Press the valve (several times 5 to 7) together with the breather cap (8), and bleed the inner pressure.

Remove capscrew (1), washer (2) and cover (3) from the upper surface of the reservoir.

Take out spring (4), valve (5) and element (6).

Replace O-ring (7) and element (6).

Clean the parts taken out with light oil.

Install the new filter element (6) and spring (4) into the tank seat.

Install cover (3) with a new O-ring (7).

Fit the fastening screws (1) of cover (3).

Tightening torque: 21.5 - 25.5 N·m (16 - 19 lb ft) Start the engine, activate all control levers and recheck oil level.

NOTE: For a machine with a hydraulic breaker, the deterioration of hydraulic oil is hastened by the breaker work compared to the standard digging with bucket. It is therefore necessary to carry out maintenance at shorter intervals.

TULI12E300056BB

7-37

3

7 - MAINTENANCE

Radiator WARNING Inhalation hazard! Risk to operators and bystanders.

Avoid running the engine in confined areas.

Make sure there is adequate ventilation at all times.

Failure to comply could result in death or serious injury.

W0156A

WARNING Burn hazard!

Hot coolant can spray and scald if you remove the radiator or deaeration tank cap while the system is hot. To remove the cap: allow the system to cool, turn the cap to the first notch, and wait for all pressure to release. Remove the cap only after all pressure has released.

Failure to comply could result in death or serious injury.

LELI11E0391AA

1

LELI11E0392BB

2

W0367A

NOTICE: 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.

Park the machine on a level surface.

Rest the bucket to the ground.

Bring throttle control lever to minimum speed, stop the engine and remove starter key, then position safety lever on LOCK position.

Wait until the machine is cold.

Open engine guard and lock it in open position.

With cold engine, remove plug (1) from radiator and plug (2) from level tub (3).

Remove draining plug (4) and let coolant drain inside a container of suitable capacity. When this operation is finished, reinstall plugs (4) and (2).

Carefully inspect the sleeves for integrity and seal (replace them if necessary) and tighten possibly loose clamps.

Check the radiator for leaks, damages and/or dirt build-up.

Proceed with system filling through plug (1) until the radiator is completely full.

NOTE: When adding coolant, proceed slowly to avoid formation of air bubbles in the system.

7-38

7 - MAINTENANCE

Install cover (1).

Start the engine and let it run for several minutes, so as to heat the coolant.

Stop the engine, wait until it cools down and check the coolant level on the level tub (3). The coolant level should be set between references FULL and LOW. If the level is low, remove plug (2) and restore level.

Close engine guard and radiator compartment lid.

NOTE: Handle and dispose of coolant according to current legislation. Use only authorized disposal procedures. If in doubt, contact authorities concerned.

NOTE: If “Long life coolant” is not used, replace the coolant twice a year (in spring and autumn).

7-39

LELI11E0393AA

3

7 - MAINTENANCE

Engine Engine 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.

LELI11E0394BA

Checking and adjustment for starter and generator There is a possibility of worn-out brushes and/or lack of grease lubrication or bearing.

This is of the adjustment to get good start ability and power generation.

7-40

1

7 - MAINTENANCE

Every 2000 hours

Engine Checking and adjustment for fuel injection timing This is to adjust the fuel injection timing to optimise the engine performance.

LELI11E0394BA

Check and adjustment of the contact surface of the intake and drain valve This is to ensure the gas-tightness on the exhaust and suction valves to optimise the engine performance.

7-41

1

7 - MAINTENANCE

Hydraulic oil tank WARNING Burn hazard!

Before performing any service on the hydraulic system, you must allow it to cool. Hydraulic fluid temperature should not exceed 40 °C (104 °F).

Failure to comply could result in death or serious injury.

W0241A

WARNING Inhalation hazard! Risk to operators and bystanders.

Avoid running the engine in confined areas.

Make sure there is adequate ventilation at all times.

Failure to comply could result in death or serious injury.

LELI11E0395AA

1

SMIL13MEX0067AB

2

W0156A

NOTICE: 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 key, then set the safety 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.

7-42

7 - MAINTENANCE

Press the valve (several times 5 to 7) together with the breather cap (3), and bleed the inner pressure.

Place an oil collecting container (1) under the hose (2).

Gradually loosen the hose (2) with a spanner ( 22 mm), and drain oil.

Once the oil has been drained retighten the hose (2).

Tightening torque: 44 - 53 N·m (32.5 - 39.1 lb ft).

Loosen four screws (4) and washers (5) and remove cover (6).

NOTE: When loosening the hose (2), pay attention not to pour fluid over yourself. Do not drop tools or capscrews and so on into hydraulic tank.

NOTICE: Dispose of all hazardous waste in accordance with environmental regulation.

7-43

SMIL13MEX0068BB

3

TULI12E300058BB

4

7 - MAINTENANCE

Remove suction filter (8) and O-ring (7).

Clean suction filter (8) with diesel oil. If the filter has to be replaced, install a new one.

Install new O-ring (7), the suction filter (8) and make sure that the complete suction filter is correctly placed.

LELI11E0398AB

5

TULI12E300059BB

6

Fill the hydraulic oil tank through filling neck (9).

Install cover (6) with screws (4) and washers (5).

Tightening torque: 21.5 - 25.5 N·m (15.86 - 18.81 lb ft).

Close the side hood.

Once the engine has started up and has operated for several minutes (5/7) to low idle, carry out telescopic motion of each cylinder. Reposition the machine in the hydraulic oil check position, and if this latter is low, restore oil level checking through level indicator (10).

7-44

7 - MAINTENANCE

Travel reduction unit oil With a new machine the first oil change is to carry out after the first 50 service hours.

NOTICE: 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.

NOTICE: This must though remain strictly outside the maneuvering 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.

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 key, then set the safety lever to the LOCKED position.

Place a container under the drain port (1) to collect oil.

LELI11E0406AA

1

LELI11E0407AB

2

LELI11E0408AA

3

LELI11E0409AA

4

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.

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.

7-45

7 - MAINTENANCE

Idler wheel and rollers change oil WARNING Pressurized fluid can penetrate the skin and cause severe injuries.

The grease in the track tensioning mechanism is under high pressure. Keep face and body away from grease nipple. Never loosen the grease nipple more than one complete turn.

Failure to comply could result in death or serious injury.

W0959A

Remove lower roller and idler wheel to discharge oil. The procedures for removal, installation and change of gear oil are described hereunder.

LELI11E0410AA

1

LELI11E0411AA

2

LELI11E0412AB

3

Crawler idler adjuster For oil discharge, remove rubber crawler according to relevant side.

NOTICE: 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 under the frame to support the machine.

Pull off the idler wheel (1) and adjuster (2) from the crawler frame.

Weight of the idler wheel: 40 kg (88 lb) Loosen the cap (3) and let the oil drain into a container.

Fill gear oil through the plug hole (3).

7-46

7 - MAINTENANCE

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.

LELI11E0413AB

4

LELI11E0414AB

5

LELI11E0415AB

6

Upper roller For oil discharge, remove rubber crawler according to relevant side.

After stopping the engine, ensure that the machine is in parking position.

Loosen the rubber track (1) of the side on which gear oil (2) is to be changed.

Raise the track with an hydraulic jack (3).

Remove the nuts (4) and the cap screws (5) from the support fixing the shaft of the upper roller (7). Remove roller.

Remove oil filling plug (8) by means of a wrench and drain oil from reduction unit into a container.

Fill reduction gear oil [ 45 cm³ (3 in³) through filling port (8).

Apply sealing (teflon) tape on the thread of drain plug (8), and securely tighten it.

Wipe off any oil around the plug.

Install the roller in reverse order from removal.

After applying thread lock sealant on thread of the cap screws (5), tighten the screws.

Tightening torque: 59 - 73 N·m (43.5 - 53.8 lb ft).

7-47

7 - MAINTENANCE

Cleaning of pilot valve and solenoid valve line filters WARNING Escaping fluid!

Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or performing work on the hydraulic system. Before applying pressure, make sure all connections are tight and all components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately.

Failure to comply could result in death or serious injury.

TULI12E300060AB

1

LELI11E0401BB

2

W0178A

The right and left pilot valve and solenoid valve are equipped with a filter adapter. Dirt in the filter decreases oil flow. If dust, etc. enter in the valve it may cause trouble.

Take out and clean filter, regularly.

Pilot valve line filter cleaning Carry out the lifting work on level ground.

Rest the bucket to the ground.

Bring throttle control lever to minimum speed, stop the engine and remove starter key, then position safety lever on LOCK position.

Carry out the air releasing from the hydraulic system.

Loosen the 2 screws (3) of the gear box and remove the cover.

Disconnect first hose (1) connected to P port of pilot valve (4). Then remove connector with filter (2).

After removal, plug the bore to prevent entry of foreign matters.

Clean the fuel filter and use compressed air to remove dust.

Inspect O-rings (5) for damage or excessive wear, replace them if necessary.

After cleaning, carry out reassembly, in the reverse order as described under (5) and (6).

7-48

7 - MAINTENANCE

Remove the right-hand hood (6).

After removing the hose, remove the filter assy (7) from the joint (9) installed on the solenoid valve (8). After removal, the holes of the joint and of the hose should be plugged.

Unscrew and remove the joint (7d), then remove the filter (7b) by using a screwdriver.

Spray oil on the air filter (7b) to clean it or eventually replace it if damaged. Do not forget to clean the inside of the case (7a). Check O-ring (7c) and if damaged, replace it with a new one.

Reassemble the filter (7b) in the housing (7a). Screw and tighten the joint (7d).

Tightening torque: 60 - 80 N·m (44.3 - 59 lb ft) Reinstall the filter assy (7) onto the joint (9) of the solenoid valve (8).

Tightening torque: 40 - 79 N·m (29.5 - 58.3 lb ft) Install the hose.

7-49

SMIL13MEX0069BB

3

LELI11E0403AB

4

7 - MAINTENANCE

Remove the 90°-fitting (13) from the valve (10).

Clean the 90°-fitting (13) from dust. After cleaning, carry out reassembly in the reverse order of removal sequence.

