Case WX210 & WX240 Industry Tier 3 Wheeled Hydraulic Excavators Operator's Manual 87618263 - PDF

Wheeled hydraulic excavators WX210 and WX240 Industry Tier 3

Operator's Manual Printed in France

87618263 EN

CASE WX 210 Industry WX 240 Industry Tier 3

OPERATOR’S MANUAL 87618263 EN

SUMMARY OF SECTIONS

1 - INTRODUCTION, SAFETY, PLATES AND DECALS 2 - CONTROLS AND INSTRUMENTS 3 - OPERATING THE MACHINE 4 - SUPPLIES AND MAINTENANCE CHART 5 - TROUBLESHOOTING 6 - STORAGE 7 - ACCESSORIES 8 - DATA AND TECHNICAL SPECIFICATIONS 9 - ALPHABETICAL INDEX

SAFETY INSTRUCTION

This warning symbol points out important messages involving your safety.

Carefully read the safety rules contained herein and follow advised precautions to avoid potential hazards and to safeguard your safety and personal integrity.

In this manual you will find this symbol together with the following key-words:

The non compliance with the warning preceded by the above mentioned key-words (WARNING and DANGER) can cause serious accidents or even the death of the persons involved.

Moreover in the present Manual have been given some instructions with texts in italics, preceded by the words NOTE and CAUTION: NOTE: it emphasizes and underlines to the operator the correct technique or correct procedure to follow.

WARNING This symbol warns about the possibility of potential damages to the machine that can involve the operator’s safety.

DANGER With specific warnings about potential dangers for the operator’s or other persons integrity directly or indirectly involved.

CAUTION It warns the operator of a possible hazard of machine damage in case he does not follow a determined procedure.

INDEX SECTION 1 INTRODUCTION, SAFETY, PLATES AND DECALS ................................................................................. 1-1 FOREWORD.............................................................................................................................................. 1-1 SAFETY INSTRUCTIONS ......................................................................................................................... 1-2 GENERAL SAFETY INSTRUCTIONS.................................................................................................... 1-2 DESIGNATED USE ................................................................................................................................ 1-3 NOISE LEVELS ...................................................................................................................................... 1-4 LEVEL OF VIBRATIONS TRANSMITTED TO THE OPERATOR .......................................................... 1-5 BEFORE OPERATING THE MACHINE ................................................................................................. 1-6 OPERATING THE MACHINE ................................................................................................................. 1-8 TRAVEL ................................................................................................................................................ 1-10 TRAVELLING ON PUBLIC ROADS ..................................................................................................... 1-12 JOB SITE OPERATION........................................................................................................................ 1-12 PARKING THE MACHINE .................................................................................................................... 1-14 LOADING THE MACHINE ON A TRAILER .......................................................................................... 1-15 MACHINE TRANSPORT ...................................................................................................................... 1-16 UNLOADING THE MACHINE FROM A TRAILER................................................................................ 1-17 MAINTENANCE AND ADJUSTMENTS................................................................................................ 1-18 PREVENTION OF FIRE OR EXPLOSIONS......................................................................................... 1-21 PREVENTION OF BURNS ................................................................................................................... 1-22 PRECAUTIONS FOR WASTE DISPOSAL........................................................................................... 1-23 MAIN COMPONENTS ............................................................................................................................. 1-24 COMPONENTS IDENTIFICATION PLATES........................................................................................... 1-27 MACHINE ............................................................................................................................................. 1-27 ENGINE ................................................................................................................................................ 1-27 CAB ...................................................................................................................................................... 1-28 CE-MARK ............................................................................................................................................. 1-28 PUMP ................................................................................................................................................... 1-29 AXLES .................................................................................................................................................. 1-29 CONTROL VALVE................................................................................................................................ 1-29 DECALS................................................................................................................................................... 1-30 NOISE LEVEL DECAL ......................................................................................................................... 1-30 POSITION OF DECALS ....................................................................................................................... 1-31 HAND SIGNALS ...................................................................................................................................... 1-38

SECTION 2 CONTROLS AND INSTRUMENTS .............................................................................................................. 2-1 SWITCHES AND PUSH-BUTTONS .......................................................................................................... 2-1 “BUZZER”: ACOUSTIC WARNING SIGNAL .......................................................................................... 2-7 CONTROLS AND PEDALS ....................................................................................................................... 2-9 MULTI-FUNCTION DISPLAY .................................................................................................................. 2-12 OPERATING MODE ............................................................................................................................. 2-18 MAIN MENU ......................................................................................................................................... 2-19 CONDITIONS OF USE ......................................................................................................................... 2-20 DISPLAY SETTING, MAIN MENU........................................................................................................ 2-21 CONTRAST .......................................................................................................................................... 2-22

INDEX BRIGHTNESS ...................................................................................................................................... 2-23 TIME ..................................................................................................................................................... 2-24 UNITS ................................................................................................................................................... 2-27 SYMBOLS ............................................................................................................................................ 2-29 STARTER SWITCH ................................................................................................................................. 2-30 RADIO ..................................................................................................................................................... 2-32 CAB ......................................................................................................................................................... 2-33 ENTRY AND EXIT ................................................................................................................................ 2-33 DOOR OPENING ................................................................................................................................. 2-34 DOOR CLOSING .................................................................................................................................. 2-34 SIDE WINDOW..................................................................................................................................... 2-35 FRONT WINDOW................................................................................................................................. 2-35 EMERGENCY EXIT.............................................................................................................................. 2-36 WINDSCREEN WIPER AND WASHER ............................................................................................... 2-37 FLOODLAMPS ..................................................................................................................................... 2-37 DOCUMENTS STORAGE BOX, FIRST-AID KIT, WARNING TRIANGLE AND FIRE-EXTINGUISHER ......................................................................................................................... 2-38 SUNBLIND............................................................................................................................................ 2-38 CAB LIGHTING .................................................................................................................................... 2-39 AUXILIARY SOCKET ........................................................................................................................... 2-40 STEERING COLUMN........................................................................................................................... 2-41 VENTILATION, HEATING AND AIR CONDITIONING (OPTIONAL)....................................................... 2-42 VENTILATION (air from outside) .......................................................................................................... 2-42 HEATING.............................................................................................................................................. 2-44 AIR CONDITIONING (OPTIONAL)....................................................................................................... 2-45 SERVICE AND PARKING BRAKES........................................................................................................ 2-47 SERVICE BRAKE................................................................................................................................. 2-47 PARKING BRAKE ................................................................................................................................ 2-48 OPERATOR’S SEAT ............................................................................................................................... 2-49 OPERATOR’S SEAT WITH PNEUMATIC SUSPENSION ................................................................... 2-49 SEAT BELT ............................................................................................................................................. 2-54

SECTION 3 OPERATING THE MACHINE....................................................................................................................... 3-1 GENERAL INSTRUCTIONS...................................................................................................................... 3-1 BEFORE OPERATING THE MACHINE ................................................................................................. 3-1 OPERATING THE MACHINE ................................................................................................................. 3-1 RUNNING-IN PERIOD ........................................................................................................................... 3-2 AFTER DAILY OPERATION - PARKING ............................................................................................... 3-3 START-UP ................................................................................................................................................. 3-4 START-UP IMMOBILIZER ..................................................................................................................... 3-4 START-UP.............................................................................................................................................. 3-9 ENGINE SHUT OFF ............................................................................................................................. 3-12 CAB AT VARIABLE HEIGHT................................................................................................................... 3-13 OPERATION......................................................................................................................................... 3-13 EMERGENCY LOWERING .................................................................................................................. 3-15 TRAVEL ................................................................................................................................................... 3-16 BEFORE STARTING THE TRAVEL..................................................................................................... 3-16 BASIC POSITION................................................................................................................................. 3-16

INDEX BASIC SETTING .................................................................................................................................. 3-18 TRAVEL ................................................................................................................................................ 3-20 GEARBOX - GEAR CHANGE .............................................................................................................. 3-23 TRAVEL WITH LOAD APPLIED TO CRANING HOOK........................................................................ 3-25 FLOATING AXLE BLOCKING AND UNBLOCKING............................................................................. 3-26 WORKING OPERATION ......................................................................................................................... 3-27 SAFETY INSTRUCTIONS .................................................................................................................... 3-27 BEFORE BEGINNING THE WORK...................................................................................................... 3-28 HOLDING AND RELEASING THE UPPER STRUCTURE SLEW ....................................................... 3-33 POWER BOOST FUNCTION - POWER BOOST................................................................................. 3-39 LEVELLING MODE .............................................................................................................................. 3-41 HYDRAULIC DAMPING ....................................................................................................................... 3-43 STABILIZATION OF THE MACHINE.................................................................................................... 3-45 OPERATING THE MACHINE WITH COLD WEATHER.......................................................................... 3-48 COLD START - PREHEATING............................................................................................................. 3-49 OPERATING THE MACHINE WITH HOT WEATHER ............................................................................ 3-51 MACHINE RECOVERY AND TOWING................................................................................................... 3-52 SECURE THE MACHINE ..................................................................................................................... 3-53 WORKING ATTACHMENT...................................................................................................................... 3-56 CLAMSHELL BUCKET OPERATION................................................................................................... 3-57

SECTION 4 SUPPLIES AND MAINTENANCE CHART .................................................................................................. 4-1 SUPPLIES AND MAINTENANCE CHART ................................................................................................ 4-1 FUEL....................................................................................................................................................... 4-2 HYDRAULIC OIL .................................................................................................................................... 4-3 SAFETY INSTRUCTIONS ......................................................................................................................... 4-5 WORKING HOURS / INTERVALS ............................................................................................................ 4-6 MAINTENANCE INTERVALS CHART ...................................................................................................... 4-7 CHECKS BEFORE START-UP AND BEFORE EACH WORKING SHIFT (10 HOURS) ........................ 4-10 MACHINE GENERAL INSPECTION .................................................................................................... 4-10 SERVICE BRAKE ................................................................................................................................. 4-11 PARKING BRAKE ................................................................................................................................ 4-11 UPPER STRUCTURE HOLDING BRAKE............................................................................................ 4-12 LIGHTS ................................................................................................................................................. 4-12 CONTROLS AND LAMPS OPERATION .............................................................................................. 4-12 ENGINE OIL - LEVEL ........................................................................................................................... 4-13 HYDRAULIC OIL TANK - LEVEL ......................................................................................................... 4-13 FUEL TANK - LEVEL............................................................................................................................ 4-15 COOLING SYSTEM LIQUID - LEVEL .................................................................................................. 4-17 SCREEN WASHER LIQUID - LEVEL................................................................................................... 4-19 WORKING ATTACHMENT - GREASING............................................................................................. 4-20 TYRES - PRESSURE CHECK ............................................................................................................. 4-22 TYRES - NUTS TIGHTENING.............................................................................................................. 4-24 WEEKLY SERVICE (50 HOURS)............................................................................................................ 4-25 CAB AIR FILTER - CLEANING............................................................................................................. 4-25 CAB RAISING....................................................................................................................................... 4-26 AIR FILTER - CLEANING ..................................................................................................................... 4-26 AIR INTAKE LINE - CHECK ................................................................................................................. 4-28

INDEX MULTI-COOLER - CLEANING ............................................................................................................. 4-29 FUEL SYSTEM - AIR BLEEDING AND WATER DRAINING ............................................................... 4-30 SLEWING GEARBOX - OIL LEVEL ..................................................................................................... 4-32 BATTERIES - LEVEL - CHARGE CHECK AND CLAMPS TIGHTENING............................................ 4-33 SLEWING BEARING CUPS AND AXLE FLOATING PINS - GREASING............................................ 4-36 MONTHLY SERVICE (250 HOURS) ....................................................................................................... 4-37 ENGINE OIL FILTER - CHANGE ......................................................................................................... 4-37 FUEL FILTER/S - CHANGE ................................................................................................................. 4-38 HYDRAULIC OIL RETURN FILTER - CHANGE .................................................................................. 4-39 STEERING AXLE - OIL LEVEL ............................................................................................................ 4-40 TRAVEL GEARBOXES - OIL LEVEL ................................................................................................... 4-41 RIGID AXLE AND GEARBOX - OIL LEVEL ......................................................................................... 4-42 AIR CONDITIONING SYSTEM ............................................................................................................ 4-43 BLADE AND STABILIZERS JOINTS, CARDAN SHAFT, STEERING TRUNNION PINS GREASING........................................................................................................................................... 4-44 FLOATING AXLE LOCKING CYLINDERS CONTACT FACES - LUBRICATION ................................ 4-45 SERVICE EVERY 12 MONTHS (500 HOURS) ....................................................................................... 4-46 ENGINE REVOLUTIONS SENSOR - CLEANING ............................................................................... 4-46 DRIVE BELTS - CHECK....................................................................................................................... 4-47 ENGINE OIL - CHANGE....................................................................................................................... 4-48 SLEWING BEARING - SCREW TIGHTENING CHECK....................................................................... 4-49 SLEWING BEARING TEETH - GREASING ......................................................................................... 4-50 SLEWING GEARBOX - SCREWS TIGHTENING CHECK................................................................... 4-50 SERVICE AFTER 1000 HOURS ............................................................................................................. 4-51 CAB AIR FILTER - CHANGE ............................................................................................................... 4-51 WINDSCREEN BLADES - CHANGE ................................................................................................... 4-51 ENGINE BRACKETS - SCREWS TIGHTENING CHECK .................................................................... 4-52 ENGINE BELT TENSIONER - CHECK ................................................................................................ 4-52 AIR FILTER - REPLACEMENT OF MAIN FILTER ELEMENT AND OF SAFETY ELEMENT............................................................................................................................................. 4-53 HYDRAULIC SYSTEM BLEEDING VALVE - CHANGE ....................................................................... 4-54 STEERING AXLE - OIL CHANGE........................................................................................................ 4-54 RIGID AXLE AND GEARBOX - OIL CHANGE ..................................................................................... 4-56 SERVICE BRAKE - PLATES CHECK .................................................................................................. 4-58 PILOT CONTROL FILTER - CHANGE ................................................................................................. 4-59 COUNTERWEIGHT - SCREW TIGHTENING CHECK ........................................................................ 4-59 AIR CONDITIONING SYSTEM - CLEANING AND OPERATION CHECK - COMPRESSOR BELT CHANGE .................................................................................................................................... 4-60 SERVICE AFTER 3000 HOURS ............................................................................................................. 4-64 HYDRAULIC OIL TANK - CLEANING AND OIL CHANGE .................................................................. 4-64 HYDRAULIC SYSTEM - AIR BLEEDING ............................................................................................. 4-67 ENGINE - CHECK AND ADJUSTMENT OF VALVES CLEARANCE .................................................. 4-67 COOLING SYSTEM LIQUID - CHANGE .............................................................................................. 4-68 FUEL TANK - CLEANING .................................................................................................................... 4-69 SLEWING GEARBOX - OIL CHANGE ................................................................................................. 4-70 SERVICE WHEN NECESSARY .............................................................................................................. 4-71 MACHINE - CLEANING........................................................................................................................ 4-71 WINDSCREEN WIPER - CHECK AND CLEANING............................................................................. 4-73 DRIVE BELT - CHANGE ...................................................................................................................... 4-73 INJECTORS - REPLACEMENT ........................................................................................................... 4-74 HYDRAULIC SYSTEM AND TANK - PRESSURE RELEASE ............................................................. 4-74

INDEX TYRES - CHANGE ............................................................................................................................... 4-76 SERVICE BRAKE - AIR BLEEDING..................................................................................................... 4-78 STEERING ADJUSTMENT .................................................................................................................. 4-78 AXLE FLOATING LOCKING CYLINDERS - AIR BLEEDING............................................................... 4-79 FUSES - REPLACEMENT.................................................................................................................... 4-80 BULBS - REPLACEMENT .................................................................................................................... 4-83 BATTERIES - REPLACEMENT............................................................................................................ 4-87 CLAMSHELL - WEAR CHECK ............................................................................................................. 4-88

SECTION 5 TROUBLESHOOTING ................................................................................................................................. 5-1 ERRORS INDICATION ON THE DISPLAY ............................................................................................ 5-2 ENGINE ..................................................................................................................................................... 5-3 STEERING SYSTEM................................................................................................................................. 5-6 BRAKES SYSTEM..................................................................................................................................... 5-7 SERVICE BRAKE ................................................................................................................................... 5-7 PARKING BRAKE .................................................................................................................................. 5-7 HYDRAULIC SYSTEM .............................................................................................................................. 5-8 TRAVEL ................................................................................................................................................... 5-10 SLEWING ................................................................................................................................................ 5-11 FLOATING AXLE BLOCKING ................................................................................................................. 5-12 STABILIZERS .......................................................................................................................................... 5-13 CLAMSHELL BUCKET ............................................................................................................................ 5-15 AXLES ..................................................................................................................................................... 5-16 CENTRALIZED LUBRICATION PUMP ................................................................................................... 5-18 HEATING/AIR CONDITIONING SYSTEM............................................................................................... 5-20 SYSTEM ............................................................................................................................................... 5-20 COOLING SYSTEM ............................................................................................................................. 5-21 BLOWER .............................................................................................................................................. 5-22

SECTION 6 STORAGE .................................................................................................................................................... 6-1 MACHINE STORAGE............................................................................................................................. 6-1 ENGINE STORAGE ............................................................................................................................... 6-1 BATTERIES STORAGE ......................................................................................................................... 6-2 RECOMMISSIONING THE MACHINE AFTER PROLONGED STORAGE............................................ 6-2 DECOMMISSIONING OF THE MACHINE ............................................................................................. 6-3

SECTION 7 ATTACHMENTS........................................................................................................................................... 7-1 CLAMSHELL BUCKET .............................................................................................................................. 7-1 SAFETY INSTRUCTIONS ...................................................................................................................... 7-1 CLAMSHELL BUCKET ASSEMBLY....................................................................................................... 7-1 CLAMSHELL BUCKET DISASSEMBLY................................................................................................. 7-3 PARAMETERS SETTING ...................................................................................................................... 7-4 SWITCHING OVER FROM STANDARD TO CLAMSHELL BUCKET.................................................... 7-4 CRANING HOOK....................................................................................................................................... 7-6

INDEX SAFETY INSTRUCTIONS...................................................................................................................... 7-6 USE OF THE CRANING HOOK ............................................................................................................. 7-6 OVERLOAD WARNING SYSTEM............................................................................................................. 7-7 “MOZELT” MAGNET.................................................................................................................................. 7-9 SAFETY INSTRUCTIONS...................................................................................................................... 7-9 SYSTEM ............................................................................................................................................... 7-10 OPERATION......................................................................................................................................... 7-12 DISPLAY............................................................................................................................................... 7-13 BREAK PROTECTION VALVES ............................................................................................................. 7-16 REAR FLOODLAMPS ............................................................................................................................. 7-17 ROTARY LIGHT ...................................................................................................................................... 7-18 SINGLE LIGHT ..................................................................................................................................... 7-18 DOUBLE LIGHT ................................................................................................................................... 7-18 SWITCHING ON AND OFF .................................................................................................................. 7-18 FUEL TRANSFER PUMP ........................................................................................................................ 7-19 CAB PROTECTIONS............................................................................................................................... 7-20 CENTRALIZED LUBRICATION............................................................................................................... 7-21 SAFETY INSTRUCTIONS.................................................................................................................... 7-21 OPERATION......................................................................................................................................... 7-21 MANUAL FILLING PUMP..................................................................................................................... 7-24 MOTORIZED FILLING PUMP .............................................................................................................. 7-25

SECTION 8 DATA AND TECHNICAL SPECIFICATIONS .............................................................................................. 8-1 DIMENSIONS - OPERATING WEIGHTS .................................................................................................. 8-1 WX 210 Industry MODELS ..................................................................................................................... 8-1 WX 240 Industry MODELS ..................................................................................................................... 8-2 DIGGING PERFORMANCE ...................................................................................................................... 8-3 WX 210 Industry MODELS ..................................................................................................................... 8-3 WX 240 Industry MODELS ..................................................................................................................... 8-4 LIFTING CAPACITIES............................................................................................................................... 8-5 WX 210 Industry MODELS ..................................................................................................................... 8-5 WX 240 Industry MODELS ..................................................................................................................... 8-6 HYDRAULIC SYSTEM .............................................................................................................................. 8-7 PUMPS ................................................................................................................................................... 8-7 CYLINDERS (ø for stroke)...................................................................................................................... 8-7 SLEWING .................................................................................................................................................. 8-7 TRAVEL ..................................................................................................................................................... 8-7 TYRES.................................................................................................................................................... 8-8 BRAKES .................................................................................................................................................... 8-8 STEERING................................................................................................................................................. 8-8 POWER STEERING............................................................................................................................... 8-8 ELECTRICAL SYSTEM ............................................................................................................................. 8-9 TIGHTENING TORQUES .......................................................................................................................... 8-9

INDEX CENTRALIZED LUBRICATION PUMP (OPTIONAL)................................................................................ 8-9 FUEL SYSTEM .......................................................................................................................................... 8-9 ENGINE ................................................................................................................................................... 8-10

SECTION 9 ALPHABETICAL INDEX .............................................................................................................................. 9-1

INDEX

SECTION 1 INTRODUCTION, SAFETY, PLATES AND DECALS FOREWORD The current Operator’s Manual is the user’s guide for correct run-in, use and maintenance of the machine.

Carefully read this Operator’s Manual and store it in the cab for quick location and reference.

Instructions concerning safety, operation and maintenance have been developed to permit safe service and operation of this machine.

In the event of queries or suggestions relevant to your machine do not hesitate to address to your Dealer. Dealers have qualified and trained personnel at disposal as well as Original Spares, means and equipment suitable to carry out all necessary maintenance.

Do not use this machine for any applications or purposes other than those described in this Manual. If you use this machine for duties involving the use of attachments, accessories, or special tools, consult your Dealer to make sure that the adaptations or modifications carried out are in conformity with the machine’s technical specifications and with current regulations on safety.

SPARE PARTS The “non-genuine” spare parts have not been controlled and authorized by the Manufacturer. The assembly and/or use of such products may have negative effects on the machine design features and could impair its operation safety. The Manufacturer is not liable for any damage caused by “nongenuine” spare parts or accessories.

WARRANTY This machine is under warranty according to the regulations in force in Your Country and in compliance with the sales agreement drawn up with the Dealer. The warranty, however, expires if the operation and maintenance instruction for this machine and contained in this manual, have not been followed.

Any modifications or adaptations which are not approved by the Manufacturer may invalidate the machine’s original conformity with safety requirements.

Before entrusting this machine to an operator, make sure that: - the operator has received necessary training on how to operate the machine correctly and safely in one of our Training Centres or from an approved organization; - the operator has read and fully understood the instructions given in this Manual.