Remove the floor plate and cover. First remove the hose (11) connected to “P” port on the pilot valve (10), then remove the 90°-fitting (13). After removal, plug the bore to prevent entry of foreign matters.

LELI11E0404BB

5

LELI11E0405AB

6

Remove dust accumulated inside the 90°-fitting (13).

Inspect O-rings (12) for damage or excessive wear, replace them if necessary.

After cleaning, carry out reassembly in the reverse order of removal sequence.

7-50

7 - MAINTENANCE

Replacement of grease in slewing grease bath When the machine works immersed in water up to the upper structure, the grease (1) inside the slewing bearing (2) 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.

NOTICE: 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, keep people away from the machine’s working range.

TULI12E300061AA

1

LELI11E0417AB

2

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.

Greasing must be performed from the lower side of the machine.

7-51

7 - MAINTENANCE

When necessary

Rubber track Repair or replace the rubber crawler under the following conditions.

Contact your dealer for the repair or the replacement of the rubber crawlers.

LELI11E0336AB

1

LELI11E0337AB

2

LELI11E0338AB

3

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.

Breakage of steel cord If the steel cords of the rubber shoe (1) are broken by more than one half of one side row, replace the shoe with a new one.

7-52

7 - MAINTENANCE

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.

LELI11E0339AB

4

LELI11E0340AB

5

LELI11E0341AB

6

LELI11E0342AB

7

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).

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 it self, even only in one point.

Replace the torn rubber crawler on which the metal core (1) is exposed.

7-53

7 - MAINTENANCE

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.

LELI11E0343AB

7-54

8

7 - MAINTENANCE

Replacement of rubber crawler 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 key removed.

•

Safety lever in LOCKED position.

LELI11E0303AA

1

LELI11E0304AB

2

WARNING Pressurized fluid can penetrate the skin and cause severe injuries.

The grease in the track tensioning mechanism is under high pressure. Keep face and body away from grease nipple. Never loosen the grease nipple more than one complete turn.

Failure to comply could result in death or serious injury.

W0959A

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.

Removing 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.

7-55

7 - MAINTENANCE

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.

LELI11E0305AB

3

LELI11E0306AB

4

LELI11E0307AB

5

LELI11E0308AB

6

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.

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.

7-56

7 - MAINTENANCE

Stop the sprocket (3) and check whether the rubber crawler (4) is correctly positioned on the crawler idler, on the lower rollers (5) and on the sprocket.

LELI11E0309BB

7-57

7

7 - MAINTENANCE

Track tension An appropriate adjustment of tension on the rubber crawler is vital both for rubber crawler and machine life.

NOTICE: 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.

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 h of new crawlers service.

LELI11E0310AA

1

LELI11E0312AB

2

Turn the upper structure by 90° and lower the bucket to lift the crawler.

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.

7-58

7 - 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”: (R) Rubber crawler: 70 - 80 mm (2.17 - 2.56 in) (S) Steel crawler: 115 - 130 mm (4.53 - 5.12 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.

LELI11E0313AB

3

LELI11E0314AA

4

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 WARNING Pressurized fluid can penetrate the skin and cause severe injuries.

The grease in the track tensioning mechanism is under high pressure. Keep face and body away from grease nipple. Never loosen the grease nipple more than one complete turn.

Failure to comply could result in death or serious injury.

W0959A

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.

7-59

7 - 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.

LELI11E0315AB

5

LELI11E0316AB

6

LELI11E0317AB

7

Making tension looser WARNING Pressurized fluid can penetrate the skin and cause severe injuries.

The grease in the track tensioning mechanism is under high pressure. Keep face and body away from grease nipple. Never loosen the grease nipple more than one complete turn.

Failure to comply could result in death or serious injury.

W0959A

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: 58.8 - 88.2 N·m (43.37 - 65.05 lb ft) Move the machine forward and backward to confirm the correct tension on the crawler belts.

7-60

7 - MAINTENANCE

Again check the tension, ad if it is not correct, adjust it again.

NOTE: When there is material (gravel. mud, etc.) Stuck between the wheel and the crawler, remove it before loosening the crawler.

LELI11E0318AB

7-61

8

7 - MAINTENANCE

Radiator CAUTION Flying debris!

Compressed air can propel dirt, rust, etc. into the air. Wear eye and face protection when using compressed air.

Failure to comply could result in minor or moderate injury.

C0049A

LELI11E0319AA

1

TULI12E300047AA

2

LELI11E0321AA

3

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 key, then set the safety 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.

7-62

7 - MAINTENANCE

Radiator cap cleaning WARNING Burn hazard!

Hot coolant can spray and scald if you remove the radiator or deaeration tank cap while the system is hot. To remove the cap: allow the system to cool, turn the cap to the first notch, and wait for all pressure to release. Remove the cap only after all pressure has released.

Failure to comply could result in death or serious injury.

W0367A

Never remove the radiator cap when the system is hot.

Wait until the engine has cooled down before removing the radiator cap.

LELI11E0322AA

1

LELI11E0323AB

2

NOTE: 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.

7-63

7 - MAINTENANCE

Work lights A light bulb of 55 W is used for the work light.

NOTICE: 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 working does not turn on after switch activation, the light bulb or fuse may be blown. If the bulb is in good conditions, check the fuse.

LELI11E0324AA

1

LELI11E0325AB

2

Lamp replacement Place the bucket on the ground and set safety lever to LOCKED position, then stop the engine.

Disconnect the connector, then remove the work light from the boom with a wrench.

Remove the screws (1) (4 pieces), then remove the rim (2) and lens (3) from the housing (4).

Remove the spring (6) fixing the socket (5).

Remove the bulb (7) from the socket (5) and install a new one.

Assemble the work light proceeding in the reverse order from above.

NOTE: Pay attention not to break the light bulb during replacement. Hold the lens when removing the screw (1), otherwise, it falls off.

7-64

7 - MAINTENANCE

Fuses and relays Fuse box NOTICE: Always make sure to install fuses of correct amperage, to avoid overloading and damaging the electric system.

NOTE: Stop the machine before replacing the fuses/relays (starter 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.

Wiper, heater - AUX 2 selection - 30 A

2.

Relay, solenoid - 30 A

3.

Work lights - 30 A

4.

Horn, dome light - 10 A

5.

Engine stop solenoid - 30 A

6.

Battery relay, gauge cluster - 10 A

LELI11E0481BB

7-65

1

7 - MAINTENANCE

Relays 1.

R-2, Safety relay - 40 A

2.

R-9, Working light relay

3.

R-1, Battery relay - 70 A

4.

R-7, Engine stop relay - 70 A

5.

R-6, Timer unit

6.

R-8, Charge indicator relay - 50 A

7.

R-3, Decel relay - 50 A

SMIL13MEX0006BB

2

LELI11E0482BB

3

Fusible link for starter In case power does not come when the starter switch is turned "ON", a disconnection of the fusible (1) link is suspected.

Inspect and replace the fusible link.

NOTE: The fusible link is of a fuse wiring of big size provided in the electric wiring for large current. It protects the electrical equipment and wiring from abnormal current just like an ordinary fuse.

7-66

7 - MAINTENANCE

Bucket teeth 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 key, then set the safety 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.

LELI11E0326AA

7-67

1

7 - MAINTENANCE

Bucket teeth 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.

WARNING Personal Protective Equipment (PPE) required.

When assembling, operating, or servicing the machine, wear protective clothing and PPE necessary for the particular procedure. Some PPE that may be necessary includes protective shoes, eye and/or face protection, hard hat, heavy gloves, filter mask, and hearing protection.

Failure to comply could result in death or serious injury.

LELI11E0327AB

1

LELI11E0328AB

2

W0353A

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.

7-68

7 - MAINTENANCE

Side cutter replacement WARNING Avoid injury!

Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protective Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety footwear.

Failure to comply could result in death or serious injury.

W0208A

Remove completely all sand and soil stuck on the cap screws. Use an acetylene torch to cut off the cap screws, 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 cap screws (3) and nuts (1).

LELI11E0329AA

1

LELI11E0330AB

2

Tightening torque: 259.6 - 298.4 N·m (191.47 - 220.09 lb ft).

After tightening the nuts (1), spot-weld them.

7-69

7 - MAINTENANCE

Buckets NOTICE: 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.

LELI11E0331AA

1

LELI11E0332BB

2

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).

7-70

7 - MAINTENANCE

Bucket installation 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.

LELI11E0333AB

3

LELI11E0334AD

4

LELI11E0335AB

5

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).

CAUTION Pinch hazard!

Always use suitable tools to align mating parts.

DO NOT use your hand or fingers.

Failure to comply could result in minor or moderate injury.

C0044A

7-71

7 - MAINTENANCE

Control levers When a control lever becomes heavy to operate or does not move smoothly, apply grease to the sliding and rotating portion (4) and the top portion (5) of the universal joint (3).

Place the machine on a firm and level ground, and engage safety lever on LOCK position. Stop the engine, pull out the starter key.

Carefully raise up the rubber boot (2) and the control lever (1) paying attention not to damage them.

LELI11E0344AB

1

LELI11E0345AB

2

Apply grease on the sliding parts and on the 4 places of rotating portion (4) and the top (5) of the universal joint (3).

Set back the rubber boot (2) to the original position.

7-72

7 - MAINTENANCE

STORAGE

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.

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.

7-73

7 - MAINTENANCE

Care during storage Periodical lubrication during storage 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.

Removal from storage 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.

7-74

8 - TROUBLESHOOTING

8 - TROUBLESHOOTING###_8_### FAULT CODE RESOLUTION

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.

Operation - Troubleshooting Problem All operating speeds are slow or power is lost

Possible Cause Low hydraulic oil level

Correction Fill oil to specified level

Air in the suction pipe

A specific cylinder functions improperly or loses power

Tighten suction pipe hose clamp or replace hose Hydraulic pump is damaged Repair or replace Pilot gear pump is damaged Repair or replace Adjust or replace Main relief valve not adjusted correctly Relief valve of pilot circuit not adjusted cor- Adjust or replace rectly Repair or replace Cylinder seal is scored

Defective control valve or overload valve or presence of air in the cylinder Pilot valve is damaged Pilot valve piping is loose The cylinder position will Cylinder seal is scored not hold with operating lever in neutral The control valve or overload valve is damaged Overload valve is not operating Pilot valve is damaged Machine does not slew The hydraulic motor (rotation) is not working or the rotation gear is damaged Slewing bearing is damaged Pilot valve is not working The rotation gear is damaged Solenoid valve is not working The control valve is not working Lock solenoid valve is not working The rotation speed is slow The control valve is not working The hydraulic motor (rotation) is not working Hydraulic pump is not working Pilot valve is not working Anomalous noise during Insufficient lubrication of upper structure rotation slewing ring and bearings Pilot valve is not working The control valve is not working

8-1

Repair or replace / remove air from cylinder Repair or replace Tighten Repair or replace Repair or replace Repair or replace Repair or replace Repair or replace Repair Repair Repair Repair Repair Repair Repair Repair

or or or or or or or or

replace replace replace replace replace replace replace replace

Repair or replace Repair or replace Grease Repair or replace Repair or replace

8 - TROUBLESHOOTING

Travel - Troubleshooting Problem Machine does not travel smoothly

Travelling power is insufficient

Machine does not travel in a straight line

Possible Cause Too much crawler tension

Correction Adjust crawler tension

Dirty or clogged crawlers Brake valve is not working Travel reduction unit is damaged The control valve is not working Travel motor damaged Main relief valve pressure is set incorrectly Damaged swivel joint Hydraulic pump is damaged

Clean crawlers Repair or replace Repair or replace Repair or replace Repair or replace Adjust or replace Repair or replace Repair or replace

Poor engine performance Main relief valve pressure is set incorrectly Low hydraulic oil level The hydraulic motor (travel) is not working Brake valve is not working Seal in swivel joint is scored or oil is leaking Unequal tensions on crawlers

Repair or replace Adjust or replace Fill to proper level Repair or replace Repair or replace Repair or replace Adjust tension

Set pressures of main relief valves unbalanced One of the travel motors loses power Unbalanced oil flow from the control valve Unbalanced discharge from hydraulic pump Unbalanced flow from brake valve Unbalanced flow between right swivel joints

Adjusting

8-2

Repair or replace Repair or replace Repair or replace Repair or replace Repair or replace

8 - TROUBLESHOOTING

Hydraulic systems - Troubleshooting Problem Temperature rise of the hydraulic oil

Possible Cause Oil cooler core clogged

Cleaning

Engine fan belt slipping Low hydraulic oil level Wrong type hydraulic oil used Hydraulic pump is not working

Adjust or replace Fill oil to specified level Replace with correct oil Repair or replace

8-3

Correction

8 - TROUBLESHOOTING

Instrument panel display - Troubleshooting Problem Engine oil pressure low

Abnormal rise in the coolant temperature

Battery charge

Possible Cause Engine oil level low Oil leaking Wrong oil viscosity Insufficient coolant

Correction Fill oil to specified level Repair and fill as recommended Replace with proper oil 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 Clean and connect corroded Low battery electrolyte level Refill V-belt loose or damaged Adjust or replace Replacing Battery service life has run down

8-4

8 - TROUBLESHOOTING

Engine - Troubleshooting Problem Possible Cause The starter does not turn Battery disconnected or turns too slowly to start the engine Battery discharged Battery terminals disconnected, loose or corroded Ground cable disconnected Engine oil viscosity too thick (Cold weather) The starter turns but the Insufficient fuel engine does not start Improper starting procedure Air in fuel line Fuel filter clogged Clogged air filter Air heater circuit malfunctioning Engine tends to stop at Low idling rpm low speed Fuel filter clogged Clogged air filter Improper valve clearance No power Fuel filter clogged Clogged air filter Improper valve clearance Loose clamps on the air inlet hose Cracked air inlet hose Engine overheats Insufficient coolant Clogged radiator V-belt loose or damaged Faulty thermostat Engine exhaust is black Clogged air filter Improper valve clearance Fuel leak Excessive fuel consumption Clogged air filter Loose clamps on the air inlet hose Cracked air inlet hose Engine oil level is too high Excessive oil Improper oil consumption Oil leaking Improper oil replacement intervals Improper preheating The engine oil pressure does not rise

Battery dies often

Oil level too low

Correction Connect

Charge Clean and connect Connect Replace with correct oil Refill Refer to 2-2 .

Bleed air Replace element Replace elements Check circuit Serviceman Replace element Replace elements Serviceman Replace element Replace element Serviceman Tighten clamps Replace Top up coolant Clean the cooling system Adjust or replace belt Replacing Replace elements Serviceman Serviceman Replace elements Tighten clamps Replace with new hose Reduce to specified level Replace with correct oil Serviceman Change at correct interval Refer to paragraph headed as “Start-up with cold weather” on 4-10.

Fill oil to specified level

Oil leaking Serviceman Improper oil viscosity Replace with proper oil Battery terminals disconnected, loose or Clean and tighten terminals corroded Low battery electrolyte level Fill cells with distilled water V-belt loose or damaged Adjust or replace belt Replace batteries Defective battery

8-5

8 - TROUBLESHOOTING

Second auxiliary hydraulic circuit - Troubleshooting Problem Possible Cause Correction Replace the selector switch Front attachment rotation Failure of selector switch function cannot be selected Failure of harness between selector valve Replace the harness and selector switch Replace the selector valve Failure of selector valve Hoses between selector valve and cylin- Tighten hoses at the correct torque Swing motion of the boom or front attachment ders are loosened rotation speed is very slow O-ring of cylinders are worn Replace the O-ring Presence of air in the line Perform the air bleeding Repair or replace the control valve Defective control valve

8-6

9 - SPECIFICATIONS

9 - SPECIFICATIONS###_9_### General specification Speed and gradeability Detail

Rubber crawler

Rotation speed Travel speed

Low (1st) 2.5 km/h (1.6 mph)

Gradient

Steel crawler 8.9 RPM High (2nd) Low (1st) High (2nd) 4.5 km/h 2.5 km/h 4.5 km/h (2.8 mph) (1.6 mph) (2.8 mph) 58 % ( 30 ° )

Engine Model Type Number of cylinders-Bore x stroke Total displacement Power Maximum torque Starter Generator

Yanmar 3TNV88–PYB Vertical, 4-cycle water-cooled diesel engine 3 – 88 mm (3.5 in) x 90 mm (3.5 in) 1.642 l (0.4 US gal) Maximum power 21.2 kW (28.8 Hp) at 2400 RPM 98.4 N·m (72.6 lb ft) / 1440 RPM 12 V / 1.73 kW 12 V / 55 A

Hydraulic components Hydraulic pump Rotation gear motor Travel gear motor Control valves Cylinder (boom, arm, swing, bucket, dozer) Return filter

Variable displacement, with axial pistons, with pilot gear pump Fixed displacement with axial pistons Fixed displacement with 2-speed axial pistons 10-spool multiple control valve Double action cylinder Safety valve containing / Filter type (30μ)

Swing and dozer Type Boom swing angle Dozer stroke (up/down)

Boom swing by hydraulic cylinder 60 ° 70 ° 560 mm (22 in) / 410 mm (16 in) 540 mm (21.3 in) / 440 mm (17.3 in)

Right Left CX35B CX39B

9-1

9 - SPECIFICATIONS

Capacities Component to be filled

Engine oil pan

Travel motor Upper rollers Idler wheels Radiator (1) Fuel tank Hydraulic oil tank (2) Attachment and dozer pin Swing cylinder pin Slewing bearing Idler adjuster Operating lever and pedal Rotation gear Air conditioning Compressor

Quantity

Consumable

2.8 - 6.7 l (0.74 - 1.77 US gal)

CASE AKCELA NO. 1™ ENGINE OIL SAE 10W-30 CASE AKCELA NO. 1™ ENGINE OIL SAE 15W-40

0.7 l (0.18 US gal) 45 cm³ CASE AKCELA GEAR (2.75 in³) 135 H EP 80W-90 80 cm³ (4.88 in³) 1.6 l (0.42 CASE AKCELA PREMIUM US gal) ORGANIC ANTI-FREEZE 38 l (10 US — gal) 38 l (10 US AKCELA HYDRAULIC gal) EXCAVATOR FLUID

Manufacturer specifications

International specifications

MS 1121 API CI 4/CH-4 ACEA E7/E5 MS 1121

MS 1316

API GL 5

—

ASTM D 3306

—

EN 590

MS 1230

—

AKCELA Multi purpose grease

251 H EP

NLGI 2

AKCELA Moly grease

251 H EP-M

NLGI 2

R134A

—

—

SANDEN SP-10 LUBRICANT

—

—

20 places 1 place 2 place — 1 place 0.7 kg (1.54 lb) 120 cm³ (7.32 in³)

NOTE: (1) Coolant to be mixed with water at 50 %. Cooling system total volume: ~ 4.6 l (1.22 US gal) NOTICE: (2) Hydraulic system total volume: ~ 54.4 l (14.37 US gal). If the machine was filled with biodegradable hydraulic oil PANOLIN HLP SYNTH 46 (option), take note that this oil cannot be mixed with mineral hydraulic oil.