Consult your Dealer to obtain extra manuals or manuals in other languages.

Your Dealer is at your disposal for any further information.

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SECTION 1

SAFETY INSTRUCTIONS GENERAL SAFETY INSTRUCTIONS Carefully read the safety rules contained herein and follow advised precautions to avoid potential hazards and to safeguard your safety and personal integrity.

In this manual you will find the following indications:

WARNING This symbol warns about the possibility of potential damages to the machine that can involve the operator’s safety.

DANGER With specific warnings about potential dangers for the operator’s or other persons integrity directly or indirectly involved.

The non compliance with the warning preceded by the above mentioned key-words (WARNING and DANGER) can cause serious accidents or even the death of the persons involved.

Moreover in the present Manual have been given some instructions with texts in italics, preceded by the words NOTE and CAUTION: NOTE: it emphasizes and underlines to the operator the correct technique or correct procedure to follow.

CAUTION It warns the operator of a possible hazard of machine damage in case he does not follow a determined procedure.

Your safety and that of people around you depends on you. It is essential that you understand this manual for the correct operation, inspection, lubrication and maintenance of this machine.

Pay particular attention to the “Fundamental safety instructions” and to all warnings and safety instructions attached to the machine.

Familiarize yourself with the machine operation and the operating patterns of the control elements prior to starting up the machine.

The operators must be fully informed about the operation and application of this or comparable machines.

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The safety messages in this section concern situations which may arise during normal machine operation and servicing. These safety messages also indicate the different ways of coping with these situations. Other safety messages are used throughout the manual to indicate specific dangers.

Always keep this manual in the storage compartment provided for it. Make sure that it is always complete and in good condition. Consult your Dealer to obtain extra manuals.

INTRODUCTION, SAFETY, PLATES AND DECALS DESIGNATED USE The machine has been built in accordance with state-of-the-art standards and the recognized safety rules. Nevertheless, its use may constitute a risk to life and limb for the user or third parties or cause damage to the machine and to other material property.

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.

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DANGER Using the excavator or its attachments for purposes other than those stated above, e.g.: - for lifting or transporting persons; - as a working platform; - for lifting crane loads without the attachment being approved for this purpose; - for pulling slung loads; - for driving in posts, supports, sheet-piles, without the attachment being approved for this purpose; is considered contrary to the designated use.

Improper use may involve a life-threatening risk for operators or other personnel or may cause injury or extensive damage.

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.

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SECTION 1 NOISE LEVELS Sound power level (acoustic external) LWA: WX 210 Industry 103 dB (A)

and

WX 240 Industry

models:

Sound power level guaranteed, determined in compliance with European standard 2000/14/EC. Sound pressure level in the operator’s seat (acoustic internal) LpA: WX 210 Industry models: 78 dB (A) WX 240 Industry models: 80 dB (A) Sound pressure level continuous, measured inside of cabin with door and windows closed and with the heater/air conditioner blower operating at 2nd speed, measured on an identical machine, in compliance with ISO 6396:1992 Standard.

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2

INTRODUCTION, SAFETY, PLATES AND DECALS LEVEL OF VIBRATIONS TRANSMITTED TO THE OPERATOR The vibration level to the operator depends mainly on the conditions of the ground where the machine is being operated and on the use conditions of the machine and its equipment.

The exposition to vibrations can be remarkably reduced if the recommendations here below are followed: - use equipment suitable for the machine and the type of work to be carried out; - adjust and lock the seat in the correct position; regularly check for the seat suspensions and carry out adjustments or maintenance as required; - carry out regularly the ordinary maintenance of the machine at scheduled intervals;

3

- operate the attachment evenly, avoiding sudden motion or extreme shocks, if possible; - avoid, as far as possible, to travel on particularly uneven soils or the impact with possible obstacles.

This machine is equipped with an operator’s seat in compliance with ISO 7096: 2000 standard.

This guarantees that the operator’s body exposures to vibrations respect the requirements for protection against vibrations when the machine is used according to its destination as explained in this manual.

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

The weighted average acceleration value to which the operator’s body is subjected does not exceed 0.5 m/s2 (1.64 ft/s2). These results have been obtained by using an acceleration gauge during the ditches excavation works.

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SECTION 1 BEFORE OPERATING THE MACHINE Read and assimilate the instructions and warnings shown in this manual before operating the machine.

The presence of grease, oil, mud or (in winter) ice on the steps and access handles can cause accidents. Make sure they are always clean.

Remove anything which might hinder visibility.

Clean the windshield, windows and rear view mirrors.

Before travelling or working at night, check that the lighting and signalling systems are operating correctly.

Make sure the doors and the engine guard are correctly fastened before undertaking any travel.

4

Make sure that no loose object or tool is left on the machine or in the operator’s compartment.

DANGER The operator should be the only person on the machine. Make sure there is nobody on or near the machine.

When mounting or dismounting from the machine always face the machine and use the steps and access handles on the left-hand side of the machine.

Wear close fitting clothing and safety equipment appropriate for the job.

It is necessary to have at disposal: - safety helmet; - safety shoes; - safety goggles, or face shield; - heavy gloves; - hearing protection; - reflective clothing; - wet weather clothing; - respirator or filter mask.

Wear close fitting clothing and safety equipment appropriate for the job. Do not leave anything to the case. Avoid wearing loose clothing, jewelry, or other items that can catch on control levers or other parts of the machine.

To operate the machine in full safety, the operator should be completely careful. Do not wear radio or music headphones while operating machine.

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5

INTRODUCTION, SAFETY, PLATES AND DECALS 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.

6 SEAT BELT On machines with a seat belt for operator’s safety: - check the seat belt attached to the operator’s seat. In the event of damage or after an accident, have it replaced immediately; - fasten seat belt before starting to work.

7 WARM-UP INSTRUCTIONS In the event of low temperatures, the engine must undergo the warm-up phase. The engine can be run at full speed only at the end of the warm-up phase.

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SECTION 1 OPERATING THE MACHINE USE HANDHOLDS AND STEPS Falling is one of the major causes of personal injury.

When you get on and off the machine, always maintain a three-point contact with the steps and handrails and face the machine.

Do not use any controls as hand-holds.

Never jump on or off the machine.

Never mount or dismount a moving machine.

Be careful of slippery conditions on platforms, steps, and handrails when leaving the machine.

8 ADJUST THE SEAT A seat poorly adjusted for operator or work requirements may quickly fatigue the operator leading to improper operations.

The seat should be adjusted whenever machine operator changes.

The operator should be able to fully press the pedals and correctly move the control levers with his back resting against the seat back.

If not, move the seat fore and aft, and check again.

9 DON’T CARRY RIDERS ON THE MACHINE Riders on the machine are subject to injuries such as being struck by foreign objects and being thrown off the machine.

Only machine operator is allowed on the machine.

Riders are not allowed.

Riders also obstruct the operator’s visibility, resulting in the machine being operated unsafely.

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INTRODUCTION, SAFETY, PLATES AND DECALS AVOID INJURY FROM REVERSE TRAVEL AND SWING ACCIDENTS If someone stands near the machine when this is swinging or in reverse travel, the same can hit or run over this person causing heavy injuries or even death.

To avoid accidents due to swinging or reverse travel check the area around the machine. Before reverse travel or swinging the machine, make sure that nobody is staying within its working reach.

Always pay attention for the presence of people within the working area. Use horn or other signals to warn bystanders before starting machine.

10 Take advantage of a person that watches the reverse travel if visibility is hindered. Always keep signalling person in view.

Use manual signals, according to local rules, if working condition require a flagman.

No motions shall be made unless signals are clearly understood by both signalman and operator.

Learn the meaning of all flags, signs, and markings used on the job and confirm who has the responsibility for signalling.

Keep windows, mirrors, and lights clean and in good condition.

Dust, heavy rain, fog, etc., can reduce visibility. As visibility decreases, reduce speed and use proper lighting.

11

Read and understand all operation instructions given in this manual.

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SECTION 1 TRAVEL BEFORE SETTING OFF Remove any soil, mud, snow, ice, grease and oil from your working footwear before operating the machine. You might otherwise slip from steps and pedals and thus initiate inadvertent movements.

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

Close the front window and the cab door.

Warn persons in the immediate vicinity by sounding the horn before setting off.

Never allow anyone to climb onto the machine.

SELECTING THE TRAVEL DIRECTION The specifications “forward” and “reverse” as well as “right” and “left” apply only when the machine is in basic position and the machine operator is looking through the front window towards the working attachment.

If the upper structure is turned more than 90° from the basic position, the machine moves in the opposite direction from the viewing direction of the operator.

Therefore check the position of the upper structure in relation to the undercarriage before setting off.

REVERSE TRAVEL

12

During reverse travel the view of the hazard zone is restricted. Therefore enlist the help of experienced flagman. Come to an agreement with the flagman to ensure that you interpret his signals correctly.

13

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INTRODUCTION, SAFETY, PLATES AND DECALS TRAVELLING OVER LONG DISTANCES Before travelling over long distances: - return the machine to basic position; - activate the upper structure holding brake in automatic mode.

The machine is then in basic position.

Before driving on public highway, familiarize yourself with local laws and the regulations in force.

Read and observe meticulously the instructions provided under “travelling on public roads” page 1-12.

TRAVELLING ON SLOPES Never drive across slopes or turn the machine on a slope.

The machine may slip or overturn.

Take special care on slippery soils.

Ensure that the tyres offer adequate grip. Only then are the steering and braking properties of the machine maintained.

TAKING A BEND Reduce the machine speed while taking a bend. If the speed is too high and the steering wheel is wrenched round, there is a risk of the machine overturning (due to a wheel of the rigid axle being lifted off the ground). Extremely hard braking while taking a bend may also cause the machine to overturn.

14

DO NOT TOW ANOTHER VEHICLE The machine is not suitable for towing trailers or other vehicles; this would result in damage to the axles and gearbox.

The towing fixture is provided solely for towing or recovery the machine from hazard areas or for lashing purposes on transport vehicles.

1-11

SECTION 1 TRAVELLING ON PUBLIC ROADS

WARNING Transfer on public roads of WX 210 Industry and WX 240 Industry excavators is prohibited.

JOB SITE OPERATION INVESTIGATE JOB SITE BEFOREHAND Clear all persons from area of operation and machine movement. Make sure worksite footing has sufficient strength to firmly support the machine.

15 CAB AT VARIABLE HEIGHT The cab at hydraulically variable height is used to elevate the control position of the machine.

The cab with hydraulic raising and lowering adjustment, works on the principle of the parallelogram.

By means of this system, the cab can move upwards and forwards in a circular motion, to give the operator a better view of the working site.

It is not allowed to move the machine with the raised cabin!

Lift and lower the cab exclusively if the environment conditions allow this.

16 During the raising stage and when the cab is already raised, a section of the hydraulic system is under pressure.

During the raising, the cab can move up to a maximum of 1 m (3.28 ft) forward and of 2.5 m (8.20 ft) in height. Pay therefore particular attention during slewing.

Never lift, nor lower the cab, if persons or other obstacles are staying within the hazard area of lifting or upper structure slewing.

When moving the machine pay attention to cab at variable height, the height raising system protrudes beyond the same cab.

1-12

17

INTRODUCTION, SAFETY, PLATES AND DECALS AVOID ELECTRIC LINES Serious injury or death can result if the machine or front attachments are not kept a safe distance from electric lines.

When operating near an electric line, never move any part of the machine or load closer than 3 m (9.84 ft) plus twice the line insulators length (L).

Check and comply with any local regulations that may apply.

Ground dampness increases the area on which people might be affected by electric shocks.

Keep all bystanders or co-workers away from the site.

18

BEWARE OF EXHAUST FUMES Engine exhaust fumes can cause sickness or death.

If you must operate in closed buildings, be sure there is adequate ventilation.

Use an extension to eliminate exhaust gases or open doors and windows to ensure a sufficient air exchange.

1-13

SECTION 1 PARKING THE MACHINE Park machine on flat and firm surface.

Return the machine to basic position.

Make sure that the cab is placed to its lowest position.

Lock the upper structure.

Place the attachment down on the ground.

Engage the parking brake.

Shut off the engine.

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

19

Place chocks under the wheels.

Set ignition key (1) to position “0” and pull it out.

Ignition key (1) is set to “P”. With key in this position, some electrical users are still under voltage, also with engine shut off.

If these users remain under voltage for a long time, the batteries may discharge and prevent a engine start-up.

Because of this, pay attention that the ignition key is always set to position “0”, before leaving the machine parked for long time (for instance at work shift end).

20

CAUTION With special attachment, move both hydraulic control levers (2) and the pedal (3) in all directions, to allow all cylinders to release pressure.

Disconnect the pilot control.

21

1-14

INTRODUCTION, SAFETY, PLATES AND DECALS LOADING THE MACHINE ON A TRAILER Travel in reverse along the ramp as shown.

Machine centre of gravity should correspond to the trailer centre of gravity.

Stop the engine and pull out the ignition key.

Cycle the hydraulic control levers to relieve any residual hydraulic pressure from the booms driving cylinders.

Move the safety lever to end of travel to the vertical lock position.

Close all windows, front windscreens, and cab door.

Cover the exhaust pipe to prevent water or dirt from entering.

22

Secure the machine to the trailer correctly, so as to prevent dangerous movements, proceed as follows: - lock the machine frame to the trailer flatbed by means of chains or metal cables of suitable size, avoid to involve metal cables or chains and panelling; - lock wheels by placing wedges (chocks) under them; - lock the front attachment (if installed) to the flatbed using chains or metal cables of suitable size.

1-15

SECTION 1 MACHINE TRANSPORT IMPORTANT: during the machine transport, the cab must be in its lowest position.

In case of transport on public roads, ask for relevant permissions to competent authorities.

In case of transport by railway, ask for permission and agree the loading and transport of the excavator with the competent railway authorities.

According to the trailer or railway wagon width, disassemble completely or partially the working attachment. Loading dimensions and weights have to be determined from section 8 “data and technical specifications”.

23

Pay the outmost attention while loading the machine on the trailer.

Enlist the help of someone.

Secure the machine from accidental movements.

Activate the parking brake by using the button (2).

Make sure that the cab is placed to its lowest position.

Pay attention to the machine transport dimensions, equipped with cab at hydraulically variable height.

Bear in mind that the height raising system protrudes beyond the cab.

Lock the upper structure by means of proper pin (3).

Lay the working attachment on the flatbed of the transporting vehicle.

Disconnect the pilot control with lever (1).

Shut off the engine.

24

In this way the upper structure holding brake engages automatically.

Remove the ignition key from the cylinder.

Close door and windows.

Place the chocks in front of the wheels.

Secure the machine properly, by anchoring chains to the points indicated on the machine by means of decals (4).

CAUTION Do not insert the chains in the steering cylinders or in the hydraulic hoses of the brake.

25

1-16

INTRODUCTION, SAFETY, PLATES AND DECALS UNLOADING THE MACHINE FROM A TRAILER Travel forward down the ramp.

26

1-17

SECTION 1 MAINTENANCE AND ADJUSTMENTS Do not carry out any service operation until you have read and understood the instructions and warnings given in this manual.

Observe the adjusting, maintenance and inspection activities and intervals set out in the operating instructions, including information on the replacement of parts and equipment as this service concerns exclusively the qualified personnel.

Wear safety equipment and suitable clothing to perform the machine maintenance.

During the service work apply a warning plate.

27 Always wear eye protection when using a tool which might project metal particles. Use a hammer with a soft face, such as copper, for installing pins.

Incorrectly performed maintenance or adjustments can cause serious injury. If you do not understand a maintenance or adjustment procedure, consult your Dealer.

If the attachment is raised or the machine moves with no operator on board, serious injury can result.

28 PRACTICE SAFE MAINTENANCE Understand service procedures before doing work.

Keep work area clean and dry.

Never lubricate or service the machine while it is moving.

Keep hands, feet and clothing from power-driven parts.

Before carrying out any maintenance operation park the machine safely on a flat surface.

If maintenance procedure must be performed with engine running, do not leave machine unattended.

29

1-18

INTRODUCTION, SAFETY, PLATES AND DECALS PROTECT AGAINST NOISE Prolonged exposure to loud noise can cause impairment or loss of hearing.

Wear a suitable hearing protective device such as earmuffs or earplugs to protect against constant or uncomfortably loud noise.

30 AVOID HIGH PRESSURE FLUIDS Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines.

Relieve the pressure by moving the hydraulic control levers several times. Tighten all connections before applying pressure. To protect the eyes wear a facial shield or safety goggles.

Search for leaks with a piece of cardboard; protect hands and body from high-pressure fluids.

If an accident occurs, see a doctor familiar with this type of injury immediately.

Any fluid penetrating the skin must be removed within few hours to avoid serious infections.

Hydraulic fluid or grease under pressure which penetrates the skin can cause serious injury. Take the necessary safety precautions (protective clothing and face and hand protection) to prevent all such risks. In addition, before handling these products, read the manufacturer’s specific instructions for their use.

When carrying out a welding operation on the machine, as authorized by the Manufacturer and in accordance with his specifications, disconnect the alternator plug and connect the welding set earth lead to the component on which the welding is to be carried out. Never connect the earth lead to a hydraulic system component.

31

32

Escaping oil pollutes the environment.

Have leaks repaired immediately.

Discard oil, rags or dirty paper in a proper way.

1-19

SECTION 1 CHECK TYRES A burst tyre can cause serious injury. Regularly check the condition of tyres and always observe the inflation pressures defined in accordance with the type of tyre and ground concerned.

When checking tyre pressures or during an inflation operation, never stay facing the tyre but always facing the tread surface. Always use an inflation cage when the wheel is removed from the machine. Keep all other persons away from the area.

Never weld near a tyre. It is essential to remove the tyre before any welding operation.

Take the necessary safety measures to protect your face when using compressed air.

1-20

33

INTRODUCTION, SAFETY, PLATES AND DECALS PREVENTION OF FIRE OR EXPLOSIONS Engine fuel can cause an explosion or a fire.

Never refuel when the engine is running.

Do not smoke during re-fuelling.

Take all the necessary safety measures when welding, grinding or when working near a naked flame.

Use a non-inflammable product for cleaning parts.

34 A spark or flame can cause the hydrogen in a battery to explode. To prevent any risk of explosion, observe the following instructions: - when disconnecting the battery cables, always disconnect the negative (-) cable first; - to reconnect the battery cables, always connect the negative (-) cable last; - never short-circuit the battery clamps with metal objects; - do not weld, grind or smoke near a battery.

Always store batteries in a safe place, out of the reach of children.

35

The electrical system or the engine exhaust may produce sparks. Before using the machine in an area which may contain inflammable vapours, ensure that there is good ventilation.

Always keep a fire extinguisher available on the machine. Make sure that it is properly maintained in conformity with the manufacturer’s instructions.

Clean the machine regularly, remove all debris and material which may catch fire.

Check for leaks. Replace damaged hoses, pipes and unions. Clean the machine after any repair work before operating it.

36

1-21

SECTION 1 PREVENTION OF BURNS Battery electrolyte causes severe burns. The battery contains sulphuric acid. Avoid any contact with the skin, eyes or clothing.

Antidote: - EXTERNAL: rinse well with water, removing any soiled clothing.

- INTERNAL: avoid vomiting. Drink water to rinse your mouth. Consult a doctor.

- EYES: rinse abundantly with water for 15 minutes and consult a doctor.

- When the electrolyte of a battery is frozen, it can explode if you attempt to charge the battery or if you try to start the engine using a booster battery.

Always keep the battery charged to prevent the electrolyte freezing.

37

Batteries generate explosive gases. Keep all flames, sparks and cigarettes away. Provide good ventilation when changing a battery or using a battery in an enclosed space. Always protect your eyes when working near a battery.

38 Never touch the battery terminals with your hands.

This can induce a state of electrolysis and impair the main organs of the body.

Boiling coolant solution can spray out if the radiator cap is removed while the system is still hot. To remove the cap: allow the system to cool down, turn the cap to the first notch and wait until there is no more pressure. Then remove the cap.

39

1-22

INTRODUCTION, SAFETY, PLATES AND DECALS PRECAUTIONS FOR WASTE DISPOSAL Improperly disposing of waste can threaten the environment.

Each country has its own Regulations on this subject. It is therefore advisable to prepare suitable containers to collect and store momentarily all solid and fluid materials that must not be scattered in the environment to avoid pollution.

At preset intervals these products will be delivered to disposal stations legally recognized and present in this Country.

Hereunder are listed some products of the machine requiring disposal: - lubricating oil;

40

- brakes system oil; - coolant mixture, condensation rests and pure antifreeze; - diesel oil; - oil and diesel oil filter elements; - engine and air conditioning air cleaners elements; - battery.

Also polluting rags, paper, sawdust and gloves must be disposed in compliance with the same procedures.

Do not use food or beverage containers that may mislead someone into drinking from them. Do not pour waste onto the ground, down a drain, or into any water source. Air conditioning refrigerants escaping into the air can damage the Earth’s atmosphere. Government regulations may require a certified air conditioning service centre to recover and recycle used air conditioning refrigerants. Obtain information on the proper way to recycle or dispose of waste from your local environmental or recycling centre, or from your Dealer.

1-23

SECTION 1

MAIN COMPONENTS

41 1. Clamshell bucket

14. Batteries

2. (Industrial) handling boom

15. Cab raising device

3. Fuel transfer pump

16. Rear stabilizers

4. Handling boom cylinder

17. Rear wheels

5. Boom

18. Rear rigid axle

6. Boom cylinders

19. Stair and storage box

7. Fuel tank

20. Undercarriage

8. Hydraulic oil tank

21. Front wheels

9. Hydraulic pumps

22. Front steering axle

10. Muffler

23. Axle floating locking cylinders

11. Diesel engine

24. Upper structure

12. Counterweight

25. Cab

13. Multi-cooler

26. Front stabilizers

1-24

INTRODUCTION, SAFETY, PLATES AND DECALS UNDERCARRIAGE The undercarriage of the hydraulic excavator is used as a stable base and for travelling.

The undercarriage is moreover equipped with components permitting stabilization of the machine during working operations, such as the levelling blade and the stabilizers.

The machine is driven hydraulically by oil motors and travel gearboxes acting on both axles.

Undercarriage and upper structure are connected by a slewing ring.

UPPER STRUCTURE The upper structure accommodates the drive engine and part of the hydraulic and electrical systems.

The upper structure carries also the working attachment.

HYDRAULIC SYSTEM All travelling and working movements are executed hydraulically. The operational controls are activated by hand and are transmitted via control circuits. The oil flow between upper structure and undercarriage is ensured by the rotor. The hydraulic system is protected against possible overloads by the pressurerelief valves.