Temperature operating ranges

Engine Travel motor, upper rollers and idler wheels Hydraulic system

Consumable CASE AKCELA NO. 1™ ENGINE OIL CASE AKCELA GEAR 135 H EP 80W-90 AKCELA HYDRAULIC EXCAVATOR FLUID

9-2

Viscosity SAE 10W-30 SAE 15W-40

Temperature operating range -25 °C - +25 °C -15 °C - +40 °C

SAE 80W-90

-25 °C - +45 °C

ISO VG 46

-20 °C - +50 °C

9 - SPECIFICATIONS

Dimension Canopy ( CX35B)

SMIL13MEX0009FB

A B C D E F G H I J K L

M N O P Q R S T U V W

1550 mm (61.0 in) 660 mm (26.0 in) 660 mm (26.0 in) 50 mm (2.0 in) 185 mm (7.3 in) 85 mm (3.3 in) (radius) 775 mm (30.5 in) 4390 mm (172.8 in) 1840 mm (72.4 in) 1380 mm (54.3 in) 775 mm (30.5 in) 2570 mm (101.2 in)

9-3

1

570 mm (22.4 in) 1550 mm (61.0 in) 1540 mm (60.6 in) 2000 mm (78.7 in) 2550 mm (100.4 in) 345 mm (13.6 in) 1550 mm (61.0 in) 330 mm (13.0 in) 300 mm (11.8 in) 1250 mm (49.2 in) 1550 mm (61.0 in)

9 - SPECIFICATIONS

Cab ( CX35B)

SMIL13MEX0010FB

A B C D E F G H I J K L

M N O P Q R S T U V W

1550 mm (61.0 in) 660 mm (26.0 in) 660 mm (26.0 in) 50 mm (2.0 in) 185 mm (7.3 in) 85 mm (3.3 in) (radius) 775 mm (30.5 in) 4390 mm (172.8 in) 1840 mm (72.4 in) 1380 mm (54.3 in) 775 mm (30.5 in) 2570 mm (101.2 in)

9-4

2

570 mm (22.4 in) 1550 mm (61.0 in) 1540 mm (60.6 in) 2000 mm (78.7 in) 2550 mm (100.4 in) 345 mm (13.6 in) 1550 mm (61.0 in) 330 mm (13.0 in) 300 mm (11.8 in) 1250 mm (49.2 in) 1550 mm (61.0 in)

9 - SPECIFICATIONS

Canopy ( CX39B)

SMIL13MEX0011FB

A B C D E F G H I J K L

M N O P Q R S T U V W

1700 mm (66.9 in) 660 mm (26.0 in) 660 mm (26.0 in) 50 mm (2.0 in) 160 mm (6.3 in) 60 mm (2.3 in) (radius) 850 mm (33.5 in) 4710 mm (185.4 in) 1910 mm (75.2 in) 1460 mm (57.4 in) 850 mm (33.5 in) 2570 mm (101.2 in)

9-5

3

570 mm (22.4 in) 1600 mm (62.9 in) 1700 mm (66.9 in) 2150 mm (84.6 in) 2680 mm (105.5 in) 345 mm (13.6 in) 1550 mm (61.0 in) 330 mm (13.0 in)710 300 mm (11.8 in) 1400 mm (55.1 in) 1700 mm (66.9 in)

9 - SPECIFICATIONS

Cab ( CX39B)

SMIL13MEX0012FB

A B C D E F G H I J K L

M N O P Q R S T U V W

1700 mm (66.9 in) 660 mm (26.0 in) 660 mm (26.0 in) 50 mm (2.0 in) 160 mm (6.3 in) 60 mm (2.3 in) (radius) 850 mm (33.5 in) 4710 mm (185.4 in) 1910 mm (75.2 in) 1460 mm (57.4 in) 850 mm (33.5 in) 2570 mm (101.2 in)

9-6

4

570 mm (22.4 in) 1600 mm (62.9 in) 1700 mm (66.9 in) 2150 mm (84.6 in) 2680 mm (105.5 in) 345 mm (13.6 in) 1550 mm (61.0 in) 330 mm (13.0 in)710 300 mm (11.8 in) 1400 mm (55.1 in) 1700 mm (66.9 in)

9 - SPECIFICATIONS

Operating mass Models

Versions

CX35B CX35B CX39B CX39B

Canopy Cab Canopy Cab

Rubber belt Long arm Standard counterweight Big bucket ( 84 kg (185 lb)) Fuel ( 42 kg (93 lb)) Operator ( 75 kg (165 lb))

Operating mass ISO 6016* 3360 kg (7408 lb) 3500 kg (7716 lb) 3760 kg (8289 lb) 3900 kg (8598 lb)

* The operating mass is measured with this configuration

Additional mass Models

Versions

CX35B CX35B CX39B CX39B

Canopy Cab Canopy Cab

Differential of rubber-steel crawler 100 kg (220.5 lb) 100 kg (220.5 lb) 100 kg (220.5 lb) 100 kg (220.5 lb)

Differential of long-short arm

Additional counterweight

Front Guard

-18 kg (-39.7 lb) -18 kg (-39.7 lb) -16 kg (-35.3 lb) -16 kg (-35.3 lb)

250 kg (551 lb) 250 kg (551 lb) 250 kg (551 lb) 250 kg (551 lb)

– 18 kg (39.7 lb) – 18 kg (39.7 lb)

9-7

9 - SPECIFICATIONS

Digging data Canopy CX35B

TULI12E300072FA

No. A A’ B C D E F G H J K L X Y

Attachment

Arm

Bucket Maximum digging reach Maximum digging reach at ground level Maximum digging depth Maximum digging height Maximum dumping clearance Minimum dumping clearance Maximum vertical wall digging depth Minimum front slew radius Height at minimum slew radius 2.44 m (8 ft) digging depth Horizontal digging stroke Stroke at ground level Minimum Above Dozer strokes Below

1

Standard arm 1.18 m (3.87 ft) 0.09 m³ (3.18 ft³) 4930 mm (194.09 in)

Long arm 1.47 m (4.82 ft) 0.09 m³ (3.18 ft³) 5200 mm (204.72 in)

4780 mm (188.19 in)

5060 mm (199.21 in)

2810 mm (110.63 in) 4770 mm (187.80 in) 3360 mm (107.09 in) 1380 mm (54.33 in) 2160 mm (85.04 in) 1920 mm (75.59 in) 3580 mm (140.94 in) 2310 mm (90.94 in) 2110 mm (83.07 in) 1620 mm (63.78 in) 560 mm (22.05 in) 410 mm (16.14 in)

3100 mm (122.05 in) 4960 mm (195.28 in) 3550 mm (116.14 in) 1110 mm (43.70 in) 2430 mm (95.67 in) 2000 mm (78.74 in) 3590 mm (141.34 in) 2660 mm (104.72 in) 2510 mm (98.82 in) 1480 mm (58.27 in) 560 mm (22.05 in) 410 mm (16.14 in)

9-8

9 - SPECIFICATIONS

Cab CX35B

TULI12E300073FA

No. A A’ B C D E F G H J K L X Y

Attachment

Arm

Bucket Maximum digging reach Maximum digging reach at ground level Maximum digging depth Maximum digging height Maximum dumping clearance Minimum dumping clearance Maximum vertical wall digging depth Minimum front slew radius Height at minimum slew radius 2.44 m (8 ft) digging depth Horizontal digging stroke Stroke at ground level Minimum Above Dozer strokes Below

2

Standard arm 1.18 m (3.87 ft) 0.09 m³ (3.18 ft³) 4930 mm (194.09 in)

Long arm 1.47 m (4.82 ft) 0.09 m³ (3.18 ft³) 5200 mm (204.72 in)

4780 mm (188.19 in)

5060 mm (199.21 in)

2810 mm (110.63 in) 4430 mm (174.41 in) 3060 mm (120.47 in) 1220 mm (48.03 in) 2160 mm (85.04 in) 2280 mm (89.76 in) 3400 mm (133.86 in) 2310 mm (90.94 in) 2110 mm (83.07 in) 1620 mm (63.78 in) 560 mm (22.05 in) 410 mm (16.14 in)

3100 mm (122.05 in) 4580 mm (180.31 in) 3200 mm (125.98 in) 930 mm (36.61 in) 2430 mm (95.67 in) 2280 mm (89.76 in) 3410 mm (134.25 in) 2660 mm (104.72 in) 2510 mm (98.82 in) 1480 mm (58.27 in) 560 mm (22.05 in) 410 mm (16.14 in)

9-9

9 - SPECIFICATIONS

Cab CX35B with Front Guard Protective System (optional)

SMIL13MEX0020FB

No. A A’ B C D E F G H J K L X Y

Attachment

Arm

Bucket Maximum digging reach Maximum digging reach at ground level Maximum digging depth Maximum digging height Maximum dumping clearance Minimum dumping clearance Maximum vertical wall digging depth Minimum front slew radius Height at minimum slew radius 2.44 m (8 ft) digging depth Horizontal digging stroke Stroke at ground level Minimum Above Dozer strokes Below

3

Standard arm 1.18 m (3.87 ft) 0.09 m³ (3.18 ft³) 4930 mm (194.09 in)

Long arm 1.47 m (4.82 ft) 0.09 m³ (3.18 ft³) 5200 mm (204.72 in)

4780 mm (188.19 in)

5060 mm (199.21 in)

2810 mm (110.63 in) 4180 mm (164.6 in) 2830 mm (111.4 in) 1100 mm (43.3 in) 2160 mm (85.04 in) 2480 mm (97.6 in) 3260 mm (128.3 in) 2310 mm (90.94 in) 2110 mm (83.07 in) 1620 mm (63.78 in) 560 mm (22.05 in) 410 mm (16.14 in)

3100 mm (122.05 in) 4300 mm (169.3 in) 2950 mm (116.1 in) 810 mm (31.9 in) 2430 mm (95.67 in) 2480 mm (97.6 in) 3270 mm (128.7 in) 2660 mm (104.72 in) 2510 mm (98.82 in) 1480 mm (58.27 in) 560 mm (22.05 in) 410 mm (16.14 in)

9-10

9 - SPECIFICATIONS

Canopy CX39B

TULI12E300074FA

No. A A’ B C D E F G H J K L X Y

Attachment

Arm

Bucket Maximum digging reach Maximum digging reach at ground level Maximum digging depth Maximum digging height Maximum dumping clearance Minimum dumping clearance Maximum vertical wall digging depth Minimum front slew radius Height at minimum slew radius 2.44 m (8 ft) digging depth Horizontal digging stroke Stroke at ground level Minimum Above Dozer strokes Below

4

Standard arm 1.32 m (4.33 ft) 0.11 m³ (3.88 ft³) 5240 mm (206.30 in)

Long arm 1.59 m (5.22 ft) 0.11 m³ (3.88 ft³) 5500 mm (216.54 in)

5110 mm (201.18 in)

5370 mm (211.42 in)

3080 mm (121.26 in) 4980 mm (196.06 in) 3580 mm (140.94 in) 1410 mm (55.51 in) 2390 mm (94.09 in) 2040 mm (80.31 in) 3780 mm (148.82 in) 2600 mm (102.36 in) 2370 mm (93.31 in) 1670 mm (65.75 in) 540 mm (21.26 in) 440 mm (17.32 in)

3350 mm (131.89 in) 5160 mm (203.15 in) 3760 mm (148.03 in) 1150 mm (45.28 in) 2650 mm (104.33 in) 2070 mm (81.50 in) 3780 mm (148.82 in) 2920 mm (114.96 in) 2770 mm (109.06 in) 1530 mm (60.24 in) 540 mm (21.26 in) 440 mm (17.32 in)

9-11

9 - SPECIFICATIONS

Cab CX39B

TULI12E300075FA

No. A A’ B C D E F G H J K L X Y

Attachment

Arm

Bucket Maximum digging reach Maximum digging reach at ground level Maximum digging depth Maximum digging height Maximum dumping clearance Minimum dumping clearance Maximum vertical wall digging depth Minimum front slew radius Height at minimum slew radius 2.44 m (8 ft) digging depth Horizontal digging stroke Stroke at ground level Minimum Above Dozer strokes Below

5

Standard arm 1.32 m (4.33 ft) 0.11 m³ (3.88 ft³) 5240 mm (206.30 in)

Long arm 1.59 m (5.22 ft) 0.11 m³ (3.88 ft³) 5500 mm (216.54 in)

5110 mm (201.18 in)

5370 mm (211.42 in)

3080 mm (121.26 in) 4660 mm (183.46 in) 3290 mm (129.53 in) 1270 mm (50.00 in) 2390 mm (94.09 in) 2350 mm (92.52 in) 3620 mm (142.52 in) 2600 mm (102.36 in) 2370 mm (93.31 in) 1670 mm (65.75 in) 540 mm (21.26 in) 440 mm (17.32 in)

3350 mm (131.89 in) 480 mm (188.98 in) 3430 mm (135.04 in) 1000 mm (39.37 in) 2650 mm (104.33 in) 2340 mm (92.13 in) 3620 mm (142.52 in) 2920 mm (114.96 in) 2770 mm (109.06 in) 1530 mm (60.24 in) 540 mm (21.26 in) 440 mm (17.32 in)

9-12

9 - SPECIFICATIONS

Cab CX39B with Front Guard Protective System (optional)

SMIL13MEX0021FB

No. A A’ B C D E F G H J K L X Y

Attachment

Arm

Bucket Maximum digging reach Maximum digging reach at ground level Maximum digging depth Maximum digging height Maximum dumping clearance Minimum dumping clearance Maximum vertical wall digging depth Minimum front slew radius Height at minimum slew radius 2.44 m (8 ft) digging depth Horizontal digging stroke Stroke at ground level Minimum Above Dozer strokes Below

6

Standard arm 1.32 m (4.33 ft) 0.11 m³ (3.88 ft³) 5240 mm (206.30 in)

Long arm 1.59 m (5.22 ft) 0.11 m³ (3.88 ft³) 5500 mm (216.54 in)

5110 mm (201.18 in)

5370 mm (211.42 in)

3080 mm (121.26 in) 4370 mm (172.0 in) 3040 mm (119.7 in) 1140 mm (44.9 in) 2390 mm (94.09 in) 2560 mm (100.8 in) 3460 mm (136.2 in) 2600 mm (102.36 in) 2370 mm (93.31 in) 1670 mm (65.75 in) 540 mm (21.26 in) 440 mm (17.32 in)

3350 mm (131.89 in) 4490 mm (176.8 in) 3150 mm (124.0 in) 870 mm (34.3 in) 2650 mm (104.33 in) 2570 mm (101.2 in) 3470 mm (136.6 in) 2920 mm (114.96 in) 2770 mm (109.06 in) 1530 mm (60.24 in) 540 mm (21.26 in) 440 mm (17.32 in)

9-13

9 - SPECIFICATIONS

Crawler type CX35B Type

Width

Wheel base between driving wheel and free wheel

300 mm (11.8 in)

Basic pressure Canopy

Cab

1550 mm (61 in)

29 kPa (4 psi)

30 kPa (4 psi)

300 mm (11.8 in)

1550 mm (61 in)

31 kPa (4 psi)

32 kPa (5 psi)

Width

Wheel base between driving wheel and free wheel

300 mm (11.8 in)

300 mm (11.8 in)

Rubber crawler

Steel crawler

CX39B Type

Basic pressure Canopy

Cab

1700 mm (66.9 in)

31 kPa (4 psi)

32 kPa (5 psi)

1700 mm (66.9 in)

32 kPa (5 psi)

33 kPa (5 psi)

Rubber crawler

Steel crawler

9-14

9 - SPECIFICATIONS

Buckets Width

Capacity ISO 7451

350 mm (13.8 in)

0.05 m³ (1.8 ft³)

450 mm (17.7 in)

0.07 m³ (2.5 ft³)

500 mm (19.7 in)

0.09 m³ (3.2 ft³)

600 mm (23.6 in)

0.11 m³ (3.9 ft³)

700 mm (27.6 in)

0.12 m³ (4.2 ft³)

Weight 62 kg (136.7 lb) 69 kg (152.1 lb) 72 kg (158.7 lb) 78 kg (172.0 lb) 84 kg (185.2 lb)

Number of teeth

Type

3

*

4

*

4

*

4

*

4

*

* = Generic digging; for digging and sand loading operations, gravel, clay, earth in general, etc, the specific weight of material should not be higher than 1400 kg/m³ (2359.8 lb/yd³)

9-15

9 - SPECIFICATIONS

9-16

10 - ACCESSORIES

10 - ACCESSORIES###_10_### AUX lines for hydraulic PTO The machine features two AUX lines for power take off (PTO) for hydraulic attachments. Connecting points for attachment hoses are located on topside of arm: hoses connection is allowed by two 1/2" GAS male threaded fittings.

SMIL13MEX0041FB

1

The hydraulic system of the machine can be set up to provide bidirectional power supply to attachments like nibbler or augers, and to provide unidirectional power supply to a breaker: see dedicated sections for proper system set up and operation.

10-1

10 - ACCESSORIES

Selection of hydraulic attachment Before fitting of the hydraulic attachment 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 attachment for the machine specifications, contact your Dealer.

NOTE: Max operating flow of hydraulic PTO is 59 l/min (15.6 US gpm). Max operating pressure of hydraulic PTO is 230 bar (3335 psi).

Before operating hydraulic attachment Contact your Dealer for pipings, for the installation of the hydraulic attachment and for the replacement of the hydraulic oil return filter, according to the maintenance schedule enclosed. Thoroughly read the hydraulic attachment operation manual and the safety instructions described in this manual to prevent damaging the machine or the hydraulic attachment during operation.

Prevention of hydraulic oil contamination Blanking plugs are provided on PTO connecting points for attachment hoses. When hydraulic PTO is not used, apply blanking plugs on machine connecting points and on attachment connecting points, to prevent the penetration of foreign bodies. Before starting operation, check the fixing clamps for looseness, and the tubes and hoses fittings for leakage.

10-2

10 - ACCESSORIES

AUX lines unload Hydraulic PTO is a high pressure hydraulic circuit. AUX have to be unloaded before connecting and disconnecting hydraulic attachment.

WARNING Escaping fluid!

Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or performing work on the hydraulic system. Before applying pressure, make sure all connections are tight and all components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately.

Failure to comply could result in death or serious injury.

W0178A

To unload AUX lines, proceed as follows: 1. Park the machine on a level surface and rest the attachment to the ground.

2. Set engine speed to MIN and lock controls.

3. Open the hydraulic compartment; use an Allen wrench (2) to loosen and remove the screw (3).

Allen wrench: 5 mm 4. Use a wrench (4) to set the selector valve to proper position.

A: to tank B: to control valve Wrench: 24 mm 5. Go back to operator station, unlock controls and right slide the AUX hand control for 2 seconds: the left side AUX line is thus unloaded.

SMIL13MEX0042BB

10-3

2

10 - ACCESSORIES

6. Lock controls, open hydraulic compartment and perform the procedure as previously described to set the selector valve to breaker free return position: the right side AUX line is thus unloaded.

A: to tank B: to attachment 7. Connect/disconnect hydraulic lines of attachment.

SMIL13MEX0018BB

3

SMIL13MEX0070AA

4

Quick couplers (optional) The AUX lines for PTO can be provided with two 1/2" female quick couplers installed on connecting points on arm to make a ready connection of attachment hoses.

10-4

10 - ACCESSORIES

Breaker 1. 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.

LELI11E0454AA

1

LELI11E0455AB

2

LELI11E0456AA

3

LELI11E0457AC

4

2. 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.

3. Operate the breaker with intervals of 30 s.

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.

4. 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.

10-5

10 - ACCESSORIES

5. 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.

LELI11E0458AC

5

LELI11E0459AA

6

LELI11E0460AA

7

LELI11E0461AA

8

6. 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.

7. 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.

8. Do not operate with arm set perpendicular to soil. The piston rod joint and the same piston can get damaged.

10-6

10 - ACCESSORIES

9. 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.

LELI11E0462AA

9

Working range 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.

LELI11E0463BA

Selection of hydraulic breaker 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.

10-7

10

10 - ACCESSORIES

Before operating hydraulic breaker Contact your Dealer for pipings, for the installation of the hydraulic breaker 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.

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 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.

Hydraulic lines Left side AUX hydraulic line (C) has to be used to supply hydraulic flow to breaker.

Right side AUX hydraulic line (D) has to be used for breaker free return.

SMIL13MEX0149AB

11

Setting breaker selector valve Check that selector valve (1) is positioned so as to connect the attachment return to the control valves block.

NOTE: Wrong switching of the selector valve, may decrease the work efficiency and operating speed of the machine and also damage it.

Be sure to switch selector valve one or twice a month.

LELI11E0449AB

10-8

12

10 - ACCESSORIES

Setting procedure NOTE: Before switching selector valve, be sure to stop the engine and lower the attachment to the ground, so as not to impair the machine stability.