STEERING The machine is equipped with a hydrostatic power steering system, that is it can be steered by hand with increased force when the engine is not running or when the hydraulic steering pump has failed.

SERVICE BRAKE The service brake is composed of four multi-plate brakes integrated in the wheel hubs. The brake is operated hydraulically.

To ensure the braking function at all times, the braking system is equipped with hydraulic pressure accumulators, which are permanently monitored.

PARKING BRAKE The parking brake can be applied by blocking the brake plates with spring pressure.

The parking brake is incorporated in the gearbox. In this way it acts on all the wheels.

FLOATING AXLE The steered axle is a floating axle. It can be locked hydraulically during the digging operations with two cylinders.

1-25

SECTION 1 ELECTRICAL SYSTEM The electrical system operates on 24 V. An electronic voltage regulator supplies also 12 V. Electronic modules (Power Control System) ensure that the available engine power is converted in the best possible way into hydraulic performance.

WORKING ATTACHMENT The working attachment is composed of boom, handling boom and clamshell bucket or other equipment.

MACHINE SIDES The terms “right”, “left”, “front” and “rear”, when used in this manual, indicate the sides of the machine as seen from the operator’s seat.

1. Front side - forward 2. Rear side - backward 3. Right side 4. Left side

42

1-26

INTRODUCTION, SAFETY, PLATES AND DECALS

COMPONENTS IDENTIFICATION PLATES When ordering parts, requesting information or assistance, always give your Dealer the type and serial number of your machine and component concerned.

MACHINE The machine plate is attached frontally on the right side of the undercarriage.

1. Machine type 2. Serial number 3. Maximum admissible axle loads

43

ENGINE The plate with the engine number is attached on the engine crankcase at pumps side.

1. Model 2. Serial number

44

1-27

SECTION 1 CAB The plate is attached to the inner right cabin side on the upper beam.

1. Serial number

45

CE-MARK The CE-mark certifies that the machine has been built in conformity with the EC directives 89/392, 91/ 368, 93/44, 93/68 and 98/37.

46

1-28

INTRODUCTION, SAFETY, PLATES AND DECALS PUMP The plate is applied on the pump body.

1. Model 2. Serial number

47

AXLES The plate is applied on the axle body.

1. Model

48

CONTROL VALVE The plate is applied on the control valve.

1. Model 2. Serial number

49 1-29

SECTION 1

DECALS

WARNING An illegible or missing decal can have far-reaching consequences. Check them everyday.

WARNING Make sure that all decals are perfectly legible.

Clean them regularly, replace them with new decals if they are damaged, missing or painted over. If there is a decal on a part that is replaced, make sure you install a new decal on the new part.

NOTE: when you clean the decals, use only a cloth, water and soap. Do not use solvents, petrol, etc.

NOISE LEVEL DECAL EXTERNAL NOISE LEVEL This decal (1) shows the value in decibel of the external noise level LWA of machine as guaranteed by the Manufacturer. As per European Directive 2000/14/EC. WX 210 Industry 103 dB (A)

and

WX 240 Industry

models:

50

1-30

INTRODUCTION, SAFETY, PLATES AND DECALS POSITION OF DECALS

51

1-31

SECTION 1 Frontal stay dangerous Nobody must stay in front of machine during the working stages.

Danger of injuries caused by the working attachment in motion. Move the attachment only after ensuring that nobody is staying in the area of danger.

1

52 Dangerous work site stay Nobody must stay in proximity of the machine during the working stages.

Risk of injury from falling loads or moving parts of the working attachment. Do not stand under suspended loads or under the working attachment.

2

53 Slinging points These decals indicate the points of the machine where to attach the lifting devices, when parts of the machine are to be removed. Do not use other points.

3

54 Battery This decal shows that you have to refer to the Operator’s Manual.

Shut off the engine before disconnecting the battery.

4

55

1-32

INTRODUCTION, SAFETY, PLATES AND DECALS Slinging points This decal shows the slinging points for machine handling. Never use any other slinging points than those shown on this decal.

5

56 Hydraulic oil tank This decal indicates the hydraulic oil tank. Make sure that the tank indicated by this decal contains exclusively hydraulic oil.

6

57 Hydraulic oil tank Read this manual carefully to avoid the risk of oil under pressure inside of the tank in case of service.

7

58 Fuel tank This decal indicates the fuel tank. Make sure that the tank bearing this decal contains fuel only.

8

59 Operator’s Manual This decal shows the manual location. Read the manual carefully to ensure you operate the machine correctly.

9

60

1-33

SECTION 1 Danger electric current Risk of injury from electric current. Keep the following distances from live wires: up to 1000 V (1 kV) = 1 metre (3.28 ft), from 1 kV to 110 kV = 3 metres (9.84 ft), from 110 kV to 220 kV = 4 metres (13.12 ft), from 220 kV to 380 kV = 5 metres (16.40 ft), unknown voltage = 5 metres (16.40 ft).

10

61 Steering risk This decal refers only to the use of the steering. The steering works only when the engine is running, refer to the Operator’s Manual.

11

62 Oil level Check the oil level in the engine before setting the machine into operation.

12

63 Danger of staying behind This decal shows that the operator must not allow anyone to stay in the back of the machine when the engine is running.

Danger of injuries caused by the rotation of the upper structure or by the machine in motion. Move the upper structure or machine only after ensuring that nobody is staying in the area of danger.

13

64

1-34

INTRODUCTION, SAFETY, PLATES AND DECALS Danger for moving parts Risk of injury from hot or rotating parts in the engine compartment.

Open the engine hood only with engine shut off.

14

65 Parking brake Emergency operation for slewing drive and emergency brake.

Refer to the Operator’s Manual.

15

66 Unscrew the tank plug This decal indicates the need to open the plug before starting to refuel with the fuel pump. This in order to avoid overpressure and following abrupt fuel ejection.

16

67

1-35

SECTION 1 Hazard area of cab height adjustment Nobody must stay in the hazard area of the cab height adjustment.

17

Risk of injuries caused by the cab lowering.

Activate the cab raising and lowering only after ensuring that nobody is staying in the hazardous area.

68 Cab emergency lowering This decal shows the position of the tap for cab emergency lowering.

18

A. Lowered position

69

1-36

INTRODUCTION, SAFETY, PLATES AND DECALS Hazard area of cab height adjustment Nobody must stay in the hazard area of the cab height adjustment.

19

Risk of injuries caused by the cab lowering.

Activate the cab raising and lowering only after ensuring that nobody is staying in the hazardous area.

70 Maintenance in progress tag 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 tag must be located on the cab door.

20

71

1-37

SECTION 1

HAND SIGNALS When operating the machine, never attempt to carry out tasks calling for fine control or to work in areas where visibility is poor or during reverse travel, without seeking the assistance of a flag man. Make perfectly sure that you and the signalman understand the signals to be used. The flag man must always keep out from the machine working area.

The operator must always keep visual contact with the flag man; stop machine immediately if the contact is lost.

START THE ENGINE

MOVE AWAY FROM ME

72 STOP THE ENGINE

75 GO THIS FAR

73 COME TO ME

STOP ALL AND HOLD

74

1-38

76

77

INTRODUCTION, SAFETY, PLATES AND DECALS STOPPING

LOWER LOAD OR BUCKET

78 EMERGENCY STOP

81 RAISE LOAD OR BUCKET SLOWLY

79 RAISE LOAD OR BUCKET

82 LOWER LOAD OR BUCKET SLOWLY

80

83

1-39

SECTION 1 TURN MACHINE LEFT

DUMP THE BUCKET

84 TURN MACHINE RIGHT

85 FILL THE BUCKET

86

1-40

87

SECTION 2 CONTROLS AND INSTRUMENTS SWITCHES AND PUSH-BUTTONS

1 2-1

SECTION 2

Ref.

Operation

1

Rotary knob/ selector

Blower

Activates the blower and has 3-speed stages: 1, 2, 3.

2

White button

Air conditioner (optional)

Activates/deactivates the air recirculation.

3

Blue button

Air conditioner (optional)

Activation/deactivation of air conditioner (ON/ OFF).

4

Rotary knob/ selector

Heating

Sets the heating power: completely to the left - low heating power (blue); completely to the right - high heating power (red).

5

Push-button

Stabilizer (optional)

Rear right stabilizer control.

Stabilizer (optional)

Rear left stabilizer control.

City Stabilizer (optional)

City stabilizer control.

Stabilizer (optional)

Front left stabilizer control.

Blade (optional)

Blade control.

Stabilizer (optional)

Front right stabilizer control.

6

7

8

2-2

Description

Push-button

Push-button

Push-button

Symbol

CONTROLS AND INSTRUMENTS Ref.

Description

Operation

Symbol

Push-button with two lights and three engagement positions.

Left light on: brake permanently locked.

9

Push-button

Parking brake

Left light off: brake permanently released.

Right light on: automatic mode (in 1st gear only).

The brake releases when the travel pedal is pressed.

10

Push-button

Creep speed

By pressing the symbol (the lamp and the symbol light up) the creep speed engages.

By pressing the symbol again (the lamp and the symbol turn off) the creep gear disengages.

Push-button with two lights and three engagement positions.

Left light on and right light out: 1st gear engaged.

11

Push-button

Gearshift

Left light out and right light on: 2nd gear engaged.

Lights off: the automatic gearshift mode is active.

By pressing the accelerator pedal, the machine will move in 1st gear up to a certain speed, at which the 2nd gear will engage.

Push-button with two lights and three engagement positions.

Left light off: floating axle locked.

Right light on: floating axle released.

Right light on (the button has been kept pressed for at least two seconds): automatic mode.

12

Push-button

Floating axle blocking

If the machine is stopped, the current conditions are saved.

Automatic mode The axle is released when: - the travel pedal is pressed and the excavator starts moving; - stabilizer legs are moved.

NOTE: the axle releases only if the safety lever is in lowered position.

13

Display

Multi-function

Controls and monitoring of the machine functions.

2-3

SECTION 2 Ref.

Description

Operation

14

Push-button

Engine rpm

Engine rpm increase up to a maximum speed in 7 steps (7 power stages with fixed speed levels).

15

Push-button

Engine rpm

Lowering of engine rpm up to idle run in 7 stages.

Activation/deactivation of automatic engine speed reduction.

16

Push-button

Auto Idle

17

Push-button

Low Idle

After activation, the speed of the diesel engine is automatically reduced to a lower speed during nowork phases lasting longer than 4 seconds.

Sets engine to idling speed. If Auto Idle and Low Idle are on at the same time, Low-Idle has higher priority.

Push-button with two lights and three engagement positions.

Lights off: brake released, upper structure free to turn.

18

Push-button

Upper structure holding brake

Left light on: holding brake engaged, upper structure braked.

Right light on: holding brake automatic mode.

Holding brake is applied and released automatically. As soon as the upper structure stops the brake applies.

Push-button with two lights and three engagement positions.

19

Push-button

Overload (optional)

Lights off: overload warning system off.

Left light on: overload warning system on (machine not additionally stabilized).

Right light on: overload warning system on (machine additionally stabilized).

Push-button with two lights and three engagement positions.

20

Push-button

Upper structure holding brake

Lights off: soft braking of upper structure slewing.

Left light on: standard braking of upper structure slewing.

Lights on: abrupt braking of upper structure slewing.

2-4

Symbol

CONTROLS AND INSTRUMENTS Ref.

Description

Operation

Symbol

Selects the road travel mode.

Ensure that the safety lever is placed to position “0”.

21

Push-button

Road travel

Activation: press the button face with the symbol (lamp lights up).

Deactivation: press the button face with no symbol (lamp turns off).

22

23

Switch

Parking brake

Switch

Cab floodlamps / attachment

Parking brake control.

To activate, press the switch face with no symbol.

To deactivate, press the switch face with the symbol.

Automatic return push-button.

24

Switch

Screen wiper/ washer

One click: a wiper stroke and a liquid jet.

The windscreen wiper operates continuously with the jet, as long as the button is kept pressed.

Automatic return push-button.

25

Switch

Windscreen wiper

One click: intermittent wiping.

Press and hold button: the windscreen wiper operates continuously.

26

Switch

Cab at variable height

Cab raising: by keeping the push-button face with the symbol ( ) pressed, until the required height or the maximum height is reached.

Cab lowering: by keeping the push-button face with the symbol ( ) pressed, until the required height or the minimum height is reached.

27

Switch

Safety during Locking: press symbol face of switch, (the lamp activation of cab at lights up red). variable height

28

Switch

Rotary light (optional)

29

Switch

Magnet (optional)

To activate depress switch face without symbol.

To deactivate depress symbol face of switch.

To activate depress switch face without symbol.

To deactivate depress symbol face of switch.

2-5

SECTION 2 Ref.

Description

Operation Additional motor (Optional)

30

Switch

Rear working floodlamps (optional)

Clamshell opening/closing 31

Activation: press the button face with no symbol.

Deactivation: press the button face with the symbol.

The opening/closing speed of the clamshell is determined by pre-set values. The speed reduction is optional.

Switch Frequency switching (optional)

32

Activation/deactivation of additional motor.

Switch

Stabilizers independent activation (optional)

Activation: press the button face with no symbol.

Deactivation: press the button face with the symbol.

Stabilizers independent raising/lowering.

Activation: press the button face with no symbol.

Rear fog lights

33

Potentiometer

Travel speed limiting device (Inching)

Deactivation: press the button face with the symbol.

Set the maximum travel speed by keeping the travel pedal pressed.

Adjustment while driving possible.

Left slewing: minimum.

Right slewing: maximum.

34

2-6

Ignition key

Activates and deactivates the electrical system.

Starting/Stopping the engine.

Symbol

CONTROLS AND INSTRUMENTS On the button of the key-pad modules and on the switches are engraved symbols; they describe the function of the button or switch below.

The button are activated by finger tip pressure. The stroke of the buttons is short and at their activation a tactile reaction takes place, warning the operator, that the button has been pushed.

The buttons carry some LEDS (lights). The current activation status of the button is indicated by lights.

The symbols on the buttons are backlighted, and this feature activates automatically as soon as the ignition key is set to “I” (ignition ON).

By activating repeatedly the buttons, different activation status can be achieved.

Some switches may have two lights: normally they have a left light (1) and a right light (2).

Some switches are assigned to special attachments. They are installed only on a machine with special attachments.

2

“BUZZER”: ACOUSTIC WARNING SIGNAL SINGLE ACOUSTIC WARNING SIGNAL After “Ignition ON”: - the self-test for electronic control is activated; - the pilot control is activated and the machine can be set in motion.

The return filters of the hydraulic system are dirty.

The switching over from dipper to blade/stabilizer operation takes place.

During the hammer or rotary cutter operation, you switch over momentarily to placing boom operation, in order to perform the adjustment movements with the control pedal.

Some troubles occur to the electronic control, but they do not impair the operator’s and machine safety seriously.

Triple sound in case of control error.

Single sound, by engaging the forward speed.

Double sound, by engaging the reverse travel.

Long single sound, by setting to idle the travel direction.

Single sound, by pushing the button for floating axle block, when the parking or service brakes are engaged.

2-7

SECTION 2 ACOUSTIC WARNING SIGNALS INCHING The brake pressure is too low.

The engine oil pressure is too low.

Coolant temperature too high.

The maximum load torque is exceeded (with overload indicator).

Battery will not charge.

Hydraulic oil temperature is too high.

The function “Stabilizers/blade raising/lowering” is activated.

The electronic control shows serious troubles.

The emergency operation is activated.

2-8

CONTROLS AND INSTRUMENTS

CONTROLS AND PEDALS

3 Ref.

Description

Operation

Slewing 1

Left hydraulic control lever Dipper/blade and stabilizers

Symbol

By shifting the lever to the right - the upper structure slews right.

By shifting the lever to the left - the upper structure slews left.

By shifting the lever forward - the dipper extends the blade/stabilizers lower.

By shifting the lever backward - the dipper retracts - the blade/stabilizers raise.

By shifting the lever upward the pilot control is OFF.

2

Safety lever

Pilot control

3

Push-button

Travel direction

Selection of idle run.

4

Push-button

Travel direction

Selection of forward travel direction.

5

Push-button

Travel direction

Selection of reverse travel direction.

By shifting the lever downward the pilot control is ON.

2-9

SECTION 2 Ref. 6

7

Description

Operation

Push-button

Clamshell rotation Left clamshell rotation. (optional)

Push-button

Dipper/blade and stabilizers controls switchover

The controls for dipper/blade and stabilizers switch over. (With blade/stabilizers activated the buzzer sounds).

With placing boom: extension/retraction of boom adjusting cylinder.

8

Pedal

Placing boom/ attachment

With hammer: hammer control.

With rotary cutter: rotary cutter control.

With shears: shears control.

9

Footrest

It selects the lights type.

10

Lever

Lights

Main beams signal: by pushing the lever upward.

Low beams: lever in middle position.

Main beams: by pushing the lever downward.

11

Lever

Warning buzzer

Acoustic signal.

12

Lever

Lights

Lights off.

13

Lever

Lights

Tail lights on.

14

Lever

Lights

Low beams on.

15

Lever

Turn signal light

Left signal light activation.

16

Lever

Turn signal light

Right signal light activation.

2-10

Symbol

CONTROLS AND INSTRUMENTS Ref.

Description

Operation

17

Push-button

Flickering lights

Flashing lights activation.

18

Steering wheel and column

Steering

Transfers the steering motion to the steering axle.

Lever

Locking of the steering column

Symbol

It locks the steering column to required inclination: 19

by pushing downward - the column can be moved; by releasing the lever - the column is locked.

20

Pedal

Travel

Starts the machine travel and determines its speed.

21

Pedal

Service brake

It brakes the machine travel. The control lever locks the service brake to braking position. At the same time, the floating axle blocks. When the brake pedal is released, also the floating axle releases automatically.

22

Push-button

Warning buzzer

Acoustic signal.

23

Push-button

Clamshell rotation Right clamshell rotation. (optional)

24

Push-button

Hammer

Hammer activation.

25

Push-button

Power Boost

Generates an engine rpm and pressure increase (for short work stages).

26

Push-button

Levelling

Allows to perform the levelling operation in an accurate and smooth way.

27

Pin

Upper structure holding brake Boom

28

Right hydraulic control lever

Bucket

Clamshell (optional) 29

Socket

It locks the upper structure to the undercarriage.

By shifting the lever forward - the boom lowers.

By shifting the lever backward - the boom raises.

By pushing the lever to the right - the bucket dumps.

By pushing the lever to the left - the bucket fills.

By pushing the lever to the right - the clamshell opens.

By pushing the lever to the left - the clamshell closes.

12 V auxiliary socket.

2-11

SECTION 2

MULTI-FUNCTION DISPLAY

4 Ref.

Description

Operation

1

Lamp

Travel direction

This light turns on when the forward travel is engaged.

2

Lamp

Turn signal light

It flashes when the left turn signal is activated.

3

Lamp

Preheating

It turns on during preheating.

4

Lamp

Main beams

It turns on blue, when the main beams are activated.

5

Lamp

Upper structure holding brake

This light turns on when the slewing brake is engaged.

6

Lamp

Turn signal light

It turns on when the right turn signal is activated.

2-12

Symbol

CONTROLS AND INSTRUMENTS Ref.

7

Description

Lamp

Operation

Travel direction

Symbol

It turns on when the reverse travel is activated.

Time in hours and minutes/machine working hours display/fuel level indication.

Time/Hourmeter/ Fuel level

Indication above the cross line = Level OK

121 HOURS

Indication under the cross line = top up fuel.

8

Display

Time/Engine power level

Time in hours and minutes / graphic display of the engine power level.

Coolant temperature/ hydraulic oil temperature

It displays the temperature of coolant and the hydraulic oil temperature.

Secret code

Input of secret code for the start-up electronic lock.

CODE

Display of service hours, according to: Operation hours

- total hours; - partial time; - days count.

OPERATION HOURS

2-13

SECTION 2 Ref.

Description

Operation

Symbol

Setting of hydraulic oil pressure and of volumetric flow for the following attachments: - 4 different hydraulic hammers; - 4 different rotary cutters; - 4 different hydraulic shears.

ATTACHMENTS

Further options can be activated by the dealer for use by the operator: Attachments

- degree of damping for equipment movements and travel function; - slewing power limiting; - activation of “Auto Power Boost” function; - setting of the levelling function; - basic setting; - clamshell rotation; - boom adjusting cylinder speed.

8

Display Display

Setting of display contrast and brightness, clock, language and measuring units.

DISPLAY

Informations

Displays operating data of the machine and the control system.

INFORMATIONS

Machine

Display of all machine data.

MACHINE

2-14

CONTROLS AND INSTRUMENTS Ref.

Description

Operation

Symbol

Display of operating hours by function groups of the machine (disabled in normal machine operation).

Display and setting of maintenance intervals (disabled in normal machine operation).

Maintenance

8

MAINTENANCE

Calibration of machine functions (reserved for Service Department).

Activation of optional machine functions (disabled in normal machine operation).

Display

Resetting of faults (reserved for Service Department - password protected).

Faults occurred are stored in detail by electronic control unit.

Faults

This menu is reserved for our Service and disabled in normal machine operation (password protected).

9

Push-button

Push-button with downward arrow

Push-button for selection and scrolldown in function and navigation menus.

10

Push-button

“set” button

Push-button for selection and confirmation of items in function and navigation menus.

11

Push-button

Push-button with upward arrow

Push-button for selection and scrollup or escape button in function and navigation menus.

FAULTS RETRIEVAL

2-15

SECTION 2 Ref.

Description

Operation Lights up yellow in the event of faults which are not safety- or functionrelevant.

When a yellow fault occurs: - yellow warning lamp lights up; - buzzer warning sounds.

Faults can be recalled by pressing the “set” button.

If several yellow faults have occurred, they are displayed one after another at certain intervals.

Faults can be recalled by pressing the “set” button again.

12

Lamp

Fault message

Not all yellow faults are displayed on the screen.

Only such yellow faults are displayed as are important for machine maintenance or of help to the service personnel in the event of technical problems.

A detailed list of yellow faults is accessible via the FAULT RECALL menu item. This item can only be activated with a code and is reserved for our Service Department.

The cause of the fault should be rectified as soon as possible. In most cases, the machine can continue to be used with all its functions.

2-16

Symbol

CONTROLS AND INSTRUMENTS Ref.

Description

Operation

Symbol

Lights up red, when the safety of persons (e.g. safety lever defective, overload warning) and the functioning of main assemblies of the machine is endangered: - this is the case, for instance, when there is no engine oil pressure or when the admissible load moment is being exceeded (with overload warning option) and when pressure- relief valves open.

13

Lamp

Fault message

When a red fault occurs, a fault number is displayed and an intermittent buzzer warning is sounded in addition to the red warning lamp lighting up.

In some fault cases, certain machine functions are deactivated or can be switched over to emergency operation.

There is also the possibility of several faults being indicated at the same time. If 2 red faults occur, both are indicated. If a yellow and red fault occur at the same time, only the red fault will be indicated. After removal of the cause of the red fault, the yellow fault is indicated.

2-17

SECTION 2 The multi-function display handles all important settings, controls and functions of the machine.

The display can operate in three different modes: - operating mode; - main menu; - set mode.

969 HOURS

The arrow keys are basically used for scrolling through the menus, whereas the “set” button is used for activating the menus.

Each press on a button is accompanied by a tactile touch sensation. The wedges in the main menu on the right and left margin of the display indicate that further menus can be accessed in the respective direction with the arrow keys In the submenus, these wedges are arranged on the right side of the display at the upper and lower margins.

5

OPERATING MODE In the operating mode, the machine operator is provided with information on machine performance, machine operating modes etc.

In this mode, the display screen is divided into five fields (1), (2), (3), (4) and (5).

Field (2) shows the fuel reserve presently available in the fuel tank.

The general information field (1) displays the following information depending on the mode of operation: - time; - operating hours; - engine speed; - travelling speed.

The temporary options selected for special modes of operation are shown in field (3). Observe the priority of the temporary symbols as per table shown.

Field (4), displays the operating mode selected.

Field (5), displays graphic information on the operating mode selected.

2-18

6

CONTROLS AND INSTRUMENTS MAIN MENU Pressing an arrow button in the operating mode calls up the main menu. The arrow keys equally permit access to the various sub-menus: - operation hours; - code; - display settings; - faults retrieval;

CODE

- informations; - service.

In this mode, the display is divided into two fields.

The symbols are displayed in the upper field while the corresponding menu text appears in the lower one.

7

The “set” button gives access to the submenus for recalling information or for changing machine settings.

Wedges under the pictograms indicate that further menus are available in the respective direction.

The tester and service functions menus are reserved for our Service Department and disabled in normal machine operation.

121 HOURS MAINTENANCE

INFORMATION

FAULTS RETRIEVAL

ATTACHMENT

DISPLAY

MACHINE CODE

OPERATION HOURS F34010

8

2-19

SECTION 2 CONDITIONS OF USE Please observe the specified ambient conditions and limits of use: - temperature between -20 to 70 °C (-4 and 158 °F); - relative air humidity < 95%.

If these conditions are not fulfilled, malfunctions cannot be excluded. In the event of malfunctions or in case of doubt, please contact our Service Department.

At low winter temperatures (below about -20 °C (-4 °F)) the function menus / displays are hardly or not at all readable. This is not a defect, but a typical effect of liquid-crystal displays.

After a short time in operation, the display is again clearly readable with a good contrast.

Some functions of the navigation menu are optional.

They can only be activated and used if the machine is equipped with the corresponding option and if the function has been enabled in the electronics.

Example: the hammer.

The display illuminates automatically as soon as the ignition key is turned to position “I” (ignition ON).

The symbols in the upper row are assigned only to one function.

2-20

CONTROLS AND INSTRUMENTS DISPLAY SETTING, MAIN MENU In operating mode depress repeatedly the arrow button, until on main menu appears “display” on grey background. Confirm with “set” button (2).

By depressing the button with the upward arrow (1) you return to main menu.

With downward arrow button (3) you can recall following sub-menus:

969 HOURS

- contrast; - brightness; - time; - units; 9

- language.

DISPLAY

German

English DATE

French F34012

10

2-21

SECTION 2 CONTRAST Under poor light conditions, strong solar light of extreme cold, the display contrast may need to be modified. In this way the readability of the informations displayed is ensured.

In operating mode depress repeatedly the arrow button, until on main menu appears “display” on grey background. Confirm with “set” button (2).

Depress repeatedly button with downward arrow (3), until the contrast symbol appears on grey background (4). Confirm the selection with “set” button (2).

11

5 F34014

12 By depressing the button with upward arrow (1), the contrast increases, by depressing the button with downward arrow (3) the contrast decreases at little steps. The contrast setting is graphically displayed like a column (5).

With button “set” (2) you exit the sub-menu “Contrast” and return to main menu “Display”. Concurrently the contrast settings are memorized.

2-22

CONTROLS AND INSTRUMENTS BRIGHTNESS Under poor light conditions, strong solar light or extreme cold, the display contrast may need to be modified. In this way the readability of the informations displayed is ensured.

In operating mode depress repeatedly the arrow button, until on main menu appears “display” on grey background. Confirm with “set” button (2).

Depress repeatedly button with downward arrow (3), until the brightness symbol appears on grey background (6). Confirm the setting with “set” button (2).

13

7 F34016

14 By depressing the button with upward arrow (1), the brightness increases, by depressing the button with downward arrow (3) the brightness decreases at little steps. The brightness setting is graphically displayed like a column (7).

With button “set” (2) you exit the sub-menu “Brightness” and return to main menu “Display”. Concurrently the brightness settings are memorized.

2-23

SECTION 2 TIME For different reasons time may need to be set in the electronic control unit and visualized on the display (for instance in case of legal time change).

In operating mode depress repeatedly the arrow button, until on main menu appears “display” on grey background. Confirm with “set” button (2).

15 Depress repeatedly button with downward arrow (3), until the time symbol (9) appears on grey background (8). Confirm the setting with “set” button (2).

On the display left appears now the symbol of a clock and right the selection of:

9

- the indication of the 12 hours; - the indication of the 24 hours;

DATE

- the date setting.

By means of the arrow button you can select one of these options and confirm the selection with “set” button (2).

F34018

16 Save changes?

Save changes?

DATE

DATE

DATE

DATE

DATE

Data input

Data input

Data input

Data input

DATE

F34019

17 2-24

CONTROLS AND INSTRUMENTS Indication of the 12 hours Depress repeatedly the arrow keys until the indication “12 h” appears on grey background. Confirm the setting with “set” button.

The display shows now the actual time, where AM means ante meridiem (morning) and PM means post meridiem (afternoon).

The cursor is now on the first digit of the hours setting. By depressing the button with the upward arrow ( ), the number increases of one unit. By depressing the button with the downward arrow ( ), the number decreases of one unit. By depressing button “set”, the setting is confirmed and the cursor slides to the right, waiting on the second digit of the hours. Set the second digit of the hours as described previously. The cursor shifts now on the first digit of the minutes. Carry out the minutes setting in the same way as described.

Once the minutes setting is confirmed with button “set”, fields PM or AM becomes actives. By means of the arrow keys you can scroll through these two settings and confirm the selection with “set” button.

After that, the settings are shown on the display and confirmed with button “set”.

Now you are asked to memorize the settings. By depressing the button with the upward arrow ( ), the new setting is not memorized and the modification is not active. By pressing button “set”, the new time setting is memorized and the modification becomes active. After that the upper menu is recalled. Now the setting can be repeated or one of the other setting options (indication of the 24 hours or date) can be repeated. The display shows now on the right near the time PM or AM.

Indication of the 24 hours Depress repeatedly the arrow keys until the indication “24 h” appears on grey background. Confirm the setting with “set” button.

The display shows the actual time.

The cursor is now on the first digit of the hours setting. By depressing the button with the upward arrow ( ), the number increases of one unit. By depressing the button with the downward arrow ( ), the number decreases of one unit. By depressing button “set”, the setting is confirmed and the cursor slides to the right, waiting on the second digit of the hours. Set the second digit of the hours as described previously. The cursor shifts now on the first digit of the minutes. Carry out the minutes setting in the same way as described.

The hours and minutes settings are now shown on the display as active and confirmed by button “set”.

Now you are asked to memorize the settings. By depressing the button with the upward arrow ( ), the new setting is not memorized and the modification is not active. By pressing button “set”, the new time setting is memorized and the modification becomes active. After that the upper menu is recalled. Now the setting can be repeated or one of the other setting options (indication of the 12 hours or date) can be repeated.

2-25

SECTION 2 Date Depress repeatedly the arrow buttons until the indication of the date appears on grey background.

Confirm the setting with “set” button.

The display shows the actual date.

The cursor is now on the first digit of the day setting.

By depressing the button with the upward arrow ( ), the number increases of one unit. By depressing the button with the downward arrow ( ), the number decreases of one unit. By depressing the button “set”, the setting is confirmed and the cursor slides to the right, waiting on the second digit of the day setting. Set the second day digit as described previously. The cursor is now on the month setting. By depressing the button with the upward arrow ( ), you scroll to next menu. By depressing the button with the downward arrow ( ) you recall the next month. By depressing the button “set”, the setting of the month is confirmed and the cursor slides to the first digit of the year setting. By depressing the button with the upward arrow ( ), the number increases of one unit. By depressing the button with the downward arrow ( ), the number decreases of one unit. By depressing the button “set”, the setting is confirmed and the cursor proceeds of one step to the right and stops on the second digit of the year setting. Set the second, third and fourth digit as described previously.

The year setting is shown on the display as active and confirmed by means of button “set”.

Now you are asked to memorize the settings. By depressing the button with the upward arrow ( ), the new setting is not memorized and the modification is not active. By pressing button “set”, the new time setting is memorized and the modification becomes active. After that the upper menu is recalled. Now the setting can be repeated or one of the other setting options (indication of the 24 hours or date) can be repeated.

2-26

CONTROLS AND INSTRUMENTS UNITS In operating mode depress repeatedly the arrow button, until on main menu appears “display” on grey background. Confirm with “set” button (2).

Depress repeatedly the button with downward arrow (3), until the unit symbol appears on grey background (10). Confirm the selection with “set” button (2).

The display shows two different units for temperature, speed, pressure and flow rate measure with the relevant symbols (10) and (11) highlighted.

Wedges on the edges and on the right and left side of the display show that it is possible to recall other settings, by means of button “set” (2).

The cursor is now positioned on the temperature unit currently set. Now on grey background is active either field “°C” (Celsius degrees) or field “°F” (Fahrenheit degrees). By means of the arrow buttons, you can scroll through these two units and confirm the selection with the “set” button (2).

18

10

11

12

The cursor is now positioned on the speed value currently set. Now on grey background is active either field “km/h” (kilometres/hour) or field “mph” (miles/hour). By means of the arrow buttons, you can scroll through these two units and confirm the selection with the “set” button (2).

The cursor is now positioned on the pressure unit currently set. Now on grey background is active either field “bar” or field “psi” (pounds per square inch). By means of the arrow buttons, you can scroll through these two units and confirm the selection with the “set” button (2).

F34021

19

The cursor is now positioned on the flow rate unit currently set. Now on grey background is active either field “l/min” (litres/minute) or field “gpm” (gallons per minute). By means of the arrow buttons, you can scroll through these two units and confirm the selection with the “set” button (2).

Now you are asked to memorize the settings of the measurement units. By depressing the button with the upward arrow (1), the new setting is not memorized and the modification is not active. By pressing button “set” (2), the new measurement units setting is memorized and the modification becomes active.

After that the upper menu is recalled. Now the setting can be repeated or one of the other setting options (contrast, brightness, time or language) can be repeated. By depressing the button with the upward arrow (1), you exit the display menu and return to the main menu.

2-27

SECTION 2 LANGUAGE In operating mode depress repeatedly the arrow button, until on main menu appears “display” on grey background. Confirm with “set” button (2).

Depress repeatedly button with downward arrow (3), until the language symbol appears on grey background (13). Confirm the selection with “set” button (2).

The display shows now 5 language options (German, English, French, Italian and Spanish). The language currently set is shown as active.

The current language setting is on grey background.

20

Save changes?

German

Italian

Italian

English

Spanish

Spanish

French

F34023

21 Depress repeatedly the arrow buttons until the required language is highlighted inside of a frame.

Confirm the setting with “set” button (2).

The display shows now the language setting on a grey background and highlighted into a frame. This has to be confirmed again by means of the button with the downward arrow (3).

After confirmation by button with downward arrow (3), you are requested to memorize the language setting.

2-28

By depressing the button with the upward arrow (1), the new setting is not memorized and the modification is not active. By pressing button “set” (2), the new language setting is memorized and the modification becomes active. After that the upper menu is recalled. Now the setting can be repeated or one of the other setting options (contrast, brightness, time or measurement unit) can be performed. By depressing the button with the upward arrow (1), you exit the display menu and return to the main menu.

CONTROLS AND INSTRUMENTS SYMBOLS

Attachments

Machine

Service hours

Code

Display

Faults

Informations

Maintenance

Contrast

Brightness

Time

Units

Languages

Temperature

Speed

Pressure

Displacement

Road travel

Hammer

Rotary cutter

Shears

Slew power limitation

Damping

Digging

Levelling

Craning hook

Stabilizer or blade lowering

Stabilizer or blade lifting

Magnet

Power Boost

Placing boom speed

Trailer

Clamshell bucket

Creep speed

Slow speed

High speed

2-29

SECTION 2

STARTER SWITCH

WARNING Before starting the engine, make sure you are fully aware of the location and the function of each control. Operating the controls wrongly can cause serious physical injury.

The ignition key (1) activates following functions: 0 = No electric user is under voltage, the engine is shut off.

A main relay disconnects all electric circuits from the battery.

P = The cab inside light and socket, as well as the radio, are electrically powered. All other users are not under voltage.

22

I = Electrical system connected.

If the start-up is locked, the relevant code input is required.

If the start-up is not locked, the electronic control unit performs the self-test.

All pilot and control lights are activated for a few seconds, the buzzer sounds shortly twice.

The display shows now some indications.

By means of the arrow buttons, you can set following indications: Time in hours and minutes (A) and visualization of the operating time of the machine (B).

12 HOURS

23

2-30

CONTROLS AND INSTRUMENTS Time in hours and minutes (A) engine power level (C).

24 The temperature of coolant (D) and of hydraulic oil (E) is displayed.

25 All screens show the fuel level graphically.

All functions are now input by the electronics as per table: Operation

Situation after ignition to ON

Power level

2

Auto Idle

OFF

Gear shifting

1st

Floating axle

blocked

Parking brake

applied

Forward/reverse gear shifting

idle

“Levelling” mode

Active, with Memory function active

Road travel

Memory

Start-up locking

Memory

Creep speed

OFF

Slewing brake behaviour

Memory ON - if set to ON when the engine is shut off

Upper structure holding brake

Automatic - if set to automatic or ON when the engine is shut off

Overload indicator

Memory

Start the engine. All indicator and control lights must turn off, while the engine keeps on running.

Exception: with the upper structure holding brake, the lamp remains on.

2-31

SECTION 2

RADIO

26 1. Preselection button 1

9. Display

2. Preselection button 2

10. Sound level button: by depressing the top it increases, while by depressing the bottom it decreases

3. Preselection button 3 4. Preselection button 4 5. Preselection button 5 6. TA activation (short pressure) and TA deactivation (long pressure)

11A.Band selection 11B.RDS activation and deactivation 12. Automatic reload

7. Audio/sound modes selection

13. Tape quick winding

8A. Activation (short pressure) and Deactivation (long pressure)

14. Tape quick rewinding

8B. Audio activation and deactivation

16. Cassette case opening

2-32

15. Cassette ejection

CONTROLS AND INSTRUMENTS

CAB ENTRY AND EXIT To mount on and off the cab always use steps (1) and handles (2) duly fitted on machine.

Use only the steps (1), the platforms and the handrails (3) specially provided for climbing onto or dismounting the machine.

Always face the machine when climbing or dismounting.

WARNING Never use the steering wheel or the control levers to help yourself entering or leaving the operator’s compartment.

27

WARNING Clean the steps and access handles and remove all traces of grease, oil, mud and ice (winter).

WARNING Never jump on or off the machine. When dismounting from the operator’s compartment always face the machine and use the steps and access handles.

28

29

2-33

SECTION 2 DOOR OPENING Opening the door from outside Unlock the door with key (1).

Withdraw the flap (2) on the door lock.

The door can now be opened.

Fully opened, the door can be locked into place.

30 Opening the door from inside To open the door from inside, push lever (3) forward.

31

DOOR CLOSING Unlock the opened, locked-in door by pushing down the lever (1). Grab the handle (2) on the upper side of the door frame and close the door.

WARNING Make sure that the doors are correctly closed before any travel.

32

2-34

CONTROLS AND INSTRUMENTS SIDE WINDOW Loosen the locking device (1) and move the glass (2) backward.

To close the glass (2), push it forward until the locking device locks.

33

FRONT WINDOW The front window can slide in the back of the cabin under the roof.

Roll up the sunblind.

Bring the screen wiper to basic position (fully to the left).

Grab both handles (2) at the front window (left and right side) and push lock levers (1) forwards.

Tilt front window inwards and slide back upwards to the stop.

Release the locks (1). They lock the window.

Make sure that both locks are properly engaged.

34

WARNING If the locks are not properly engaged, the front window may move forward under high vibration.

The lower segment of the front window, when closed, can be moved to “Ventilation” or “Opening” position.

VENTILATION Loosen the left and right locks of the lower front window, by depressing and holding the upper lever (3) downwards against the handle (4).

Slide lower front window segment downwards to the stop. Creating a 3.5 cm (1.38 in) wide slot, to allow the cab ventilation.

Release lever (3) on the left and right.

35

2-35

SECTION 2 OPENING Roll up the sunblind.

Loosen the left and right locks of the lower front window, by depressing and holding the upper lever (3) downwards against the handle (4).

Slide lower front window segment by means of handles (4) upwards in front of the upper segment of the front window and let levers (3) engage in the notches (5).

In the open position, the lower segment together with the upper segment of the front window can be pushed under the cab roof.

36

EMERGENCY EXIT Use the front window as an emergency exit, if the cab door cannot be opened after it has been damaged (e.g. in case of an accident).

To break the glass panes in case of danger, use the little hammer (1) on the rear wall behind the operator’s seat on the left.

37

2-36

CONTROLS AND INSTRUMENTS WINDSCREEN WIPER AND WASHER The windscreen wiper and washer are activated by the relevant switches located on the cab right dashboard.

Intermittent wiping Depress rocker switch (2) once. (The switch face without symbol is depressed and the lamp in the switch is lit up).

Permanent wiping Depress rocker switch (2) twice. (The switch face without symbol is depressed and the lamp in the switch is lit up).

Switching the wiper off

38

Disconnect switch (2). (Depress symbol face of switch, the lamp goes out).

Activating the wipe / wash function Depress button (1). (The lamp inside of button lights up).

The screenwasher pump is switched on with the wiper being activated at the same time.

After releasing the button, the wiper continues to perform wiping movements for a short time.

NOTE: if the front screen is pushed back under the cab roof, the functions of switches (1) and (2) are automatically deactivated.

FLOODLAMPS Front working floodlamps activation Depress the blank face of switch (1).

The working floodlamps on top of the cab and on the working attachment are on.

Front working floodlamps deactivation Depress the symbol face of the switch (1).

The working floodlamps on top of the cab and on the working attachment are off.

39

2-37

SECTION 2 Rear working floodlamps activation The rear working floodlamps can only be switched on, if the key of the electrical system is set to “I” (ignition ON).

Connect switch (2). (Depress switch face without symbol, the lamp inside the switch lights up).

Switching the floodlamps off Disconnect switch (2). (Depress switch face with symbol, the lamp goes out).

40

DOCUMENTS STORAGE BOX, FIRSTAID KIT, WARNING TRIANGLE AND FIRE-EXTINGUISHER The operator’s seat (1) is equipped behind with a storing compartment for documents (2) where to stow the Operator’s Manual.

This compartment can also stow a fire-extinguisher, a first aid-kit and the warning triangle.

The triangle can also be stowed in the tool box.

41

SUNBLIND The sunblind is fitted in a holder above the front window.

It can be pulled out in front of the front window or the roof window.

Rolling out the sunblind Grab the end of the sunblind (1), roll out against spring action (2) and engage in the holders.

42 2-38

CONTROLS AND INSTRUMENTS Rolling in the sunblind Take the end of the blind (1), detach from holders (3) and let it be pulled in (2) slowly by the spring. Do not let go the unrolled sunblind (2); it might get damaged.

43

CAB LIGHTING The cab interior lighting is switched on and off with the switch (1).

The lighting can be switched on even if the ignition key has been pulled out from the cylinder.

If the light remains accidentally alight for a longer period (all over the week-end), the batteries may be unnecessarily discharged.

Therefore always check that the interior lighting is switched off, before leaving the machine.

44

2-39

SECTION 2 AUXILIARY SOCKET A socket outlet (1) is installed in the panelling on the right behind the operator’s seat.

This provides the output voltage of the voltage transformer (12 V) for connection of the cool-box (option).

Other electrical consumers can also be connected as long as the maximum output of the voltage transformer is not exceeded.

The voltage transformer installed at the factory is designed so as to supply not only a cassette radio but also the cool-box (option); the maximum output is 90 W (67 ft·lb/s).

For this reason, before connecting a device, check the power input it requires. When the voltage transformer is overloaded, its temperature rises so that the overload protection switches off and leaves the connected unit without current. In this case pull the plug out of the socket (1). After 5 - 10 minutes, the overload protection has cooled down and reactivates the voltage transformer.

If the overload condition persists, the thermal shutdown does not work anymore and the fuse of the supply line blows. To replace the fuse, the panelling below the radio must be removed.

The socket is live when the ignition-key is pulled out from the ignition cylinder.

A user remaining accidentally connected for a long period (about a week-end) can cause the discharge of the machine’s batteries.

Therefore, before leaving the machine, check that the connected user is switched off.

2-40

45

CONTROLS AND INSTRUMENTS STEERING COLUMN Do not adjust the steering column during travel.

Before adjusting the steering column: - stop the machine; - position the button of travel direction to idle; - activate the parking brake.

The angle of the steering column can be adjusted to suit the height and posture of the operator. For this operation proceed as follows: - press lever with toe cap down and keep in position lever (2) to unlock the steering column; - tilt steering column (1) into required position; - release lever (2) to lock steering column (1); - check that the steering column is locked.

46

2-41

SECTION 2

VENTILATION, HEATING AND AIR CONDITIONING (OPTIONAL) VENTILATION (air from outside) WITH ENGINE RUNNING Use handle (1) to activate and to adjust the blower speed.

WITH ENGINE SHUT OFF Turn first of all the ignition key (2) to position “I”.

Now it is possible to activate the knob (1).

47 By means of rotary knob or selector (3) you can set the air warmth intensity.

48 Defrosting the front, side and rear windows

WARNING Windows that are steamed or iced up obstruct the operator’s view of the hazard zone.

Never move the machine until the windows are defrosted and the hazard zone can be clearly seen.

Start the engine. Full heating output is attained only when the engine is at operating temperature.