Use an Allen wrench (2) to loosen and remove the screw (3).

Allen wrench: 5 mm Use a wrench (4) to turn the selector valve (1) to proper position.

A: to tank B: to attachment Wrench: 24 mm When the valve is positioned correctly, tighten the screw (3).

SMIL13MEX0018BB

13

Hydraulic breaker operation NOTICE: 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 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.

Activate the breaker using the push-button (1).

Release the push-button (1) to stop the breaker.

LELI11E0445AB

14

LELI11E0484AB

15

NOTICE: To operate breaker longer than 30 s, could cause premature wear or damage to the machine attachment. If material is not breaking, reposition breaker and repeat operation at 30 s interval.

Never leave the operator cab with engine running.

NOTE: The breaker can be activated by sliding the slider (2) to the left. But use the breaker push-button (1) as much as possible to operate the breaker.

10-9

10 - ACCESSORIES

Regular inspection and maintenance 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 filters, referring to the following table: Inspection and maintenance table Hydraulic oil Return filter

Location Hydraulic oil tank Hydraulic oil tank

First 50 h

Replacement interval 2nd Replacement 250 h

Regular Every 600 h Every 250 h

Maintenance record sheet (example) Date

Hours

Filter replacement

10-10

Hydraulic oil change

10 - ACCESSORIES

Nibbler NOTE: If it is required to install a nibbler to the excavator, select a nibbler model that meets the requirements of stability, flow rate and pressure of the excavator hydraulic system. Contact your authorized Dealer to select a type of nibbler suitable for this machine.

1. Do not allow the machine weight to be supported by prying with the nibbler and cylinders fully extended or retracted. Doing so may damage the front attachment.

In particular, avoid doing so with the nibbler cylinder fully extended as the front attachment will be more easily damaged.

2. Do not perform crushing on wither side of the machine, always do so at front or rear, parallel with tracks. Otherwise, the machine may overturn.

3. When operating the nibbler up high with the boom fully raised, be careful of falling objects.

4. When operating the nibbler on a floor in a building, first confirm that the floor has sufficient strength to support the load caused by crushing in addition to machine weight.

5. Always operate the nibbler on a firm level surface, not on a slope or crushed scraps.

6. Do not use the nibbler to haul or move crushed scraps.

7. Always remove the nibbler from the machine before transporting the machine. Do not travel the machine with the bucket cylinder fully extended. This made damage the attachment due to high travel vibrations.

10-11

10 - ACCESSORIES

Selection of nibbler During the fitting of the hydraulic nibbler 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 nibbler for the machine specifications, contact your Dealer.

Before operating nibbler Contact your Dealer for pipings, for the installation of the nibbler and for the replacement of the hydraulic oil return filter, according to the maintenance schedule enclosed.

Thoroughly read the hydraulic nibbler operation manual and the safety instructions described in this manual to prevent damaging the machine or the nibbler during operation. When the nibbler 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 nibbler, follow maintenance procedures observing the time schedule indicated in this manual.

Prevention of hydraulic oil contamination When the nibbler is not installed on the machine, apply blanking plugs on the tube ends of arm and nibbler, to prevent the penetration of foreign bodies.

Before starting operation, check the fixing clamps for looseness, and the tubes and hoses fittings for leakage.

10-12

10 - ACCESSORIES

Hydraulic lines Sliding the control slider (2) to left, hydraulic flow is supplied to the left side AUX hydraulic line (C).

Sliding the control slider (2) to right, hydraulic flow is supplied to the right side AUX hydraulic line (D).

LELI11E0484AB

1

2

SMIL13MEX0149AB

Setting nibbler selector valve Check that selector valve (1) is positioned so as to connect the attachment return to the control valves block.

NOTE: Wrong switching of the selector valve, may decrease the work efficiency and operating speed of the machine and also damage it.

Be sure to switch selector valve one or twice a month.

LELI11E0449AB

10-13

3

10 - ACCESSORIES

Setting procedure NOTE: Before switching selector valve, be sure to stop the engine and lower the attachment to the ground, so as not to impair the machine stability.

Use an Allen wrench (2) to loosen and remove the screw (3).

Allen wrench: 5 mm Use a wrench (4) to turn the selector valve (1) to proper position.

A: to control valve B: to attachment Wrench: 24 mm When the valve is positioned correctly, tighten the screw (3).

4

SMIL13MEX0019BB

Nibbler operation NOTICE: 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 lever downwards (B) and set it to the UNLOCKED position.

Set the throttle lever to HIGH IDLING. Set the nibbler to the desired position.

Use the slider (2) to open/close the nibbler.

NOTICE: Do not touch the breaker push-button (1) when you operate the nibbler.

LELI11E0445AB

5

LELI11E0484AB

6

NOTE: Before using the slider (2), carefully read the operator manual, because slider operation varies in accord with specifications. The slider is always operative and, if it accidentally activated, it could cause serious injuries.

10-14

10 - ACCESSORIES

Additional AUX lines for hydraulic PTO Two additional AUX lines are provided for power take off ( PTO ) for hydraulic attachments featuring secondary hydraulic actuations, e.g. rotating grabs.

Using a rotating grab, the base AUX lines ( AUX1, see page 10-1) provide bidirectional power supply to the main actuation of attachment (grab).

NOTE: read the hydraulic attachment operation manual to identify grab lines. Connect grab lines to AUX1 circuit.

The additional AUX lines ( AUX2 ) provide bidirectional power supply to the secondary actuation of attachment (rotation).

NOTE: read the hydraulic attachment operation manual to identify rotation lines. Connect rotation lines to AUX2 circuit.

AUX2 connecting points for attachment hoses are located on top side of arm, close to connecting points of AUX1 circuit: • hoses connection for AUX1 is allowed by two 1/2" female quick couplers (1) • hoses connection for AUX2 is allowed by two 3/8" female quick couplers (2) NOTICE: always use AUX1 as hydraulic PTO to supply a breaker, a nibbler, an auger, a mulcher. Use AUX2 only as hydraulic PTO to supply secondary function of attachments, e.g. positioning rotation or tilt.

SMIL13MEX0044AB

Selection of hydraulic attachment Before fitting of the hydraulic attachment 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 attachment for the machine specifications, contact your Dealer.

NOTE: Max operating flow of AUX2 hydraulic PTO is 25 l/min (6.6 US gpm). Max operating pressure of AUX2 hydraulic PTO is 230 bar (3335 psi).

Before operating hydraulic attachment Contact your Dealer for pipings, for the installation of the hydraulic attachment and for the replacement of the hydraulic oil return filter, according to the maintenance schedule enclosed. Thoroughly read the hydraulic attachment operation manual and the safety instructions described in this manual to prevent damaging the machine or the hydraulic attachment during operation.

10-15

1

10 - ACCESSORIES

AUX2 operation AUX2 operation is alternative to boom swing function. Therefore, the operating system of AUX2 features an activation device and a control device.

SMIL13MEX0007GB

1.

2.

AUX2 selector switch AUX2 control pedal

10-16

2

10 - ACCESSORIES

• The AUX2 selector switch (1) is used to activate either the swing motion of the boom or the rotation of hydraulic attachment, as indicated on the decal (4). To select the boom swing, rotate the AUX2 selector switch (1) to the left side (C). To select the attachment rotation, rotate the AUX2 selector switch (1) to the right side (D).

• According to switch selection, the pedal (2) operates the boom swing or the attachment rotation. When the selector switch is in (C) position, by pushing right side of pedal (E) the right swing is operated. By pushing left side of pedal (F) the left swing is operated. When the selector switch is in (D) position, by pushing right side of pedal (E), hydraulic flow is supplied to the left side AUX2 hydraulic line. By pushing left side of pedal (F), hydraulic flow is supplied to the right side AUX2 hydraulic line.

SMIL13MEX0013AB

3

SMIL13MEX0150AB

4

SMIL13MEX0151BB

5

NOTE: the pedal can be locked by pulling the cover (5) downwards.

WARNING Unexpected machine movement!

ALWAYS lock the auxiliary pedals when not in use.

Failure to comply could result in death or serious injury.

W0222A

10-17

10 - ACCESSORIES

On the right side of the machine, the decal (3) illustrating the various movements of the machine as a function of the controls is applied. Read and heed the functions associated with the respective controls listed on this decal prior to operating the machine

SMIL13MEX0008GB

A. B.

6

Canopy version Cab version

NOTICE: AUX2 operation is alternative to boom swing function. Do not switch on-the-run from one function to the other: - using AUX2, stop operation with hydraulic attachment and then switch to boom swing - using boom swing, stop swing operation and then switch to AUX2 power supply.

10-18

10 - ACCESSORIES

AUX2 lines unload CAUTION Escaping fluid!

Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or performing work on the hydraulic system. Before applying pressure, make sure all connections are tight and all components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately.

Failure to comply could result in minor or moderate injury.

C0104A

AUX2 hydraulic PTO is a high pressure hydraulic circuit.

AUX2 lines have to be unloaded before connecting and disconnecting hydraulic attachment.

To unload AUX2 lines, proceed as follows: 1. Park the machine on a level surface and rest the attachment to the ground.

2. Shut down engine and set start key to ON position.

3. Set AUX2 selector switch to the right side.

4. Press left side of pedal for 2 s: the left side AUX line is thus unloaded.

5. Press right side of pedal for 2 s: the right side AUX line is thus unloaded.

6. Connect or disconnect hydraulic lines of attachment.

10-19

10 - ACCESSORIES

Load handling WARNING Improper operation or service of this machine can result in an accident.

When lifting a load the machine must be equipped with: - safety valves, - an overload indicator, - a load fixing point, - a load handling chart corresponding to the type of machine and to its attachment.

Failure to comply could result in death or serious injury.

W1168A

NOTICE: The machine has been specially designed for digging/loading operations. The moving of hanging loads to complete the working cycle digging and/or loading, is always allowed, only if the machine is equipped with specified optional equipment.

NOTICE: Carry out the handling of hanging loads by strictly following the national law concerning the prescribed safety rules, the national safety rules, the rules listed here below and those described on chapter safety rules.

For the handling of hanging loads, observe following: NOTICE: Before starting to work check the valves for any remarkable damage or abnormal noise. If troubles are noticed, refer to your dealer and, in the meantime, do not use the machine for handling hanging loads. To avoid injuries, do not exceed the machine load rated capacity.

If the machine is not set on a level ground, load capacities are reduced. Anyway, always operate with care.

Lower the dozer to the ground to increase machine stability.

Pre-arrange the engine RPM according to the hydraulic effort required.

Evaluate (if unknown) the weight of the object to be handled and compare it with the data of the table located in the cab and shown in this chapter. Do not lift loads exceeding the maximum values shown on the table.

Before any lifting operation, press switch (1) to connect anti-tipping sensor. This sensor activates the acoustic alarm when reaching safety limit load.

10-20

LELI11E0464AB

1

10 - ACCESSORIES

Fasten the load by means of the appropriate hook (2), provided on the connecting rod of the bucket linkage, by means of hooking devices and chains suitable for the load to be lifted.

NOTICE: Check for lifting devices (hooks, chains, etc.) integrity and make sure they are not too much worn out.

Keep to the rules in force concerning checking procedures of said devices (not supplied with the machine). The device can only be used for lifting objects that are not anchored to the ground. It cannot be used for towing, uprooting and breakout.

In order to avoid the load swing, do not sling a load with too long ropes and/or chains.

Check the working area and make sure the load run is free from obstacles.

Lift the load slowly avoiding sudden motion that can cause load swing. As a rule, keep the load close to the machine in order to increase stability and operate lengthwise rather than crosswise.

Lift the load from the ground at the minimum distance from ground.

NOTICE: Loads can turn and swing in all directions, therefore they might hit persons or machine cab. In order to limit this danger, keep people within machine safe area of operation and shift the load slowly. In case the load turns or swings during transport, slow down until you stop and slowly lower it to the ground, then correct the hooking system.

In case sound alarm is active during load handling, lower the load to the ground and check for load conditions with the help of the special table in the cab.

Lay the load onto the desired position and make sure it is firmly and safely rested on a solid surface.

10-21

LELI11E0465AB

2

10 - ACCESSORIES

Liftable loads table located in the cab Canopy CX35B

TULI12E300077FB

3

NOTE: The indicated values are calculated by using a 500 mm (19.69 in) standard bucket weighing 72 kg (159 lb).

1.

Boom length

5.

2.

3.

Length (LD) of arm alternatively Bucket width

6.

7.

4.

Distance of load from slew centre

10-22

Maximum liftable load in kg to roll-over limit according to ISO 10567 Counterweight weight Setting pressure of main overpressure relief valve/hydraulic system safety valves

10 - ACCESSORIES

Cab CX35B

TULI12E300078FB

4

NOTE: The indicated values are calculated by using a 500 mm (19.69 in) standard bucket weighing 72 kg (159 lb).

1.

Boom length

5.

2.

3.

Length (LD) of arm alternatively Bucket width

6.

7.

4.

Distance of load from slew centre

10-23

Maximum liftable load in kg to roll-over limit according to ISO 10567 Counterweight weight Setting pressure of main overpressure relief valve/hydraulic system safety valves

10 - ACCESSORIES

Canopy CX39B

TULI12E300079FB

5

NOTE: The indicated values are calculated by using a 600 mm (23.62 in) standard bucket weighing 78 kg (172 lb).

1.

Boom length

5.

2.

3.

Length (LD) of arm alternatively Bucket width

6.

7.

4.

Distance of load from slew centre

10-24

Maximum liftable load in kg to roll-over limit according to ISO 10567 Counterweight weight Setting pressure of main overpressure relief valve/hydraulic system safety valves

10 - ACCESSORIES

Cab CX39B

TULI12E300080FB

6

NOTE: The indicated values are calculated by using a 600 mm (23.62 in) standard bucket weighing 78 kg (172 lb).

1.

Boom length

5.

2.

3.

Length (LD) of arm alternatively Bucket width

6.

7.

4.

Distance of load from slew centre

10-25

Maximum liftable load in kg to roll-over limit according to ISO 10567 Counterweight weight Setting pressure of main overpressure relief valve/hydraulic system safety valves

10 - ACCESSORIES

Air conditioning Functions of each control 1.

2.

3.

4.

5.

Main power switch Temperature control dial Air flow control dial I Low II Medium III High Air intake control lever (fresh or recirculated air selector) Grille

LEPH11E0470AB

1

LEPH11E0471AB

2

LEPH11E0472AB

3

Operation of air conditioner Press the main power switch (1).

First, turn the air flow control dial (3) from “OFF” to I (Low), and turn the dial to desired position.

(When the air flow control dial is positioned at I, II or III, the main power switch is illuminated.)

Operate the air conditioner on condition that the temperature control dial is within the blue range.

Turn this dial (2) counterclockwise to lower the outlet temperature.

Move the fins of grilles (5) to direct the cool air outlet to the desired direction.

Each time the recirculated and fresh air select lever (4) is switched, the mode is switched from/to fresh air to/from recirculated air.

Air recirculation Fresh air intake NOTE: If the air in the cab is very hot due to sun heat, before starting of air conditioner, ventilate the total air in the cab by opening the door and window.

10-26

10 - ACCESSORIES

Precautions • When parked in the sun heat When parked in the sun heat for long time, the temperature in the cab is greatly raised. In such case, open window fully and get the heat out, and then start operating the cooler. Close window after the inside of cab is cooled and control it to favourite temperature.

• Moderate cooling temperature The cooler refreshes by cooling down the temperature.

It is said that the temperature in which you feel slightly cool (The difference of temperature about 5 - 6 °C (41 43 °F) lower than atmospheric temperature) is good for health.

Too much cooling will give bad effect for health and therefore be careful for cooling temperature when controlling temperature.

• When glass is fogged up The glass is easily fogged up in rainy day and the visibility will be poor.

In this case, the fog is removed by operating cooler.

• When eyes are irritated When smoking in the closed cab eyes are irritated sometime. This is caused by dry air which weakens resistance of eyes.

In this case open window and get smoke out.

NOTE: If the cooler fail, stop the cooler and contact our service shop for checking. High pressure gas could spout out by loosening pipe connections and compressor section. Do not repair the cooler by yourself, contact our service shop.

Periodical inspections For a long life and for comfortably using the air conditioner, contact your Dealer and have the air conditioner periodically checked.

10-27

10 - ACCESSORIES

Check and maintenance WARNING

W0268A

Maintenance hazard!

Never try to service the air-conditioning system yourself. Contact your dealer for service.

Failure to comply could result in death or serious injury.

Check and maintenance interval Every 500 h Every 1000 h O O O O O O O (Every 250 h) O O

Check and maintenance items Refrigerant (gas) Condenser Compressor Idling pulley V belt

Filling amount Clogging of fins Operating condition Operating condition Damage and tension

Blower motor, fan Control mechanism Each piping installation

Inner filter

Operating condition Operating condition Installation condition Damage, looseness, gas leak Cleaning

Receiver dryer

Replace

O O (Once a week) Every 2 to 4 seasons

10-28

O

10 - ACCESSORIES

Checking the air conditioner refrigerant WARNING Avoid injury!

Avoid breathing air-conditioning refrigerant, lubricant vapor or mist. If accidental system discharge occurs, ventilate the work area before resuming service.

Failure to comply could result in death or serious injury.

W1000B

WARNING Explosion hazard!

Air-conditioning refrigerant boils at -12 °C (10 °F)!

-NEVER expose any part of the air-conditioning system to a direct flame or excessive heat.

-NEVER disconnect or disassemble any part of the air-conditioning system.

Discharging refrigerant gas into the atmosphere is illegal in many countries.

Failure to comply could result in death or serious injury.

W0340A

WARNING Escaping refrigerant may cause frostbite!

Always wear protective goggles when handling refrigerant. If you get refrigerant in your eye, immediately flush your eyes with water for 15 minutes. Seek medical assistance immediately.

Failure to comply could result in death or serious injury.

W0339A

10-29

10 - ACCESSORIES

The R134A refrigerant gas in use is a refrigerant with safety characteristics.

This means that this refrigerant is non-flammable, nonexplosive, nontoxic, non-irritating, tasteless and colorless.

Nevertheless, it is necessary to take some precautions.

Avoid any contact with the refrigerant. In case of skin contact with the refrigerant, immediately treat the skin.

Wear the safety glasses to protect your eyes. If although these measures the coolant comes in contact with your eyes, rinse them immediately with cold and clean water and then obtain medical attention immediately.

Empty the system before carrying out repairs on it. Do not let the refrigerant release in the surrounding areas.

To suck it, only use duly approved aspirators.

Regardless of the system being full of refrigerant or empty, heat determines a remarkable overpressure, which could not only damage the system, but also cause explosions.

Never expose the air conditioning components to a flame or a too hot heat source, to prevent fire or explosion hazard, with following emission of toxic gas.

Empty refrigerant cylinders must not be discarded. When full, refrigerant cylinders must not be exposed to sun rays or other heat sources for a long time. The maximum allowed temperature for a full refrigerant cylinder must not exceed 45 °C (113 °F).

10-30

10 - ACCESSORIES

Checking procedure NOTICE: Before cleaning, maintenance and checking, turn the cooler control switch off to stop operating.

The lack of refrigerant causes low efficiency of cooling.

Run the engine at high idling and rotate the cooler at high speed. Then remove the rubber cap (1), and inspect the flowing refrigerant condition from the sight glass (2) of the receiver dryer (3).

A. B. C.

No bubbles Proper Bubbles appeared Insufficient (Bubbles appear continuously) Transparent Over charged or no refrigerant

LELI11E0489BB

4

LELI11E0474AB

5

NOTICE: The machine guard is slippery with oil, water, and grease. therefore to avoid tumbling and falling, use the equipment for safety, when you check the refrigerant condition.

NOTE: • When bubble is continuously found, the refrigerant falls short. Contact our service shop to fill up. The operation in short of refrigerant may damage compressor.