Close the air-flow vents (4) under the operator’s seat.

49

2-42

CONTROLS AND INSTRUMENTS Open the two air-flow vents (5) for the front windows as wide as possible and direct onto the front windows.

Open the air-flow vents (6) for the side window as wide as possible and direct onto the side window.

50 Open the air-flow vents (7) of the rear window as wide as possible and direct onto the rear window.

51 Set heating output to max.

Set the blower speed to stage 3 by means of knob (3).

52

2-43

SECTION 2 HEATING The engine coolant flows through the heat exchanger of the heating system. The heating output is therefore also dependent on the engine temperature. The full heating output is not achieved until the engine has run up to operating temperature.

Even if the heating is not required for an extended period, switch heating system on at full output once a week for about 5 minutes in order to mix the coolant in the engine and that in the heating system.

When working in dusty, severely contaminated air, the heating system can be operated temporarily in the circulating air mode (only with optional air conditioner).

Turn rotary knob (3) clockwise according to required heating output.

Depending on the quantity of hot air required, switch blower to stage 1 - 3 with rotary knob (1).

53 The slats of the air outflows (4) are adjustable. The air flow can thus be deflected laterally and upwards.

54

2-44

CONTROLS AND INSTRUMENTS AIR CONDITIONING (OPTIONAL) During summer time, when the air conditioner has cooled down the cab temperature, the air inside of it can further be cooled by activating the air recirculation.

Also during winter it is possible to activate the air conditioner in order to dry the cabin air.

SWITCHING ON THE AIR CONDITIONER Start the engine.

Depress button (4). The lamp inside the button lights up blue.

The blower is switched automatically to stage 1.

Turn rotary knob (1) to select the desired blower performance (stages 1 - 3).

AIR TEMPERATURE ADJUSTMENT The temperature of the air blown into the cab can be adjusted with heater rotary knob (3).

Positions: - left stop (min) = cooled air blown into cab;

55

- right stop (max) = heated air blown into cab.

The temperature between these two positions can be adjusted continuously.

For higher cooling or heating performance, the blower can be switched to stages 2 and 3.

SWITCHING OFF THE AIR CONDITIONER Depress button (4). The lamp inside the button turns off.

SWITCHING ON RECIRCULATED AIR Depress button (2). The lamp inside the button lights up.

SWITCHING OFF RECIRCULATED AIR Depress button (2). The lamp inside the button turns off.

Air recirculation can also be used when the air conditioner is off.

2-45

SECTION 2 CONDITIONS FOR A GOOD COOLING INTENSITY

REFRIGERATING AGENT R 134a

The air intakes ports are on the rear of the cab and should neither be covered nor contaminated.

If handled in a wrong manner the refrigerating agent R 134a can be dangerous. Therefore it is important the following warning and directions are adhered to.

The filter element for outside air and the evaporator slats must be clean.

The cab door and panes must be closed.

NOTE: the air in the air conditioner is not only cooled but also dried, this avoids the steaming of the cab panes and increases the operator comfort and safety.

INSTRUCTION FOR A CORRECT USE First of all to eliminate the heat stagnation.

Ventilate the cab then proceed with the cooling (with windows and door closed).

Set for maximum cooling: recirculation, maximum blower output, minimum temperature, average air distribution.

When the inside room is sufficiently cooled, set the normal cooling: blower to level 1 or 2, wished temperature, air from outside instead of recirculation.

Clearing off the window misting: set air conditioning to ON, set full heating output, full blower out put and direct air blow toward the window panes.

Preventing the glass panes misting: with cold and moist weather, work with air conditioning activated, direct air flow toward the panes, temperature and blower set according to needs.

Protection against exhausts and dust: with air very dusty and with poisonous exhausts, activate the air conditioner and space out the operation with periods of recirculation.

Temperature: a temperature of 20-23 °C (68-73.4 °F) is the best, minimum 18 °C (64.4 °F).

If you have to dismount or to climb into the cab with very hot weather, increase the temperature to 25 °C (77 °F).

2-46

The refrigerating agent R 134a has a boiling point of 12 °C (53.6 °F).

Never expose any part of the air conditioning system to flames or excessive heat, because of the risk of fire or explosion and the production of phosgene gas.

Never disconnect or disassemble any part of the air conditioning system as escaping coolant can cause frostbite.

If coolant comes into contact with your skin, use the same treatment as for frostbite.

Warm the exposed area of skin with your hand or lukewarm water 32 °C (89.6 °F), cover loosely with a bandage to protect against infection and consult a doctor immediately.

If coolant comes into contact with your eyes, rinse them immediately with cold water for at least 5 minutes and consult a doctor immediately.

CONTROLS AND INSTRUMENTS

SERVICE AND PARKING BRAKES SERVICE BRAKE The service brake is composed of four multi-plates brakes integrated in the wheel hubs. The brake is operated hydraulically.

To ensure the braking function at all times, the braking system is equipped with hydraulic pressure accumulators which are permanently monitored.

If the pressure lowers under a preset minimum value, the red lamp (1) will light up on the display and the buzzer will release an intermittent warning sound.

Concurrently the display will show an error code and the symbol “Brake pressure too low”. You are also required to switch off the engine immediately.

56

WARNING If, during an operation lamp (1) lights up: - stop the machine immediately; - apply the parking brake; - place the machine in a safe condition.

Reset the machine in motion only after clearing the problem.

SERVICE BRAKE ACTIVATION To brake the machine, press the pedal (2).

Concurrently also the floating axle is blocked (independently from the position of the floating axle blocking button).

The machine cannot be started as the service brake is applied.

By activating the travel pedal with the travel direction selected but with the service brake blocked, the display warns only once for some seconds that the service brake must be released.

If not only the service brake but also the parking brake is applied, and the travel direction has been selected, and you press the travel pedal, the display warns that the parking brake has to be released.

57

The brake is released by releasing the pedal (2). If the floating axle had not been blocked beforehand by means of button (3), it is unlocked at the same time.

2-47

SECTION 2 PARKING BRAKE

WARNING Apply the parking brake only with machine stationary! Only in emergency case, for instance if the service brake fails, you can activate the parking brake while the machine is still moving.

In this case the braking effect is immediate, and the wheels lock!

The gearbox contains two packs of plates, that are pressed by preloaded springs, when the parking brake is applied.

PARKING BRAKE ACTIVATION The parking brake is engaged by keeping the button (1) pressed until the left lamp lights up. This button has two lights and three engagement positions: - left lamp on: brake engaged; - left light off: brake released; - right light on: automatic mode is active (in 1st gear only).

When the engine is stopped, the current engagement condition is saved.

By using the buttons for travel direction, you can select the travel direction, but you cannot start the machine as the parking brake is engaged.

AUTOMATIC MODE To select the automatic mode, press and hold button (1) for more than two seconds.

To exit automatic mode, press the button (1) again.

Switching always occurs with no delay.

In the automatic mode, when the machine is stopped, the parking brake is automatically engaged.

If the travel direction has already been set, the machine moves when the travel pedal (2) is activated.

If the travel pedal (2) remains unused for more than 0.5 seconds, the parking brake is engaged.

2-48

58

CONTROLS AND INSTRUMENTS

OPERATOR’S SEAT To operate the machine correctly with maximum efficiency and comfort, the seat should be correctly adjusted to suit the weight and height of the operator.

WARNING Before using the controls, make sure that the seat is adjusted and positioned correctly.

DANGER Never adjust the seat while travelling, because you must concentrate on the road.

Before adjusting the seat: - stop the machine; - position the button of travel direction to idle; - activate the parking brake.

The locking levers for fore-and-aft adjustment and for backrest adjustment must engage in the required position.

After locking, the operator’s seat and the backrest can no longer be moved into other positions.

OPERATOR’S SEAT WITH PNEUMATIC SUSPENSION An electrically operated compressor installed in the seat supplies the suspension of the seat suspension and the air chambers of the backrest with compressed air. Corresponding valves are installed in the seat.

ADJUSTING THE SEAT CUSHION ANGLE Pull handle (1) at front edge of seat upwards, adjust seat cushion, engage handle (1).

Adjustment range 3° - 11°, in 4 steps.

59

2-49

SECTION 2 ADJUSTING THE SEAT CUSHION HEIGHT Pull handle (2) at front edge of seat upwards, adjust seat cushion, engage handle (2).

60 FORE-AND-AFT ADJUSTMENT OF SEAT WITHOUT CONSOLES Pull locking lever (3) upwards, shift seat to required position and release locking lever.

61 ADJUSTING THE SUSPENSION/SEAT HEIGHT Suspension The operator’s weight should be adjusted upwards with the machine stationary and the seat loaded by brief actuation of the handle (4). The suspension is adapted automatically to the operator’s body weight.

Seat height Pull handle (4) upwards or downwards until the seat (6) has reached the required height. Release the handle (4).

62

2-50

CONTROLS AND INSTRUMENTS FORE-AND-AFT ADJUSTMENT OF SEAT WITH CONSOLES Pull bracket (5) upwards, shift seat and engage bracket.

63 FOLD-BACK ARMRESTS The armrests (7) can be folded upwards for entering and leaving the seat.

64 ARMRESTS ANGLE The angle of the slope can be changed in the lowest position irrespective of the backrest angle, using the integrated handwheel (8).

Adjustment range +10° up to -30°.

65

2-51

SECTION 2 ADJUSTING THE LONGITUDINAL HORIZONTAL SUSPENSION Unlocking Move lever (9) forward.

Locking Move lever (9) backward.

66 BACKREST ADJUSTMENT Sit down on seat and lean lightly against the backrest.

Pull locking lever (10) upwards. Bring backrest to required position by pressing back or leaning forward, release locking lever. Release the locking lever.

67 ADJUSTING THE ARMREST HEIGHT Remove plastic cap (11), slacken nut (size 13 mm 0.51 in)), adjust to required height, tighten nut, fit plastic cap.

68

2-52

CONTROLS AND INSTRUMENTS ADJUSTING THE LUMBAR SUPPORT An upper and a lower air chamber are integrated into the backrest. They can be inflated or deflated independently of each other. The backrest convexity can be adapted to the shape of the operator’s spine with the two push-buttons (12).

For both push-buttons: - by pressing + the air chamber is inflated; - by pressing - the air chamber is deflated.

SEAT HEATING 69 Two electric heating elements (seat and backrest) are installed in the operator’s seat.

The maximum heating capacity is preset. The temperature is thermostat-controlled.

Switching on and off This is done with a rocker switch (13) on the left side of the backrest.

“0”:

heating OFF

“I”:

heating ON

The seat heating can be switched on only if the ignition key is set to position “I” (Ignition ON).

70

BACKREST EXTENSION (OPTIONAL) (HEAD SUPPORT) The backrest extension can be suited individually in height, by pulling the same out (14) up to stroke end by means of a toothed rod.

Adjustment range: 100 mm (3.94 in) in 7 places To remove the backrest extension, override the resistance of the stroke end with a light pull.

71

2-53

SECTION 2

SEAT BELT

WARNING Always fasten your seat belt before starting the engine. The machine is equipped with a roll over protection system (ROPS) which ensures your safety. The seat belt will protect you efficiently if you attach it correctly and if you always wear it. The seat belt must not be too loose. It must not be twisted or caught in the seat.

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 run belt over rigid or fragile objects such as bunches of keys or spectacles. In this way your body could get injured in case of accident. The operator’s seat is fitted with a lap-type seat belt. The belt tensioning roller is incorporated on the left side of the seat.

FASTEN SEAT BELT Insert the hooking tongue (2) in the buckle (1). Pull the tongue against the buckle to check if the seat belt is well secured.

The belt should not be entangled or rolled.

72 RELEASE SEAT BELT Press the lock (3) of the buckle (1) and take out the hooking tongue.

The belt rolls in automatically.

73

2-54

SECTION 3 OPERATING THE MACHINE GENERAL INSTRUCTIONS BEFORE OPERATING THE MACHINE

OPERATING THE MACHINE

WARNING

WARNING

Read and assimilate the instructions and warnings shown in this manual before operating the machine.

Check that all the controls and all the safety devices operate correctly in a safe, clear area before beginning work.

Before operating the machine, observe the following instructions: - Check the levels (engine oil, hydraulic fluid and coolant fluid) and make sure that the various fluids correspond to the conditions of use.

- Carry out the daily maintenance operations.

- Walk around the machine, look for any leaks and inspect the hoses.

- Before undertaking any road travel, lock the equipment, and connect the safety systems required by regulations.

- Before any road travel or job site work at night, check that the lighting and signalling systems are operating correctly.

- Check the condition of the tyres and the tyre pressure.

- Clean the steps and access handles and your shoes.

The presence of oil, mud or ice (winter) can cause accidents. Make sure they are always clean.

- Clean or replace safety decals which are no longer legible.

- Make sure that the engine hood is closed and latched correctly.

- Check that the cab door is closed correctly.

- Remove anything which might hinder visibility. Clean the windshield windows and rear view mirrors.

- Make sure that no objects or tools are left on the machine or in the operator’s compartment.

- Make sure to know the escape manoeuvres from machine (emergency exit).

- Make sure that nobody is under or on the machine.

The operator should be the only person on the machine.

- Make sure that nobody is within the working range of the machine.

When operating the machine the following instructions must be observed: - Start the engine taking into account weather conditions.

- Regularly consult the hourmeter to ensure Maintenance Intervals are observed.

- If you use the machine under particularly severe conditions (dusty or corrosive atmosphere, etc.), the Maintenance Intervals should be reduced.

- Make sure that you know the location of pipes and cables before beginning work.

- Do not work near overhead high-voltage electrical cables without checking beforehand that all necessary measures have been taken to respect the minimum distances: 5 metres (16.40 ft).

- On job sites on the public highway, use regulation signals, taking into account the working range of the machine. Local regulations define the number, type and location of reflective strips.

- Make sure that the operator’s seat is correctly adjusted and positioned.

- Never operate any control or driving component unless you are seated correctly in the operator’s seat with the seat belt adjusted and attached correctly.

- Adapt your operating style to the type and conditions of work.

- Do not allow anyone to stand in the machine working area. Stop all movement until the person has moved away.

- Operate all controls progressively so the machine works smoothly.

- When loading the machine onto the trailer of an articulated vehicle, see “Transporting the machine”.

- When towing the machine, see “Machine recovery and towing”.

- Avoid running the engine in an enclosed space. If necessary, ensure good ventilation under all circumstances.

- Dust, smoke or fog can reduce visibility and cause an accident. Stop or slow down the machine until normal visibility is restored.

3-1

SECTION 3 - If there is any operating problem, immediately lower the loader equipment to the ground, engage the parking brake and stop the engine. Find the cause or inform responsible persons and take the necessary measures to forbid the use of the machine.

- When stopping the engine take account of weather conditions.

- To park the machine, see “Parking the machine”.

RUNNING-IN PERIOD Your machine will last longer and give better and more economical performance if you pay particular attention to the engine during the first twenty hours of operation.

During this period: Keep a close watch on the instrument panel.

Operate the machine at normal speeds. Do not run the engine too much at stalling speeds (with the wheels turning slowly or stopped and the engine at full speed).

To ensure adequate lubrication, idle the engine at 1000 rev/min. for one minute before increasing the rpm.

Maintain the engine at the normal operating temperature.

Do not run the engine at idle speed for long periods.

During the running-in period, the following inspections and maintenance operations must be carried out in addition to the operations shown in the Maintenance Programme: Every ten hours or daily Check the engine oil and coolant levels.

Check the transmission and rear axle oil levels.

Check the greasing of the front equipment.

After the first 10 operating hours Check the tightness of the wheel nuts.

After the first 50 operating hours After the first 50 operating hours, consult your Dealer for the 50 hours maintenance operations recommended by the Manufacturer.

3-2

OPERATING THE MACHINE AFTER DAILY OPERATION - PARKING Secure the machine: - Carry out daily service operations.

- Park the machine.

- Park machine on dry and level ground. Place the working equipment on a stand or on the ground.

- Return the machine to basic position.

- Make sure that the cab is placed to its lowest position.

- To stop the machine on a grade: park the machine with face downhill and with the teeth of the bucket pushed firmly into the ground.

- Secure the machine with the wheel chocks.

- Lock the upper structure.

- Activate the parking brake.

- Shut off the engine (turn the ignition key to position “0”).

- Remove the ignition key.

- With special attachment, move both hydraulic control levers and the pedal in all directions, to allow all cylinders and the system to release pressure.

- Disconnect the pilot control.

- Close cab glasses and windows.

- Lock the cab door and all machine covers and hoods.

- Remove gross dirt from machine.

- Visual check of hydraulic system, axle and reduction gears tightness.

- Visual check of machine and attachment status: verify the presence of possible damages to the upper structure and undercarriage.

- Visual check of tyres tightness and status.

- Protect the machine against unauthorized starting.

3-3

SECTION 3

START-UP START-UP IMMOBILIZER This machine is equipped with an electronic immobilizer as a standard feature. When activated, the immobilizer prevents unauthorized starting of the machine.

The immobilizer is not active on delivery from the factory. It can be activated by the customer when the machine is handed over. Before activation, the customer has to enter a 4-digit code chosen by him.

NEW CODE ENTER In the operating mode, press the arrow button until the lock symbol (4) is highlighted grey and the text “CODE” appears. Confirm the setting with “set” button (3).

Using the downward arrow button (2), activate the lock symbol (4) and confirm the selection with the “set” button (3).

Enter the presently valid 4-digit code with the arrow buttons and the “set” button. Attention when making the change for the first time: the code preset at the factory is 1111.

After confirming the fourth digit, you are requested to enter the new code.

NOTE: note the code and keep it in a safe place.

Confirming with the “set” button, saves the entered code, whereas upward arrow button (1) rejects the change. This takes you back to main menu.

3-4

CODE

1

OPERATING THE MACHINE

INPUT CODE

SAVE CHANGES?

NEW CODE

WRONG CODE

INPUT CODE INPUT NEW CODE

PRESS ANY KEY

INPUT NEW CODE

F34081

2 key = ON

ERROR MESSAGE

System check ok?

NO

• Engine does not start.

• Set ignition key to OFF. • Restart procedure.

YES

Code active?

YES Code correct?

NO

F34429

3 3-5

SECTION 3 CODE ACTIVATION In operating mode depress repeatedly the arrow button, until on main menu appears “CODE” on grey background.

By means of the arrow buttons you can select “closed-lock” symbol and confirm the selection with “set” button.

CODE DEACTIVATION In operating mode depress repeatedly the arrow button, until on main menu appears “CODE” on grey background and confirm with button “set”.

By means of the arrow buttons you can select now the “open-lock” symbol and confirm the selection with “set” button.

FURTHER SETTINGS Similar to the above procedure, the code can also be changed and deactivated in this sub-menu and a time set after which the code is to become active.

The machine can thus be put back into operation after a pause without the need to re-enter the new code, if this is done within the preset time.

3-6

OPERATING THE MACHINE IMMOBILIZER, ACTIVATING THE CODE TIMER FUNCTION This menu can be used for setting a time after which the code is to be activated. The machine can thus be put back into operation after a pause without the need to re-enter the new code, if this is done within the preset time.

In the operating mode depress the arrow button repeatedly, until on main menu appears “CODE” on grey background. Now activate button “set”.

By means of the arrow buttons you can select “closed-lock” symbol and confirm the selection with “set” button.

By means of the arrow buttons you can activate now the clock symbol and confirm the selection with “set” button.

Enter the activation time with the arrow buttons and the “set” button, this time can be between 1 minute and 12 hours. After confirming the last number you are requested to confirm once again.

Confirming with the “set” button, saves the selected time of activation, whereas arrow up button rejects the change. This takes you back to main menu.

CODE

Save changes?

F34083

4

3-7

SECTION 3

CODE

Active code after:

Save changes?

Data input

Active code after: minimum = 1 minute maximum = 6 hours

F34250

5

3-8

OPERATING THE MACHINE START-UP The following text describes starting of the machine without entering a number code.

Disconnect the pilot control by lifting the safety lever (1) to position “0”.

6 Set the travel direction to neutral with push-button (2).

Insert the ignition key into the cylinder (3) and turn it to position “I”.

The display shows the logo.

The machine performs a test check of the system.

A brief warning is sounded.

7 After approximately two seconds, the display shows a information relevant to the next service to be performed.

After two more seconds the display shows the actual time, the service hours performed until now and the fuel level indication.

Turn the ignition key to position “II”.

The engine starts.

Release the ignition key that returns to position “I”.

Now you can set the safety lever (1) to position “I” and the machine can be operated.

8

3-9

SECTION 3 ENGINE DOES NOT START

BEFORE JUMP-STARTING

If the engine does not start, reset the ignition key to position “0” and repeat the start-up operation.

Switch off all electrical consumers in receiving machine (with discharged battery) and turn ignition key to position “0”.

During this operation hold the key continuously to start-up position for at least 30 seconds. Between one start trial and the other observe a pause of 2 minutes.

If the engine does not start even after three attempts, check the fuel supply. The absence of blue or white smoke from the exhaust tube during start-up, indicates that the engine receives fuel.

Watch for the fault messages.

Maybe there is water in the fuel.

Drain water and try to start the engine again. If, after all, the engine fails to start, address to the Aftersales service.

ASSISTED STARTING (JUMP-STARTING)

CAUTION Keep any potential ignition sources, such as unshielded lights or burning cigarettes, away from the batteries. Battery gases are readily flammable.

A high current flows on connection of the earthing cable. Sparks occurring at the contact point may ignite gases at the discharged battery.

The ground clamp should therefore be connected as far as possible from the discharged battery.

Never lean over the batteries when jump-starting a vehicle. Wear goggles.

Never use assisted starting when the batteries are defective or frozen.

Never connect batteries (battery sets) unless they have the same voltage.

Use only tested jumper cables with insulated terminal clips and an adequate lead diameter.

Ensure that the bodies of the supplying and receiving machines are not in contact. Otherwise a current flow might result from connecting the positive poles. Risk of short-circuiting.

Never use jumper cables with overvoltage, e.g. two or three batteries or booster units connected in series and generating voltages in excess of 12 V. Never use welding generators or welding transformers as a source of current.

Position jumper cables in such a way that they cannot be caught by rotating engine components.

3-10

Switch off all consumers in supplying machine (booster battery) and shut off engine.

The charge of the batteries supplying electric power should not be lower than the charge of the flat batteries.

OPERATING THE MACHINE CONNECTING THE JUMPER CABLES Connect the red jumper cable to the positive clamp of the discharged battery (1) and then to the positive clamp of the booster battery (2).

Connect the black jumper cable first to the negative clamp of the booster battery (3) and then to a brightmetal point on the receiving machine (4).