• When refrigerant is not found through sight-glass and the cooler does not function, the refrigerant is empty.

Take the following measures.

Contact our service shop to check it for leakage of refrigerant.

Fill refrigerant to the specified level. (Check the level through sight-glass.)

Then, simultaneously add 120 cm³ of ND-8 oil from the low pressure side.

(In compressor, in low pressure hose and so on).

Be sure to obey the following rules which are provided for global environmental preservation.

• Do not release refrigerant which is sealed in this product in the air.

• Before disposal of this product, recover the sealed refrigerant.

10-31

10 - ACCESSORIES

Cleaning of inner filter The clogging of the filter causes low efficiency of cooling.

Removal of the filter Grip the handles of filter (B) and pull out the filter.

LEPH11E0484AB

10-32

6

10 - ACCESSORIES

Cleaning procedure of the filter CAUTION Eye injury hazard!

Wear protective goggles when using compressed air.

Failure to comply could result in minor or moderate injury.

C0035A

Clean the filter by compressed air.

Soak the filter in clean warm water with mild detergent when the filter is excessively dirty and clogged. Shake the filter in the water containing detergent to wash. After rinse of the filter by clean water, dry it naturally in the shade.

LELI11E0475AB

7

LEPH11E0476AB

8

NOTE: Do not use the organic solvent (gasoline, trichloroethylene, thinner) for wash.

Checking and adjustment of V belts NOTICE: Do not insert bar or hand into air vent hole.

Since the fan is rotating inside of casing, it may cause injury.

Do not touch fan, fan belt and so on when the engine is running. It may cause injury.

NOTICE: Before cleaning, maintenance and checking, turn the cooler control switch off to stop operating.

Open the hood of engine and check the damage and tension of the V belts.

NOTICE: Stop engine and place the safety lever in the LOCKED position. Before attempting any inspection or maintenance procedures to the machine, stop the engine to avoid injury or death.

NOTE: adjust the belt tension correctly. Failure of belt tension causes the performance degradation of compressor and the damage of belt and compressor.

Measure the amount of belt deflection.

Check the tension of the belt by applying a load of 19 N (4.3 lb) and make sure that the arrow does not exceed 4 mm (0.16 in).

To adjust the belt tension, loosen slightly the nut (1) of idler pulley, and adjust the tension by turning the adjusting bolt (2).

Tighten the nut (1).

After adjustment, start the engine and idle it at low speed for about 5 min. Recheck the belt tension.

10-33

10 - ACCESSORIES

Front Guard Protective System Working in areas where there is the danger of rocks or debris projection, the use of FGPS (Front Guard Protective System) structure to be installed on the front side of the cab is unavoidable.

• The label (1), containing the approval specification, is localized on the right side of the protective structure.

NOTICE: FGPS is an operator protective structure, and it is a special safety component of your machine.

DO NOT attach any device to the protective structure for pulling purposes. DO NOT drill holes to 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 and replacement. After an accident, fire, tip over, or roll over, the following MUST be performed by a qualified technician before returning the machine to field or job-site operations: • The protective structure MUST BE REPLACED. • The mounting or suspension for the protective structure, and mounting components 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 OVER, ROLL OVER, COLLISION, OR ACCIDENT. If it is necessary to remove the front guard, install it again by means of fastening bolts M12 X 30 (quantity: 4) and relevant washers.

- Tightening torque 85 - 95 N·m (62.7 - 70.1 lb ft) NOTE: for the digging data of the machine with Front Guard Protective System, see chapter “SPECIFICATIONS”.

10-34

SMIL13MEX0022AB

1

10 - ACCESSORIES

Biodegradable hydraulic oil Specifications Recommended oils PANOLIN +AG - HLP SYNTH 46 CASE AKCELA HYDRAULIC EXCAVATOR FLUID BIO.

Operating range Ambient temperature: From -20 - 40 °C (-4 - 104 °F).

Instructions for use NOTICE: Biodegradable hydraulic oil must not be mixed with mineral hydraulic oil.

Oil change Every 2000 h

Oil sampling for analysis Every 500 h

Oil samples to be analyzed should be taken every 500 h 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.

NOTICE: If special equipments (hydraulic breaker, etc.) are used, oil sampling for analysis should be done every 250 h.

NOTICE: 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

NOTICE: When buying a machine filled with mineral hydraulic oil and wanting to replace it with 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.

10-35

LELI11E0418AA

1

10 - ACCESSORIES

10-36

Index ###_Index_###

ACCESS TO OPERATOR'S PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 AUX lines for hydraulic PTO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 Additional AUX lines for hydraulic PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15 Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26 Biodegradable hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35 Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5 Front Guard Protective System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-34 Load handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20 Nibbler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11

COMMISSIONING THE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Daily inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine coolant level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warning lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Windscreen washer reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Work lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

CONTROLS/INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Front console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Hoods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 Instrument cluster panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Operator's seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Right-hand side controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Seat belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Work lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

ELECTRICAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 Work lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

EXTERIOR CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 Hoods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Every 1000 hours. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40 Hydraulic return filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36 Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38

Every 2000 hours. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41 Cleaning of pilot valve and solenoid valve line filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic oil tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Idler wheel and rollers change oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacement of grease in slewing grease bath . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Travel reduction unit oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-48 7-41 7-42 7-46 7-51 7-45

Every 250 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom, arm, and attachment grease points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-29 7-22 7-24 7-26

Fan belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radiator hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radiator hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Separator filter cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Swing bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-25 7-32 7-33 7-28 7-31

Every 50 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bucket grease fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Track tension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-20 7-18 7-19 7-17

Every 500 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35 Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34

Every 8 hours. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14 General check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14 Separator filter draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16

FAULT CODE RESOLUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Engine - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic systems - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Instrument panel display - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation - Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Second auxiliary hydraulic circuit - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Travel - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-5 8-3 8-4 8-1 8-6 8-2 8-1

FORWARD CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Front console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electro-Magnetic Compatibility (EMC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Machine components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Machine orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Note to the Owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator's Manual storage on the machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-9 1-4 1-8 1-7 1-1 1-7 1-5

GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Caution while using rubber crawlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 Getting out of soft ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Lowering the arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 Lowering the bucket in emergency situations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Machine operation in adverse weather conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 Machine operation in water/on soft grounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Machine travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Operating the controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Practices to improve efficiency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Swing control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Bleed air from the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11 Break-in period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12 Fluids and lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 General safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Maintenance parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 Maintenance summary decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Maintenance tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Releasing pressure in the hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 Torque specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20 Bleed air from the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11 Boom, arm, and attachment grease points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22 Break-in period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12 Bucket grease fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18 Bucket teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-68 Bucket teeth and side cutters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-67 Buckets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-70 Care during storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-74 Cleaning of pilot valve and solenoid valve line filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-48 Control levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-72 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24 Engine oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26 Fan belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25 Fluids and lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34 Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19 Fuses and relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-65 General check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14 General safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Hydraulic oil tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42 Hydraulic return filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36 Idler wheel and rollers change oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-46 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 MAINTENANCE CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13 Maintenance Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13 Maintenance parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 Maintenance summary decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Maintenance tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Precautions when storing the machine for a long period. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-73 Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38 Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-62 Radiator cap cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-63 Radiator hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32 Radiator hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33 Releasing pressure in the hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 Removal from storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-74 Replacement of grease in slewing grease bath . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51 Replacement of rubber crawler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-55 Rubber track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52 Separator filter cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28 Separator filter draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16 Side cutter replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-69 Swing bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31 Torque specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Track tension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17 Track tension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-58 Travel reduction unit oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-45 Work lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-64

OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Daily inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Engine coolant level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Engine warm up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Fuel level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Hydraulic oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Hydraulic oil warm up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Inspection after starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 Parking the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Stopping the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 Warning lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Windscreen washer reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Work lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

OPERATOR'S SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Operator's seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Seat belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

PARKING THE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Parking the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

RIGHT-HAND SIDE CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Instrument cluster panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Right-hand side controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

ROAD TRANSPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Transporting on a trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Hand signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35 Noise levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Safety signs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44 Signal word definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Towing the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43 Vibration levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42

SHIPPING TRANSPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Lifting the machine – CX35B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Lifting the machine – CX39B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Load specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 Buckets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15 Crawler type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14 Digging data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8 Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 Operating mass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7

STARTING THE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Engine warm up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic oil warm up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection after starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-16 4-17 4-14 4-10

STOPPING THE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 Stopping the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-73 Care during storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-74 Precautions when storing the machine for a long period. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-73 Removal from storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-74

TRANSPORT OPERATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Lifting the machine – CX35B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Lifting the machine – CX39B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Load specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 Transporting on a trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Engine - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic systems - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Instrument panel display - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation - Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Second auxiliary hydraulic circuit - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Travel - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-5 8-3 8-4 8-1 8-6 8-2 8-1

WORKING OPERATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Caution while using rubber crawlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 Getting out of soft ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Lowering the arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 Lowering the bucket in emergency situations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Machine operation in adverse weather conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 Machine operation in water/on soft grounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Machine travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Operating the controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Practices to improve efficiency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Swing control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

When necessary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52 Bucket teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bucket teeth and side cutters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Buckets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuses and relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radiator cap cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacement of rubber crawler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rubber track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Side cutter replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Track tension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Work lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-68 7-67 7-70 7-72 7-65 7-62 7-63 7-55 7-52 7-69 7-58 7-64

Dealer’s stamp

CNH Europe Holding S.A. reserves the right to make improvements in design and changes in specifications at any time without notice and without incurring any obligation to install them on units previously sold.

Specifications, descriptions, and illustrative material herein are as accurate as known at time of publication, but are subject to change without notice.

Availability of some models and equipment builds varies according to the country in which the equipment is being used. For exact information about any particular product, please consult your Case dealer.

Copyright © 2013 CNH Europe Holding S.A. All Rights Reserved.

Case is a registered trademark of CNH Europe Holding S.A. Boulevard Royal, 24 L-2449 Luxembourg.