9 STARTING THE ENGINES Start the engine of the supplying machine and run it with stepped-up revolutions.

Start the engine of the receiving machine (with discharged battery). If the engine does not start up after 15 seconds, wait one minute before restarting.

Once the engine has started up, proceed as follows: Switch on some high-consumption users, e.g. complete lighting system, blower on stage 3 and the airconditioning system if present. All this prevents that when the cables are detached, peaks of current are generated, that could on their turn damage the electronic units.

Disconnect battery jumper cables in this way: - negative terminal on receiving machine (4); - negative terminal on delivering machine (3); - positive terminal on receiving machine (2); - positive terminal on delivering machine (1).

Switch off high-consumption units again.

Run the engine at moderate speed for about half an hour. Batteries are partially re-charged.

Have the electrical system of the machine checked, to determine why the batteries were discharged.

WARNING

10

If, after all, the engine fails to start, address to the After-sales service.

3-11

SECTION 3 ENGINE SHUT OFF

WARNING Do not shut off the engine when running at full speed, but let it run idle for three/five minutes to cool it down.

Place the working attachment on the ground.

By means of push-button Low Idle (1) bring the engine to idle run.

11 Turn the ignition key (2) to position “0”. The engine is shut off and stops.

Remove the ignition key (2) from the cylinder.

The key can be pulled out only if placed to position “0”.

12

3-12

OPERATING THE MACHINE

CAB AT VARIABLE HEIGHT The cab at hydraulically variable height is used to elevate the control position of the machine.

The cab with hydraulic raising and lowering adjustment, works on the principle of the parallelogram.

By means of this system, the cab can move upwards and forwards in a circular motion, to give the operator a better view of the working site.

The maximum allowed angle for the machine to work with a raised cab is of 7.5°.

Never move the machine with the cabin raised.

The raising of the cab has to be controlled exclusively from the cab.

13

The upper edge of the raised cab (without rotary light), when the machine is leaning on the stabilizers, reaches the maximum height of 5600 mm (220.47 in).

The front edge of the cab, with respect to the slew axis, reaches the maximum horizontal slew radius of 3000 mm (118.11 in).

OPERATION SAFETY LEVER To avoid leaving the cab when raised, a prolonged red safety lever (1) has been installed.

When this lever is not positioned to “I”, the machine pilot control is disabled, therefore also the cab rising and lowering push-buttons are disabled.

With raised cabin, the safety lever (1) is disengaged and an acoustic warning is released.

14

3-13

SECTION 3 RAISING AND LOWERING Fasten seat belt.

Start the engine.

Shift red safety lever (1) to lowest position.

For the raising, press push-button (2) by holding the button face with the symbol ( ) pressed, until the required height or the maximum height is reached.

For the lowering, press push-button (2) by holding the button face with the symbol ( ) pressed, until the required position or the lowest position is reached.

When pressing the push-button for cab lowering, an acoustic warning is released, alerting the bystanders not to enter the hazard area of cab height adjustment.

15

When the cab has reached its lowest position, the acoustic warning clears off.

CAB HEIGHT ADJUSTMENT LOCKING Under particular circumstances, with cab raised, it could be necessary to disconnect the pilot control for cab height adjustment.

Because of this, press switch (3): - pilot control disconnected: press the button face with the symbol; - pilot control connected: press the button face with no symbol.

16

3-14

OPERATING THE MACHINE EMERGENCY LOWERING In order to lower the cab without any risk, also in presence of technical troubles, for instance because of an electric fault of the cab lowering/raising button, the cab at hydraulically variable height has been equipped with an emergency lowering device.

To activate the cab emergency lowering control, a cock (1) has been installed inside of the cab and another one has been installed in the rear of the raising frame (2).

On the cock, placed on the rear side of the raising frame (2), is applied a warning plate.

During normal operation, the cocks are closed (position “0”).

17

According to the situation, in order to lower the cab, turn the cock inside of cab or the cock behind the raising frame to “I” position.

During the emergency lowering, the electric control is by-passed, while the cab sets slowly to lowest position.

As soon as the cab has reached its lowest position, turn the clock again to “0” position.

WARNING Before activating the emergency lowering, make sure that nobody is staying in the hazard range.

18

The acoustic warning signal for bystanders, with the emergency lowering does not operate.

3-15

SECTION 3

TRAVEL BEFORE STARTING THE TRAVEL Remove any soil, mud, snow, ice, grease and oil from your working footwear. You might otherwise slip from steps and pedals and thus initiate inadvertent movements.

Raise the working attachment only to such an extent that the machine can pass under overhead power lines without risk.

Make sure that the cab is placed to its lowest position.

Adjust the operator’s seat, the steering column and the rear view mirrors before setting off.

If the machine is equipped with seat belt, fasten it.

Close the front window and the cab door.

Warn persons in the immediate vicinity by sounding the horn before setting off.

Never travel across slopes.

Take the utmost care on slippery and greasy ground.

Check for correct tyre pressure.

Make sure the wheels have adequate grip; only then are the steering and braking properties assured.

Give the engine 2 to 3 minutes time to warm up before setting off.

Run the engine at full load only if warm.

BASIC POSITION The specifications “forward” and “reverse” as well as “right” and “left” apply only when the machine is in basic position and the machine operator is looking through the front window towards the working attachment.

Bear in mind that the required and the actual directions of travel “forward” and “reverse” as well as the required and actual directions of cornering “right” and “left” are identical only when the machine is in basic position.

If the upper structure is turned more than 90° from its basic position, the machine moves in the opposite direction from the viewing direction of the operator.

Therefore check the position of the upper structure in relation to the undercarriage before setting off.

3-16

OPERATING THE MACHINE The machine is in its basic position when the cab (1) is over the left pair of wheels of the steering axle (2).

A = travelling forwards: the wheels of the steered axle are in front.

B = travelling backwards: the wheels of the rigid axle are in front.

Only in the basic position are the travel direction selected and the true travel direction the same.

WARNING If the upper structure is slewed more than 90° out of basic position, the machine moves in the opposite direction of the one selected.

19 Example: The upper structure (3) is turned by more than 90° out of its basic position.

The operator looks through the front window and wants to move in this direction.

He depresses the travel pedal. The machine, however, does not travel in direction B but in direction A. The operator wants to travel “forward”, he is actually travelling in “reverse”.

Because of this: If the position of the upper structure (3) in relation to the undercarriage (4) is not exactly known, look out of the windows to check the direction of the upper structure (3) with respect to the undercarriage (4).

If this is not possible, depress first the travel pedal slightly.

In this way you can determine the machine travel direction.

Depress the travelling pedal fully only after the actual travelling direction is perfectly clear.

20

3-17

SECTION 3 BASIC SETTING According to the operation requirements and conditions, to the pedals and control levers reactions for working and travel movements, you can select up to four different basic settings.

Following setting are possible: - (A) - SPORTIVE = bright - (B) - CLASSIC = balanced - (C) - COMFORT = smooth and sensitive - (D) - EVOLUTION = flexible with specific feature of machine rotation The letter relevant to the basic setting selected, from A to D (1), is shown always on the middle of the display.

21

The machine is delivered ex-works with configuration C - smooth and sensitive.

Have these setting performed by the After-sales service.

BASIC SETTING SELECTION

MACHINE

Save changes?

LEVELLING A

BASIC SETTING SPEED LIMITATION

BASIC SETTING B - BALANCED C - SMOOTH D - FLEXIBLE

BASIC SETTING

BASIC SETTING

B - BALANCED

B - BALANCED

C - SMOOTH D - FLEXIBLE

C - SMOOTH

BASIC SETTING A - BRIGHT

D - FLEXIBLE

F34092

22

3-18

OPERATING THE MACHINE In operating mode depress repeatedly the arrow button, until on main menu appears “MACHINE” inside of a frame. Confirm with “set” button.

Depress the arrow buttons repeatedly until the bar is on “BASIC SETTING”. Confirm with “set” button.

To get back to “MACHINE” menu, depress the button with the upward arrow ( ) repeatedly or the downward arrow button ( ), until the beginning or the end of the display selection is reached. If, after reaching the end or the beginning, the display scrolls in the same direction, you return to the higher menu. If the buttons are not depressed for a prolonged period, the return to the next higher menu is automatic.

Confirming with “set” button, the sub-menu “BASIC SETTING” is recalled.

The display shows four choices as basic settings (BRIGHT, BALANCED, SOFT AND FLEXIBLE). The current active basic setting is displayed.

Depress repeatedly a arrow button, until the required basic setting is highlighted into a frame.

Confirm with “set” button.

Once the selection is confirmed with button “set”, you are requested to memorize the basic setting. By depressing the button with the upward arrow ( ), the setting is NOT memorized and the modification is not active. By pressing button “set”, the basic setting is memorized and the modification becomes active.

After that the higher menu is recalled. Now the setting can be repeated or one of the other setting options (for instance the hydraulic hammer) can be repeated. By depressing the button with the upward arrow ( ) you exit the menu “MACHINE” and return to main menu.

3-19

SECTION 3 TRAVEL Raise the blade and the stabilizers completely.

Before starting the travel, perform a visual inspection of the machine.

Lock the upper structure with the stud (1).

Apply the upper structure holding brake, by depressing button (2), until the left lamp of the button lights up.

23 Move the safety lever (3) to position “0”.

24 Then depress the “Road travel” button (6) and the right lamp of button lights up; the display shows the road travel symbol.

Insert the “Road travel” mode.

Select the gears shifting mode.

Release/disengage the parking brake. At the same time the floating axle is unlocked while the selected travel direction is restored.

Select the travel direction by means of button (4) or (5).

25

3-20

OPERATING THE MACHINE Depressing button (4): selection of forward travel direction, shown by lamp (A) on the display.

A single acoustic warning is sounded Depressing button (5): select forward travel direction, shown by lamp (B) on the display.

26 If you have to work at a particularly low speed, select the 1st speed (off-road travel) with push-button (8) and than the creep speed with push-button (7).

A double acoustic warning is sounded.

Activate the travel pedal (9), the machine starts travelling.

The display shows the selected gear and speed; the lamps indicated the travel direction selected.

Set the speed with the travel pedal (9).

27 INCHING - TRAVEL SPEED ADJUSTER The travel speed can be adjusted by using the knob / potentiometer (1).

By turning it to the left: travel speed is decreased.

By turning it to the right: travel speed is increased.

When travelling uphill, machine speed does not decrease. When travelling downhill, the braking effect of the engine is increased, so that the machine speed does not increase. In this way, a non-permitted increase in travel speed and danger situations both for persons and for the machine are prevented.

When stopping the machine on slopes (travel speed in “0” position), the machine keeps still, even without actuating the service brake and the automatic mode of the parking brake.

28

Thanks to the closed oil circuit, as regards inner leaks, wheel movement is prevented by blocking the travel engine.

3-21

SECTION 3 TRAVEL SCREEN DISPLAY By depressing the button for “Road travel” the display shows and highlights the relevant symbol.

F34443

29

F34099

30

3-22

OPERATING THE MACHINE GEARBOX - GEAR CHANGE According to the machine operation kind, you can afford different operation types at gear change: - 1st speed: left light on button (1) lit and right light out; - 2nd speed: left light out and right light on; - automatic gearshift active: both lamps are out.

31 When the pedal (2) is activated, in the middle of the lower section, the display shows the symbol of gear engaged [the tortoise (A) = 1st speed or the hare (B) = 2nd speed].

32 CREEP SPEED The engagement/disengagement of the creep speed is possible only at a travel speed lower than 20 km/h (12.43 mph). The creep speed can be engaged/disengaged with button (3) (the right lamp lights up at creep speed engagement). At the same moment, on the display bottom right, the snail symbol (C) appears. The speed of the relevant speed engaged, lowers of about 80%.

33

34

3-23

SECTION 3 OPERATION AND SPEED OF AUTOMATIC GEAR CHANGE During travel at 1st speed (left lamp on button (1) lit and right lamp out), the machine travels at low speed “Tortoise” up to 5 km/h (3.11 mph), then the automatic gear change engages and the speed switches over to 2nd gear. Speed can increase up to 14 km/h (8.69 mph).

If during 1st speed travel you depress the “Snail” button (3), speed will be reduced automatically to 1 km/h (0.62 mph).

During travel at 2nd speed, if speed lowers up to 5 km/h (3.11 mph), the automatic gear change engages and speed decreases to 1st gear, if you travel at 2nd speed and depress the button “Snail” (3), the speed decreases up to 2 km/h (1.24 mph), the automatic gear change engages and the machine runs at 1st speed.

35

Automatic speed change

F34447

36

3-24

OPERATING THE MACHINE TRAVEL WITH LOAD APPLIED TO CRANING HOOK Turn the load toward travel direction. The flywheel must be placed in this case over the steering axle.

Approach the load as near as possible to the earth and to the machine.

Lock the upper structure with the stud (1).

Apply the holding brake of the upper structure with push-button (2). The symbol left lamp lights up. At the same time the lamp lights up on display.

Release the blocking the floating axle by depressing push-button (3) (the right lamp lights off).

Proceed with caution and slowly.

37

3-25

SECTION 3 FLOATING AXLE BLOCKING AND UNBLOCKING The steered axle is suspended from the undercarriage in such a way that it can float about the longitudinal axis of the machine (floating axle). This feature is an advantage when driving on uneven terrain. During working it is, however, necessary to avoid axle floating. To achieve this, the oil exchange between two hydraulic cylinders taking support on the axle is prevented. The floating axle is then blocked and the stability of the machine considerably increased. Before using the machine for driving, the floating axle must be unblocked.

OPERATION The blocking and unblocking of the floating axle activates by depressing button (1), that has two lamps and three engagement positions: - left and right lights out: blocking of floating axle activated; - left light on and right light out: blocking of floating axle deactivated; - left light out and right light on: automatic operation.

Depress button (1) many times until you achieve the required condition.

AUTOMATIC MODE To select the automatic mode or to exit this mode, depress button (1) and hold for more than two seconds.

In automatic mode some of the following conditions take place: - the floating axle is blocked if the travel pedal remains inoperative for more than 0.5 seconds; - the floating axle is released when you depress the travel pedal; - for the full time of stabilizers or blade operation, the floating axle is blocked. At the end of operation, the axle blocking is restored.

Beware, at machine departure from the factory this option is disabled. This option can be enabled or disabled through the Service menu.

3-26

38

OPERATING THE MACHINE

WORKING OPERATION SAFETY INSTRUCTIONS Inspect the site for underground gas, power and water lines before starting work.

Any damage to these lines is a life-threatening risk.

Clean off any earth, mud, snow, ice, grease and oil from your working footwear before operating the machine.

There is otherwise a risk of slipping off the pedals and steps and initiating inadvertent movements.

Warn persons in the immediate vicinity by sounding the horn before starting work.

Stop working if anyone is staying in the hazard range of the machine.

39

Make sure such persons have left the hazard range before resuming work.

Work with the machine only when it is standing on level and flat ground and in its basic position.

Make sure the clearance between working equipment and overhead power lines and other structures is sufficient!

If a power line has been contacted, drive the machine out of the hazard zone or lower the working attachment.

Pay attention to machine load capacities.

Components of the working attachment may damage the machine when the working attachment is used beyond its capacities.

Work with caution and avoid similar extreme conditions.

3-27

SECTION 3 BEFORE BEGINNING THE WORK Every day, before setting the machine in operation, carry out daily maintenance.

Enter the cab and seat on the operator’s seat.

Carry out all start-up operations.

With engine at service temperature, set the required rpm by means off push-button (1). According to the operation mode, it is possible to set up to 7 stages the rpm/power ratings.

Working mode

Power levels

Craning Road travel

1-3 DRIVE

Magnet

40

1-7

MACHINE IN WORKING POSITION Return the machine to basic position. Work possibly in this position to achieve the maximum balance.

Stop the machine.

Engage the parking brake by pressing the button (2).

Lower the stabilizers.

The machine can be installed with different stabilizers configurations.

41

3-28

OPERATING THE MACHINE AUTOMATIC SPEED REDUCTION (AUTO IDLE) The speed reduction function (Auto Idle) automatically reduces the engine speed in no-load working conditions.

The drive engine is throttled down to idling speed if work with the working equipment is interrupted for longer than 4 seconds.

Fuel consumption and noise and exhaust emissions are reduced.

When the operator activates a hydraulic function, the drive engine speed is again increased to the previously set speed of the respective power level.

The switching state of the Auto Idle function (ON/ OFF) is saved after engine shut-off.

NOTE: do not activate the engine speed automatic reduction with following functions: craning, hammering, rotary cutter or during travel.

Risk of unexpected changes in machine power.

To activate the engine automatic speed reduction depress push-button (1): the right lamp lights up.

To deactivate the engine automatic speed reduction depress push-button (1) again: the right lamp lights off.

The Auto-Idle speeds and the time to activation are pre-programmed at the factory. These parameters can be modified depending on the conditions of use of the machine. Contact the After-sales service if a modification of the programmed values is required.

42

3-29

SECTION 3

AUTO IDLE

YES

Not operating > for 10 seconds AUTO IDLE

NO AUTO IDLE Selection

Power level adjustment

F34112

43 POWER LEVEL SELECTION Select the power level by means of buttons (1) and (2). If the arrow buttons are depressed longer, the values keep changing automatically.

The engine speed can be varied in 7 stages up to maximum engine speed and pump performance.

Power levels 6 and 7 are used for working with high pump output.

Power levels 4 and 5 are used for working with a engine power rating called “economic”. Engine speed and pump output are reduced and the working speed is slightly lower.

With power levels 1 thru 3, the machine works with further reduced engine speed and pump output.

These power levels are particularly useful for precision work, e.g. lifting operations, and for further reduction of the fuel consumption.

3-30

44

OPERATING THE MACHINE The selected power level is indicated on the display by dark bars representing the power stages (3).

3

F34114

45

The power level is associated to 3 different operation modes: - digging (A); - levelling (B); - loads moving (C).

The display will show 3 different symbols.

A

B

C

F34115

46

3-31

SECTION 3 PILOT CONTROLS ACTIVATION/DEACTIVATION Perform the activation with following operations: Shift safety lever (1) to position “I”.

47 Now the electrical pilot control is activated; the hydraulic control levers (2) and (3) as well as pedal (4) are operational.

48 Deactivation is performed as following: Move the safety lever (1) to position “0”. The pilot control is now deactivated.

49

3-32

OPERATING THE MACHINE HOLDING AND RELEASING THE UPPER STRUCTURE SLEW UPPER STRUCTURE HOLDING Return the machine to basic position. the locking pin (1) is set right above the opening of the undercarriage.

Lift the pin (1), turn it away from the seat and push it downward.

The locking pin engages in the opening of the carriage. If the locking pin cannot be turned at all or only with difficulty, slew the upper structure slowly to the left or to the right. Meanwhile push the locking pin downwards.

RELEASING THE UPPER STRUCTURE

50

Pull up locking pin (1), turn towards the seat and engage.

If the locking pin cannot be turned at all or only with difficulty, slew the upper structure slowly to the left or to the right. Meanwhile pull the locking pin upwards.

UPPER STRUCTURE HOLDING BRAKE The slewing gearbox is equipped with a multi-plate brake. This is applied by spring pressure and released by hydraulic pilot pressure.

The upper structure holding brake can be applied at any time with button (1), (left lamp lit). The holding becomes active only after hydraulic control lever (2) is in neutral position and the upper structure slewing moving has come to a halt. About 3 seconds later, the “Holding brake” lamp (3) lights up on the display.

51 With ignition key is off, with engine shut off or in the event of system voltage failure, the upper structure holding brake is active. The upper structure is then braked.

The upper structure holding brake can be operated in the following three modes: - right light on and left light out, by depressing button (1) only once: upper structure holding brake applied; it releases automatically when the left hydraulic control lever (2) is shifted toward one of the two rotation directions; - left lamp on and right lamp out; upper structure holding brake always applied (necessary condition for road travel);

52

- left and right lights out: upper structure holding brake always applied.

3-33

SECTION 3 Automatic operation The holding brake is automatically applied when the upper structure comes to an halt. It releases when a slewing movement is initiated.

If the upper structure holding brake is set to “Applied”, during a slewing movement, left lamp lights up.

For safety reasons, the brake is applied, however, only after the slewing movement has ended.

Technical problems can lead to a change of the functions of button (1).

The following switching states of the upper structure holding brake that are active when the ignition is switched off, are active again when the ignition is switched on.

Ignition OFF

Ignition ON

Brake released

Automatic

Automatic

Automatic

Applied

Applied

Releasing the upper structure holding brake Depress repeatedly button (1), until lamps on pushbuttons turn off. The holding brake is released and the upper structure is free to turn (not possible when pilot control is off).

In the automatic mode (with right lamp lit up), the holding brake is released when the slewing control lever is moved out of neutral position.

Upper structure holding brake faults - All 3 switching states continue to be available; in the “automatic” or “applied” states, the respective lamp flashes (“in automatic”, right lamp; “applied” left lamp).

- Only the “released” and the “applied” states are available; while with “applied” state the left lamp flashes.

3-34

OPERATING THE MACHINE Upper structure holding brake, emergency activation

WARNING The upper structure slewing is free as soon as the upper structure emergency brake is released with the emergency activation!

In such case, the upper structure is not able to stop automatically after the end of the slewing movement.

When working on slopes or in an inclined position of the excavator, the upper structure can continue to slew uncontrolled if the slewing movement is not stopped by countering.

To avoid dangerous situations, the emergency release function should be used only in exceptional cases.

Rectify any faults of the upper structure holding brake immediately (or have them repaired).

The pilot pressure needed for releasing the upper structure holding brake is controlled by means of a solenoid valve.

In the event of solenoid failure, the upper structure holding brake can be released with the emergency release device.

The solenoid valve is installed in the frame behind the cab (1).

Remove the base-plate of the maintenance opening below the valve stack.

Screw the setscrew (3) down to the limit stop using an Allen key (2). The upper structure holding brake is released and the upper structure can turn freely.

After removal of the fault, screw the setscrew back out to the upper stop.

53

3-35

SECTION 3 UPPER STRUCTURE SLEWING Switch the upper structure holding brake into the automatic mode by depressing button (1) until lamp is lit up (this mode is selected automatically on engine start-up).

Activate the pilot control by pushing forward the safety lever (3).

Unlock the upper structure.

To slew the upper structure to the right push hydraulic control lever (2) to the right.

To slew the upper structure to the left push hydraulic control lever (2) to the left.

The slewing speed increases the further the hydraulic control lever (2) is moved to the right or to the left.

UPPER STRUCTURE HOLDING The maximum slewing speed depends on the slewing features set by button (4): - lamps off: low slewing speed; - left lamp on: standard slewing speed; - lamps on: high slewing speed; - intermittent lamps: fault message.

UPPER STRUCTURE BRAKING The slewing movement of the upper structure is braked when the hydraulic control lever returns to neutral position.

By means of push-button (4) you can set the braking effect of the upper structure holding brake. The time of braking from lever release to upper structure stop can be suited to individual requirements according to 3 levels.

- Lamps off:

soft braking of upper structure slewing movement.

- Right lamp on:

standard braking action.

- Lamps on:

hard braking of upper structure slewing movement.

Countering (i.e. shifting the slewing control lever in the opposite direction) enhances the braking action even further.

WARNING Both lamps flash at intervals if a fault occurs in the system. Push-button (5) operation is disabled. The switching functions are blocked. In neutral position of slewing control lever, the slewing braking action is weaker. If necessary, increase the slewing braking action by moving the lever to the opposite direction (countering).

3-36

54

OPERATING THE MACHINE SLEWING POWER LIMITATION The hydraulic slewing power of the upper structure can be individually adapted to the working needs and to the conditions of use of the machine.

In the working mode, depress repeatedly a arrow button until the background of “MACHINE” (1) on main menu is highlighted grey. Confirm with “set” button.

MACHINE

55 Depress repeatedly an arrow button until “SLEWING MOMENT” (2) is selected and confirm with button “set”.

The arrows on the right side of display indicate that other sub-menus can be recalled: ON = slewing power limitation active. The slewing power preset is indicated as a percentage, e.g.

40%.

OFF = slewing power limitation inactive.

The values are increased or decreased with the arrow keys in 5% steps.

A long press of the arrow keys starts automatic scrolling of the values.

56

The desired hydraulic slewing power of the upper structure can be set with the UP and DOWN arrow buttons. Higher values mean more power available for slewing with a simultaneous reduction of the hydraulic power available to other working movements such as “Raising the boom” and vice versa.

The settings are shown as a bargraph display between 30% and 100%. Confirm the setting by depressing button “set” twice. Depressing “set” only once and then the upward arrow button, all changes made are rejected and the main menu returns.

DEFAULT = resets the settings depending on the type of machine, the standard parameters are reset to the factory-defined standard values.

3-37

SECTION 3 The standard values may vary with the type of machine.

When the slewing power limitation is on and active, the slewing power symbol is displayed in the lower left corner of the screen.

In this case, observe the priority of the temporary symbols displayed.

Save changes?

Save changes?

MACHINE DAMPING SWING POWER

SLEWING POWER LIMITATION

AUTO POWER BOOST

SWING SPEED LIMITATION

PARAMETERS NOT UPDATED. RE-TEST. PRESS ANY KEY

SWING SPEED LIMITATION

Slewing speed

DEFAULT

PARAMETERS NOT UPDATED. RE-TEST. PRESS ANY KEY

SWING SPEED LIMITATION

SWING SPEED LIMITATION

Slewing speed

DEFAULT

SWING SPEED LIMITATION

ADJUSTMENT

ADJUSTMENT

DEFAULT

DEFAULT

Slewing speed

DEFAULT F34121

57

3-38

OPERATING THE MACHINE POWER BOOST FUNCTION - POWER BOOST The “Power boost function” is always automatically active in power levels 1 - 3 and in the travelling function (travel pedal depressed).

In the event of heavier loading, the hydraulic pressure for the working functions and for travelling is increased.

This means higher lifting force, higher extraction force, higher breaking force, higher traction forces and improved precision control at reduced working speeds.

When button (1) on left hydraulic control lever (2) is depressed, the activation of the power boost function is displayed on the screen The function remains active for about 10 seconds.

The function activates only if power levels 4 - 7 are active and the activation time is not exceeded.

In power levels 1 - 3 and during travelling, the automatic activation of the function is not displayed, in order to have more free space on the screen for other symbols during the work.

The increase of hydraulic pressure is now available for about 10 seconds. After about 10 seconds, the increased hydraulic pressure is shut off again.

The state of activation of the Power boost function is simultaneously displayed on the screen.

58

To activate the function once again release button (1) and press it again.

POWER BOOST, AUTOMATIC FUNCTION The Auto Power Boost function can be activated and deactivated with the help of the multi-function display’s movements menu “Fill bucket” and/or “Retract dipper”.

The Auto Power Boost is not active on delivery from the factory.

With Auto Power Boost on, the Power Boost function is activated automatically in performance levels 4 - 7, if maximum system pressure is prevailing for prolonged periods for the “Fill bucket” and/or “Retract dipper” movements and if the corresponding control lever is at maximum deflection.

3-39

SECTION 3 AUTO POWER BOOST ACTIVATION In operating mode depress repeatedly the arrow button, until on main menu appears “MACHINE” on grey background. Depress the “set” button.

Depress the arrow buttons repeatedly until the bar is on “Auto Power Boost” activates. Depress the “set” button.

Use the arrow buttons to select the working attachment for which you want to activate or deactivate the “Auto Power Boost”. Depress the “set” button.

By means of the arrow buttons you can activate or deactivate this option and confirm the selection with “set” button.

59 Confirm the change with the “set” button or keep the old setting by depressing an arrow button.

Activation of the standard Power Boost function with button (1) is always possible, even when Auto Power Boost is on.

60

MACHINE DAMPING SWING POWER AUTO POWER BOOST

AUTO POWER BOOST

PARAMETERS NOT UPDATED. RE-TEST. PRESS ANY KEY

AUTO POWER BOOST DIPPER IN

NO

YE

Updating performed

by ESX?

BUCKET FULL

AUTO POWER BOOST DIPPER IN

AUTO POWER BOOST DIPPER IN

BUCKET FULL

AUTO POWER BOOST DIPPER IN

Save changes?

F34127

61

3-40

OPERATING THE MACHINE LEVELLING MODE The “levelling” mode can be activated in the power levels 4 - 7.

Depress button (1). The display shows the symbol “Levelling”. The hydraulic control levers performs controls in a smoother way.

If both levers are brought to position “0”, an automatic return to the “Digging” mode is executed after 4 seconds.

If the “Levelling” mode is to be switched off out of hydraulic control lever movement (with no waiting time), press button (1) again.

CONFIGURATION OF SETTING LEVELLING MODE

62

Save levelling The “Levelling” mode remains activated in permanence after having been switched in with push-button (1) if this mode has been preconfigured on the display.

If the machine is shut off while in the “Levelling” mode, this mode is active again after new starting.

In operating mode depress repeatedly the arrow button, until on main menu appears “MACHINE” on grey background. Depress “set” button.

Depress the arrow buttons repeatedly until the bar is on “LEVELLING SETTING”. Depress “set” button.

Press the arrow buttons until the control “SAVE LEVELLING” appears. Depress the “set” button.

63

Confirm the changes with the arrow buttons or leave the existing setting. Depress the “set” button.

Confirm the change with the “set” button or keep the old setting by depressing an arrow buttons.

3-41

SECTION 3 Fine levelling The “Fine levelling” mode can permits even more sensitive working. In this case, the maximum equipment speed is no longer available for boom and dipper movements.

This working mode must have been configured beforehand on the display.

In operating mode depress repeatedly the arrow button, until on main menu appears “MACHINE” on grey background. Depress “set” button.

Depress the arrow buttons repeatedly until the bar is on “LEVELLING SETTING”. Depress “set” button.

Press the arrow buttons until the control “FINE LEVELLING” appears. Depress the “set” button.

Confirm the changes with the arrow buttons or leave the existing setting. Depress the “set” button.

Confirm the change with the “set” button or keep the old setting by depressing an arrow buttons.

MACHINE LEVELLING BASIC SETTING LEVELLING

SPEED LIMITATION

PARAMETERS NOT UPDATED. RE-TEST. PRESS ANY KEY NO

YE

Updating performed

by ESX?

LEVELLING SAVED LEVELLING FINE LEVELLING

LEVELLING FINE LEVELLING

LEVELLING SAVED LEVELLING FINE LEVELLING

LEVELLING FINE LEVELLING

Save changes?

F34127

64

3-42

OPERATING THE MACHINE HYDRAULIC DAMPING By means of the hydraulic damping, the working movements acquire smoothness. Abrupt movements of the hydraulic control levers and travel pedal are converted into smooth machine movements.

The controls of boom, dipper, bucket and travel are in this way suited in the best way to the operator’s ability and to the machine’s operational state.

For instance: - low damping: exact and progressive sequence of the hydraulic control levers movements, during building and craning works; - high damping: smooth power boost or braking during the transfer movements.

PARAMETERS SETTING

MACHINE

MACHINE

MACHINE

MACHINE

DAMPING

HAMMER

LEVELLING

SWING POWER

ROTARY CUTTER

BASIC SETTING

AUTO POWER BOOST

SHEARS

BUCKET

MACHINE

A

SPEED LIMITATION

F34157

65

3-43

SECTION 3

MACHINE

LEVELLING

DAMPING

PARAMETERS NOT UPDATED. RE-TEST.

SWING POWER AUTO POWER BOOST

DAMPING BUCKET TRAVEL

PRESS ANY KEY

DAMPING ALL STANDARD VALUES

Save changes

BOOM DIPPER

SOFT

SOFT

TRAVEL STANDARD STRONG

TRAVEL

SOFT

TRAVEL

STANDARD STRONG

STANDARD STRONG

F34132

66 NOTE: by pressing “ALL STANDARD VALUES”, all devices will set to DEFAULT value. In such a case the word “STANDARD” will be shown under the device name.

In operating mode depress repeatedly the arrow button, until on main menu appears “MACHINE” inside of a frame. Confirm with “set” button.

Depress the arrow buttons repeatedly until the bar is on “DAMPING”. Confirm with “set” button.

The arrows on the right side of display indicate that other sub-menus can be recalled.

By depressing the button with the upward arrow ( ), you scroll to main menu.

Confirming with “set” button, the sub-menu “DAMPING” is recalled.

By depressing the buttons with the upward arrow ( ) or downward arrow ( ), you can select following machine assemblies “set”: - BOOM - DIPPER - BUCKET - TRAVEL

3-44

The selected assy is now confirmed with button “set”.

By depressing the buttons with the upward arrow, you can set for each machine assy four different damping adjustments, spacing from soft damping to firm damping. Both have to be confirmed with button “set”. If the selected assy is set or the standard value is set, under the assy reference appears for instance BOOM, the word “STANDARD”. If a different setting from the standard value is defined, the word “STANDARD” does not appear.

Confirming with “set” button, the main menu “MACHINE” is recalled. First of all you are though asked to memorize the settings. By depressing the button with the upward arrow ( ), the setting is NOT saved. By pressing button “set”, the setting is memorized and the modifications becomes active.

In the sub-menu “TRAVEL” the action of the travel control piston is damped. According to this setting, and with the pedal a soft or firm travel operation of the machine is started.

OPERATING THE MACHINE STABILIZATION OF THE MACHINE The standard version of the machine does not permit independent control of the stabilizers. This means that the stabilizer legs are lifted and lowered in common. An independent control of the stabilizers is available as an option in stabilization variants.

The openings for switches not needed are covered up, depending on the equipment options.

STABILIZERS AND BLADE ACTIVATION Bring hydraulic control lever (1) to neutral position.

By means of button (2) switch over operation to “Stabilizers/blade”. The buzzer sounds intermittently, until this operation is activated.

When the function “Stabilizers/blade” is activated, the dipper is not operational.

INDEPENDENT STABILIZER CONTROL (OPTION) After installing the option, the stabilizers can be moved up and down by depressing push-buttons (A), (B), (C) and (D) without changing the proportional control.

67

To activate this operating mode, the switch face without symbol (3), must be pressed.

68 The stabilizing cylinders move only as long as the push-button is pressed. The speed of the up and down movement is fixed.

As long as the function is active, it is not possible to activate the “Power Boost” function. Automatic addition of the power boost function in power levels 1 - 3 and during travelling as well as of the Power Boost setting for some movements of the equipment remains available.

As long as the function is active, the proportional control of a levelling blade, if any, is not available.

button (A)

button (B)

button (C)

button (D)

3-45

SECTION 3

Stabilizers options

3-46

Standard stabilizers control

Independent stabilizer control

lowering at the rear rear right and left stabilizers at the same time: activate button (D) and push forward the left hydraulic control lever

lowering at the rear

raising at the rear rear right and left stabilizers at the same time: activate button (D) and pull backward the left hydraulic control lever

raising at the rear

- front right stabilizer: activate button (C)

Blade lowering in the front activate button (B) and push forward the left hydraulic control lever

- rear left stabilizer: activate button (D) and push forward the left hydraulic control lever

- front right stabilizer: activate button (C) - rear left stabilizer: activate button (D) and pull backward the left hydraulic control lever

raising in the front activate button (B) and pull backward the left hydraulic control lever

OPERATING THE MACHINE lowering in the front and in the back push the left hydraulic control lever forward (without switches A, B, C and D all stabilizers lower at the same time)

lowering in the front and in the back - front right stabilizer: activate button (A) - front left stabilizer: activate button (B) - rear right stabilizer: activate button (C) and/or - rear left stabilizer: - activate button (D) and push forward the left hydraulic control lever

lifting in the front and in the back push the left hydraulic control lever backward (without switches A, B, C and D all stabilizers lift at the same time)

lifting in the front and in the back - front right stabilizer: activate button (A) - front left stabilizer: activate button (B) - rear right stabilizer: activate button (C) - rear left stabilizer: activate button (D) and pull backward the left hydraulic control lever

3-47

SECTION 3

OPERATING THE MACHINE WITH COLD WEATHER FUEL Refill the fuel tank after each working day to prevent the formation of condensation and the entry of water into the fuel system.

To prevent the formation of crystals (-2 °C (2.84 °C)) use a low temperature fuel or mix a protective fluid with your fuel.

LUBRICATING OIL Select oil viscosity (SAE grade) according to ambient temperature before starting engine.

Increase oil change frequency when operating below -10 °C (14 °F).

BATTERY Efficient cold starting requires that battery is wellcharged.

Starting limit temperatures can be lowered by 4 or 5 °C (39.2 or 41 °F) by heating batteries up to about +20 °C (68 °F) (to do so, remove batteries and store in warm place).

COOLANT When temperature approaches to 0 °C (32 °F) it is necessary, to avoid the hazard of freezing, to check whether the cooling circuit is filled with anti-freezing mixture: otherwise, replace the coolant of radiator with this mixture.

We recommend to use AGRIFLU coolant liquid, see in the table hereunder the mixture percentages according to outer temperature: Outer temperature (up to ...)

AGRIFLU

Water

- 8 °C (17.6 °F)

20%

80%

- 15 °C (5 °F)

30%

70%

- 25 °C (- 13 °F)

40%

60%

- 35 °C (- 31 °F)

50%

50%

3-48

69

OPERATING THE MACHINE COLD START - PREHEATING The machine can be equipped with a preheating device.

By means of this system and using winter grade fuel, resistant up to -15 °C (5 °F), the operation is safe up to a temperature of about -25 °C (-13 °F).

If with temperatures lower than -25 °C (-13 °F), fuel should still be so thick to prevent the engine from starting, bring the machine for a certain time, into a warm environment.

1

2

Fuel additives (fluidizing) and similar products have not to be mixed up with diesel oil at all.

With temperatures (engine coolant) between -1,5 °C (29.3 °F) and -28 °C (18.4 °F), the preheating stage starts about 1-2 seconds after the setting of the ignition key to position “I”. The lamp (1) on display lights up for about 10-15 seconds. As soon as the lamp turns off, bring key to position “II” and start the engine. When the preheating stage is ended (lamp (1) turns off), to activate the post-heating stage in stand-by, still 30 seconds are available for the engine start and for the activation of the post-heating. If this is not the case, for the starting stage are still available from 0 to 15 seconds, for the heating of the intake air.

3

4

F34468

70

In order to activate the post-heating phase, the engine should necessarily be started within a limit time of 40-45 seconds from ignition activation.

The post-heating stage begins after the loading voltage for alternator is available. It lasts between 60 and 120 seconds according to the temperature.

To obtain the best cold start performance, the engine should be started (ignition key turned to position “II”) immediately after the turning off of the lamp (1).

If the engine temperature is higher than 10 °C (50 °F), after start-up, the engine turns idle for 3 seconds.

If the engine temperature is lower than 10 °C (50 °F), after start-up, the engine turns for 3 seconds between 900 and 1400 rpm (depending on temperature).

After that and in both cases, the engine sets automatically on rpm of power level 2.

3-49

SECTION 3 During engine preheating, the display shows every 3 seconds and for 1 second long, the indication that the preheating stage is still ongoing. The preheating degree reached by the engine, is shown as a bargraph, placed horizontally.

During the preheating stage, the power level can be set with arrows (3) and (4). Up to power level 5, this setting becomes active also during the preheating phase. By setting the power levels 6 and 7, they are activated only after the engine has reached the service temperature.

AFTER THE ENGINE START - PREHEATING The oil contained in the hydraulic system activates the cylinders and the different hydraulic motors.

Cold hydraulic oil is viscous. In such a case, some machine functions as travel and rotation movements, are performed more slowly than with hot oil.

WARNING It is absolutely forbidden to force the oil heating, because this procedure can damage the machine remarkably.

WARNING With very low temperatures, the hydraulic system can reduce the machine speed. For this reason we recommend the outmost attention before the system has reached the service temperature, to avoid the hazard of injuries.

It is vital that oil inside of the machine hydraulic system is brought to the right operating temperature correctly. For this reason, to bring oil to service temperature, you have to observe following conditions: Start the engine and let it run idle and at low speed for five minutes.

Let the machine perform a several number of movements like lifting, extension/retraction, slewing and travel, to allow the hot hydraulic oil to reach all cylinders and the motor.

Carry out these movements until the hydraulic system of the machine reaches the service temperature.

3-50

OPERATING THE MACHINE

OPERATING THE MACHINE WITH HOT WEATHER Air density decreases as altitude or ambient temperature increases. As a result of this, the engine’s maximum output, quality of exhaust gas, temperature level and, in extreme cases, starting behaviour, are impaired. Engine can be used at altitudes up to 1000 metres (3280.83 ft) and temperatures up to 30 °C (86 °F) for mobile operations.

If the engine is to operate at higher altitudes or temperatures, it will be necessary to reduce the injected fuel quantity and thus engine power.

71 Observe the following recommendations: Maintain the correct level of coolant solution in the coolant reservoir.

Check the condition of the cooler cap before starting. Replace the cap if necessary.

Clean the radiator and the engine carefully.

Check the condition of the alternator and blower belt.

Use lubricants with the recommended degree of viscosity.

Use a suitable coolant.

3-51

SECTION 3

MACHINE RECOVERY AND TOWING Tow the machine only with a tow rod.

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

The towing vehicle must have adequate tractive and braking power.

Drive slowly, carefully and smoothly.

All persons must keep clear of the tow-rod.

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

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

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

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

The machine is not suitable for towing trailers or other vehicles; this would result in damage to the axles and gearbox. The tow coupling is designed solely for towing or recovering vehicles from hazardous areas or for lashing purposes on transport vehicles.

GEARBOX DISENGAGEMENT Disengage the drive in the travel gearbox by turning the hex-head bolt (2) off about 180° to the right or the left until the index ball is felt to engage.

The connection between travel gearbox and the axles is now interrupted.

72

3-52

OPERATING THE MACHINE DURING RECOVERY AND TOWING Limit the hazard area as large as possible.

Proceed with caution and slowly.

When the engine is running, the service brake is active.

When the engine is not running, the service brake is only partially active.

The legal requirements are fulfilled even with the engine stationary, a filled brake pressure accumulator permits about 6 to 8 braking cycles until standstill of the machine.

AFTER RECOVERY AND TOWING Secure the machine against inadvertent movements.

Place the working attachment on the ground.

Press the bucket into the soil.

Place chocks under the wheels.

Protect the machine against unauthorized starting.

Re-engage the drive in the travel gearbox by turning the hex-head bolt (2) off about 180° to the right or the left until the index ball is felt to engage.

The connection between travel gearbox and the axles is now restored.

SECURE THE MACHINE For transport purposes, the machine must be tied down in front and at the rear with two tying chains each.

Depending on the existing tying points, working equipment or stabilization variant, the following prescriptions / spacings are applicable for tying down of the machine.

FASTENING POINT A IN FRONT, WITHOUT BLADE AND STABILIZERS Tie down the machine to both sides (not crosswise) at the outer holes using heavy-duty shackles.

Shackles Form A / DIN 82101, tensile load 8500, 9500 or 12000 kg (18700, 20900 or 26400 lb).

Tie-down chains Ø 13 mm (0.51 in) and an admissible tensile load of 10000 daN (22480.9 lbf) (10 t) / EN 12195-3.

73

3-53

SECTION 3 FASTENING POINT A LEVELLING BLADE IN FRONT NOTE: always drive the machine onto the low-bed trailer in forward gear. Lower the levelling blade for transport and for fastening onto the loading platform.

Tie down the machine at the central fastening point, using heavy-duty shackle.

Shackle Form A / DIN 82101, tensile load 8500, 9500 or 12000 kg (18700, 20900 or 26400 lb).

Tie-down chains Ø 13 mm (0.51 in) and an admissible tensile load of 10000 daN (22480.9 lbf) (10 t) / EN 12195-3.

The fastening points on the loading platform must be at least 2 m (6.56 ft) apart.

Models

Tying distance a

WX 210 Industry

800 - 1050 mm (31.49 - 41.34 in)

WX 240 Industry, width 2500

1000 - 1600 mm (39.37 - 62.99 in)

WX 240 Industry, width 2000

500 - 900 mm (19.68 - 35.43 in)

74

FASTENING POINT A STABILIZERS IN FRONT WITH TIE-DOWN BRACKET Tie down the machine to both sides (not crosswise) at the outer holes using heavy-duty shackles.

Shackles Form A / DIN 82101, tensile load 8500, 9500 or 12000 kg (18700, 20900 or 26400 lb).

Tie-down chains Ø 13 mm (0.51 in) and an admissible tensile load of 10000 daN (22480.9 lbf) (10 t) / EN 12195-3.

The fastening points on the loading platform must be at least 2 m (6.56 ft) apart.

Models

Tying distance a

WX 210 Industry

450 - 700 mm (17.72 - 27.56 in)

WX 240 Industry

450 - 550 mm (17.72 - 21.65 in)

3-54

75

OPERATING THE MACHINE B FASTENING POINT, LEVELLING BLADE IN THE REAR NOTE: always drive the machine onto the low-bed trailer in forward gear. Lower the levelling blade for transport and for fastening onto the loading platform.

Tie down the machine at the left and right fastening holes, to the respective side (not crosswise) using heavy-duty shackles.

Shackles Form A / DIN 82101, tensile load 8500, 9500 or 12000 kg (18700, 20900 or 26400 lb).

Tie-down chains Ø 13 mm (0.51 in) and an admissible tensile load of 10000 daN (22480.9 lbf) (10 t) / EN 12195-3.

76

FASTENING POINT B, STABILIZERS IN THE REAR, WITH TIE-DOWN BRACKET Tie down the machine to both sides (not crosswise) at the outer holes using heavy-duty shackles.

Shackles Form A / DIN 82101, tensile load 8500, 9500 or 12000 kg (18700, 20900 or 26400 lb).

Tie-down chains Ø 13 mm (0.51 in) and an admissible tensile load of 10000 daN (22480.9 lbf) (10 t) / EN 12195-3.

The fastening points on the loading platform must be at least 2 m (6.56 ft) apart.

Models

Tying distance b

WX 210 Industry

1400 - 1650 mm (55.11 - 64.96 in)

WX 240 Industry

1550 - 1650 mm (61.02 - 64.96 in)

77

FASTENING POINT B, WITHOUT BLADE AND STABILIZERS Tie down the machine to both sides (not crosswise) at the outer holes using heavy-duty shackles.

Shackles Form A / DIN 82101, tensile load 8500, 9500 or 12000 kg (18700, 20900 or 26400 lb).

Tie-down chains Ø 13 mm (0.51 in) and an admissible tensile load of 10000 daN (22480.9 lbf) (10 t) / EN 12195-3.

78 3-55

SECTION 3

WORKING ATTACHMENT The machine can be equipped with various working equipments. Components can be combined in various ways for optimum adaptation of the equipment to the specific application.

Operate the machine only with the equipment and component combinations expressly approved by the Manufacturer.

Equipments from other manufacturers may be assembled and put into operation only if in compliance with Machine Directive 89/392 EEC and only if the Manufacturer Declaration of Conformity of equipment as well as the Manufacturer Declaration of Compatibility of the machine are available.

Assembly work may be carried out only by operating or servicing personnel who have the necessary know-how at their disposal.

If such know-how is lacking, meticulous instruction must be given by experienced personnel.

Only such persons may start up the machine during assembly work in order to adjust the attachments.

3-56

Incorrect operation of the machine or the attachments may cause life threatening situations.

Tools, hoists, slings, trestles and other devices must be in a safe and reliable state of operation.

Metal splinters may cause injury when attachment pins are being driven in or out. A brass or copper mandrel should therefore be used for this purpose, and goggles must be worn.

At the end of work, place equipment on the ground in such a way that no movements can be made if mechanical or hydraulic connections become detached.

When working in jointed areas, block off the joints.

Remove the blocks on finishing work.

Secure any equipment or component which is to be mounted or dismantled, or whose position is to be changed, with hoists or appropriate slinging/supporting devices to prevent them from moving, slipping or falling inadvertently.

OPERATING THE MACHINE CLAMSHELL BUCKET OPERATION

79 UPPER STRUCTURE SLEWING To slew the upper structure to the right: Shift the left hydraulic control lever (1) to the right.

To slew the upper structure to the left: Shift the left hydraulic control lever (1) to the left.

RAISING AND LOWERING THE BOOM To raise the boom: Pull the right hydraulic control lever (2) back.

To lower the boom: Push the right hydraulic control lever (2) forward.

3-57

SECTION 3 EXTENDING AND RETRACTING THE DIPPER First switch over to dipper function with push-button (6).

To extend the dipper: Push the left hydraulic control lever (1) forward.

To retract the dipper: Pull the left hydraulic control lever (1) back.

OPENING AND CLOSING OF THE CLAMSHELL (OPTIONAL) To open the clamshell: Shift the right hydraulic control lever (2) to the right.

To close the clamshell: Shift the right hydraulic control lever (2) to the left.

ADJUSTING THE OPENING AND CLOSING SPEED OF THE CLAMSHELL (OPTIONAL) Activate the clamshell switch on the left panel. The clamshell opening and closing speeds now correspond to the values preset on the display.

CLAMSHELL ROTATION (OPTIONAL) To turn the clamshell to the right: Depress button (8) of right hydraulic control lever (2).

To turn the clamshell to the left: Depress button (5) of left hydraulic control lever (1).

AUTO POWER BOOST ACTIVATION Depress button (3) of left hydraulic control lever (1).

HORN ACTIVATION Depress button (7) of right hydraulic control lever (2), the horn releases an acoustic signal.

3-58

SECTION 4 SUPPLIES AND MAINTENANCE CHART SUPPLIES AND MAINTENANCE CHART

Component to refill

Cooling system

Windscreen washer system Fuel tank Engine (with filter) Hydraulic system

Hydraulic oil tank

Slewing gearbox Front steering axle: - axle body - travel gearboxes

Quantity (litres) (gal)

Suggested Product

Case standard

International Standard

Viscosity

Waten and liquid AKCELA PREMIUM ORGANIC ANTIFREEZE 50% and 50%

NH 900 C

-

-

26 (6.80)

TUTELA PROFESSIONAL SC35

-

-

-

5 (1.30)

Decanted and filtered diesel fuel

-

-

-

325 (85.60)

Oil AKCELA No. 1 ENGINE OIL

NH 330 H

API CI-4 ACEA E7

SAE 15W40

16 (4.20)

NH 668 HV

MIL-H-24459

ISO VG 68

285 (75.00)

ISO VG 46

160 (42.10)

SAE 80W-90

4 (1.10)

Oil AKCELA AW HYDRAULIC FLUID 68 HV or oil PANOLIN HLP SYNTH 46

DIN51524T2

Oil AKCELA AXLEPOWER 80W-90

NH 520 C

Oil AKCELA TRANSAXLE FLUID 20W-40

NH 434 B

API GL5 MIL-L-2105D

API GL4

SAE 20W-40

Rear rigid axle: - axle body - gear box

Oil AKCELA TRANSAXLE FLUID 20W-40

NH 434 B

API GL4

SAE 20W-40

R 134a

-

-

-

Grease AKCELA MOLY GREASE

NH 585/GR

NLGI2

-

- travel gearboxes

Air conditioning system: - coolant Greasing of grease nipples

WX 210 Industry

WX 240 Industry

11.5 (3.00) 2x2.5 (0.70)

13.5 (3.60) 2x2.5 (0.70)

12 (3.20) 2.4 (0.60) 2x2 (0.5)

14 (3.70) 2.4 (0.60) 2x2 (0.5) 950 g (2 lb)

-

-

4-1

SECTION 4 FUEL Use commercially available diesel fuel with less than 0.5% sulphur content. If the sulphur content is higher, oil change intervals should be reduced. The following fuel specifications / standards are approved: - DIN EN 590 - BS 2869 - ASTM D 975-96; 1-D and 2-D - NATO Code F-54 / F-34 / F-44 and XF 63 Exhaust emission values which may be determined in the case of type approval tests always refer to the fuels prescribed by the authorities for the type approval test.

WINTER-GRADE FUEL Waxing may occur at low temperatures, clogging the fuel system and reducing engine efficiency. If the ambient temperature is less than 0 °C (32 °F) use winter-grade fuel, suitable down to -15 °C (5 °F) should be used; this fuel is available at the filling stations well in advance of the cold season. Diesel fuel containing additives (Super diesel) is often available, for use down to -20 °C (-4 °F) approximately.

- At temperatures below -15 °C or -20 °C (5 °F to 4 °F), add petroleum to diesel fuel. The relevant percentages are given in the adjacent diagram.

If summer-grade diesel fuel must be used at temperatures below 0 °C (32 °F), up to 60% petroleum can be added (see diagram).

In most cases, adequate resistance to cold can also be obtained by adding a fluidizing additive for winter operation.

Legend: I

Summer-grade diesel fuel

II

Winter-grade diesel fuel

A

Outer temperature

B

Percentage of petroleum

CAUTION Diesel fuels must never be mixed with gasoline (normal and super grades).

4-2

1

SUPPLIES AND MAINTENANCE CHART HYDRAULIC OIL For the first refilling, Manufacturer uses PANOLIN HLP SYNTH 46.

Hydraulic oil is not soluble in water; this can generate condensate water in the hydraulic oil tank.

Therefore drain condensate water periodically, particularly after a long downtime period. Dispose of drained liquid as used oil.

VISCOSITY Generally, multi-grade oils shall be used. In closed heated rooms at temperatures > 5 °C (41 °F), also single-grade oils can be used. As the viscosity of lube oil is dependent on temperature, the choice of SAE grade should be governed by the ambient temperature prevailing at the engine operating site.

Optimum operating behaviour will be attained if you take the accompanying oil viscosity diagram as a guide. Should the temperature fall temporarily below the limits of the SAE grade selected, cold starting may be affected but the engine will not be damaged.

The application of a certain oil at higher temperatures than those indicated in the chart, should be as far as possible limited, in order to keep wear to a minimum.

Synthetic lube oils feature an improved temperature and oxidation stability.

2

4-3

SECTION 4 BIODEGRADABLE HYDRAULIC OIL The hydraulic system of this machine can be filled at with environmentally compatible, biodegradable hydraulic fluid too (special equipment). Stickers with corresponding instructions are then attached to the machine.

This biodegradable hydraulic fluid “PANOLIN HLP SYNTH 46” has been tested by the Manufacturer and approved for application on the machines.

The biodegradable oil must be analyzed every 500 hours of work, to verify that it keeps its features.

With special tools (the hydraulic hammer for instance) the analysis should be performed every 250 working hours.

Oil can be drawn for analysis by means of the sample-kit and the relevant instruction delivered by the Dealer.

The sample should then be sent by the customer to PANOLIN AG., that will carry out the necessary checks. The Dealer will care to inform the customer in case the oil has lost the necessary features for use.

NOTE: should the Dealer inform the customer that oil has exceeded the service limits, this must be replaced. If this indication is not observed, the warranty may become void and null and the machine may get damaged.

A change from mineral hydraulic oil to this biodegradable hydraulic fluid can be performed at a later date. Environmentally compatible biodegradable hydraulic fluid must not be simply poured away as normal waste. It must be disposed of in the same way as any used oil!

If hydraulic fluid seeps into the ground, the machine Owner and the Competent Authorities must be informed. The use of PANOLIN HLP SYNTH 46 is restricted only to hydraulic systems.

Do not mix this hydraulic liquid with oils of other makes; this kind of mixture will decrease the oil biodegradability.

4-4

SUPPLIES AND MAINTENANCE CHART

SAFETY INSTRUCTIONS No inspection and servicing work may be carried out until the Operator’s Manual has been read and understood.

CAUTION There is a risk of serious injury if maintenance or repairs are not performed correctly. If you do not understand the maintenance procedures, consult your Dealer.

Any modification to this machine without prior authorization could cause serious injury. Do not make any modifications without authorization. Consult your Dealer.

Respect the maintenance intervals prescribed by this Manual carefully.

IMPORTANT: if you use the machine under particularly severe conditions (dusty or corrosive atmosphere, etc.) reduce the intervals between maintenance operations.

MACHINE SAFETY Before carrying out any servicing or repair work the machine must be secured as follows: - park the machine on flat and firm surface; - place the working equipment on the ground; - lower the cab; - lock the upper structure; - apply the parking brake; - shut off the engine; - move both hydraulic control levers in all directions, to release possible residual pressure inside of the hydraulic system; - disconnect the pilot control; - set the ignition key to position “0” and pull it out;

3

- secure machine with wheel chocks to avoid its rolling or overturning.

SERVICING PERSONNEL Inspection and servicing personnel must have the necessary know-how on the inspection and servicing of this or comparable machines.

The necessary know-how can be acquired in several days’ instruction, for instance by a specialist fitter or by attending a training course.

4-5

SECTION 4

WORKING HOURS / INTERVALS A condition for the Manufacturer to take over the costs of the warranty service, is the regular performance of all inspection, maintenance and repair operations prescribed, as instructed by this Operator’s Manual and the use of genuine spares.

During the warranty period, all inspection works, maintenance and repair, with exception for the daily and weekly maintenance, have to be performed by the After-sales service or by an authorized workshop.

To ensure the correct operation and life of the machine and of its components, a time schedule has been established, to perform all maintenance service that has to be done.

The maintenance intervals indicated in this manual are valid for normal use conditions. If the use conditions are more severe, the intervals are shortened accordingly.

The working hours (1) necessary to determine the maintenance intervals, are shown on the multi-function display inside of the cab.

At machine start, the multi-function display shows besides an indication of the expiry and next interval type.

12 HOURS

4

4-6

SUPPLIES AND MAINTENANCE CHART

MAINTENANCE INTERVALS CHART D

Cleaning

W

Oil change

O

Pressure release

V

Level check and top-up

S

Check

2

Water draining

J

Greasing

Q

Replacement / Change

P

Air bleeding

Maintenance

Every 10 h

Every 50 h

Every 250 h

Every 500 h

Every 1000 h

Every When 3000 h necessary

Page

General checks General inspection

S

4-10 D

Machine

4-71

Cab S

Cab raising Controls functionality

4-12

S

4-12 SD

Windscreen wiper Q

Windscreen wiper - Blades Windscreen washer liquid

4-51

V

4-19 D S

Air filter

4-73

Q

4-26/4-51

Diesel engine and fuel system Engine speed sensor Engine oil

V

DS

4-46

W

4-13/4-48

Q

Engine oil filter

4-37 S

Drive belt

Q S

Belt tensioner

4-52 S

Valve clearance

Engine brackets Screws tightening

4-38 S

4-52 Q

Injection nozzles Fuel tank

4-67

Q

Fuel filter

V

4-47/4-73

2P

4-74

D

4-15/4-30/ 4-69

Q

4-17/4-68

Cooling system Coolant Cooler

V D

4-29

Air intake system Air filter - main filter element

DS

Air filter - safety element

Q

4-26/4-53

Q

4-53

Air filter - dust discharge valve

D

4-26

Hoses, pipes and sleeves

S

4-28

4-7

SECTION 4

Maintenance

Every 10 h

Every 50 h

Every 250 h

Every 500 h

Every 1000 h

Every When 3000 h necessary

Page

Hydraulic system Hydraulic oil tank

V

DW

O

Q

Return filter

4-13/4-64/ 4-74 4-39

Bleeding valve

Q

4-54

Pilot control filter

Q

4-59

Upper structure Upper structure holding brake

S

4-12 V

Slewing gearbox

W

4-32/4-70

Slewing gearbox - Screws tightening

S

4-50

Slewing bearing - Screws tightening

S

4-49

Counterweight - Screw tightening

S

4-59

Transmission components V

Steering axle

W

Steering axle - Steering adjustment

4-40/4-54 S

V

Rigid axle and gearbox

W

4-78/4-56 4-42

Axle floating locking cylinders

P

4-79

Tyres

Q

4-76

Tyres - Pressure

S

4-22

Tyres - Nuts tightening

S

4-24

Brakes system Service brake

S

P S

Service brake - Plates Parking brake

4-11/4-78 4-58

S

4-11

Electrical system Q

4-12/4-83

Fuses

Q

4-80

Battery

Q

4-87

Lights - Bulbs

S

Battery - Electrolyte

V

4-33

Battery - Charged

S

4-33

Battery - Clamps

S

4-33

Heating - Air conditioning S

4-43/4-60

Filter and panel

D

4-60

Evaporator and heat exchanger

D

4-60

Condenser

D

4-60

Compressor belt

Q

4-60

Air conditioning system

4-8

S

SUPPLIES AND MAINTENANCE CHART

Maintenance

Every 10 h

Every 50 h

Every 250 h

Every 500 h

Every 1000 h

Every When 3000 h necessary

Page

Attachment S

Clamshell - Wear

4-88

Greasing Various grease nipples Working attachment

J

4-20 J

Slewing bearing - Cups

4-36 J

Slewing bearing - Teeth Axles floating pins

J

4-50 4-36

Blade and stabilizers joints

J

4-44

Cardan shaft

J

4-44

Steering trunnion pins

J

4-45

Floating axle locking cylinders contact face

J

4-45

4-9

SECTION 4

CHECKS BEFORE START-UP AND BEFORE EACH WORKING SHIFT (10 HOURS) SERVICE POINTS

Check

Cleaning

Machine - General inspection

S

D

Service brake

S

Parking brake

S

Upper structure holding brake

S

Lights

S

Controls and lamps functionality

S

Level check and top-up

Engine oil - Level

V

Hydraulic oil tank - Level

V

Fuel tank - Level

V

Cooling system liquid - Level

V

Screen washer liquid - Level

V

Greasing

Working attachment lubrication

J

Greasing, off-set boom

J

Tyres - Pressure

S

Tyres - Nuts tightening

S

MACHINE GENERAL INSPECTION Before operating the machine it is advisable to carry out a general inspection of: - Check visually the machine and working equipment for possible breaks or damages to components or to the machine structure. Should problems be noticed, address to an authorized workshop to have the necessary repairs done.

Replace all the damaged or worn parts with original spares.

- Check for leaks; and if present, rectify them.

- Keep the machine clean daily from the dirt buildup during the work.

4-10

SUPPLIES AND MAINTENANCE CHART SERVICE BRAKE Before starting the machine, check the proper operation of: - service brake.

Check the operation of the service brake by depressing pedal (1).

5 The service brake operation is always monitored by the multi-function display.

If during the working stages lamp (2) is on: - stop the machine immediately; - apply the parking brake; - place the machine in a safe condition; - clear off the trouble.

6

PARKING BRAKE Before starting the machine, check the proper operation of: - parking brake.

Check the operation of the parking brake by pressing the button (1).

7

4-11

SECTION 4 UPPER STRUCTURE HOLDING BRAKE Before starting the machine, check the proper operation of: - upper structure holding brake.

Check the correct operation in this way: - Start the engine The upper structure holding brake can be operated in AUTOMATIC mode by the centralized electronic system.

Lamp (B) on button (1) lights up.

The upper structure is braked when the slewing control lever (2) is not activated and at slewing end.

- Activate the pilot control with the safety lever (3).

- When you shift the hydraulic control lever (2), the upper structure holding brake is releases and the upper structure is free to slew.

- Depress button (1) until all lamps switch off.

Upper structure holding brake is released.

The upper structure can be turned freely, even if the hydraulic control lever (2) is not activated.

- Depress the button (1) once. The lamp (B) lights up.

The upper structure holding brake is applied.

The upper structure is braked and should not move.

- Depress the button (1) once more. The lamp (2) lights up. The upper structure holding brake is applied in automatic mode. The accurate stop of the upper structure during slewing is ensured also under severe use conditions.

LIGHTS Before operating the machine it is advisable to carry out a general cleaning and operation check of all lights.

CONTROLS AND LAMPS OPERATION Before starting the machine, check the proper operation of all controls and instruments and lamps of the control dashboard.

Should faults be noticed, shut off the engine and locate the trouble.

4-12

8

SUPPLIES AND MAINTENANCE CHART ENGINE OIL - LEVEL Park the machine on a level surface and protect the same against inadvertent movements.

Shut off the engine and wait for about five minutes before checking the oil level. This down-time allows the oil to flow into the oil sump.

Remove the oil dipstick (1).

Wipe dipstick (1) clean with a lint-free cloth and reinsert.

Pull out again the oil dipstick (1).

If the oil level is close to or under the “min” mark, perform the top up (2).

Top up oil until you reach the notch “max”.

9

NOTE: the oil level must always be above the notch “min” and under the notch “max”.

HYDRAULIC OIL TANK - LEVEL

WARNING Before starting to work on the hydraulic system, make sure that this is not under pressure and relieve any residual pressure from it.

Never let hydraulic oil to come in contact with the skin. The skin contact with hydraulic oils is harmful to health.

Park the machine on a flat surface and place the working equipment on the ground.

Engage the parking brake. Shut off the engine.

Relieve the pressure from the hydraulic system by moving both hydraulic control levers repeatedly until the hydraulic cylinders do not react to controls.

Open the cover of the pump compartment on the right side of the upper structure. The level indicator of the hydraulic oil is on the side of the hydraulic tank.

Check that the oil level is above the “min” notch of the dipstick (1) inside of hydraulic oil tank (2).

10

If this is not the case, top up the hydraulic oil.

No matter what the position of the working attachment is, the oil level must always be between the notches “min” and “max”.

4-13

SECTION 4 HYDRAULIC OIL TOP UP The hydraulic oil tank is slightly under pressure at about 0.3 bar (4 psi).

As mentioned previously, before performing any top up of the hydraulic oil, it is important to relieve the residual pressure inside of the hydraulic system.

11 Unscrew the screws (1) paying attention to cover (2) that is under the spring (4) pre-load.

Reassemble the cover (2) with the spring (4) and the gasket (3).

In the filter housing can now be seen the return filter (5).

The top up has to be performed by letting the oil flow though this filter, until the oil level sets between references “min” and “max” of dipstick.

Before replacing the cover (2), check the gasket (3).

If this is damaged, replace it.

Reassemble the cover (2) with the gasket (3) and the spring (4).

4-14

12

SUPPLIES AND MAINTENANCE CHART FUEL TANK - LEVEL Use commercial-grade diesel fuels with a sulphur content of less than 0.5%.

The following fuel specifications are approved: - DIN EN 590 - BS 2869 - ASTM D 975-96; 1-D and 2-D The quantity of Cetane (CZ) inside of fuel should not be lower than 49.

WARNING Do not smoke and do not use open flames.

Diesel fuel may be harmful to the skin, wear protective gloves or use a barrier cream.

Shut off the engine.

Never take off the cap or refuel when the engine is running. While you refuel keep the control of refuelling gun.

Before refuelling, clean the seat of the filler neck to avoid the introduction of foreign bodies in the tank.

After refuelling, retighten the cap firmly.

Do not spill fuel and do not let it penetrate into the ground: environmental pollution hazard.

Soak up spilt fuel immediately with rags or binding agents, then discard without polluting the environment.

Report accidents involving fuels without delay to the machine owner or his agent.

LEVEL CHECK The fuel level must be checked with the multi-function display.

At the screen side, column (1) is always showing the fuel quantity contained in the machine.

Indication above the cross line = level OK. Indication under the cross line = top up fuel.

12 HOURS

13

4-15

SECTION 4 FUEL TOP UP AND REFUELLING If the machine is refuelled often or regularly with fuel from cans or barrels, there is an increased risk of foreign matter and water penetrating into the fuel system.

In this case: - always refuel through a fine mesh filter; - user only intake hoses with a fine mesh filter; - bleed water and sludge from the fuel tank at more frequent intervals; - change all fuel filters at more frequent intervals.

Refuel with following operations: - open the filler cap cover (1); - refuel through the filler neck filter (2). Do not remove the filter.

14

4-16

SUPPLIES AND MAINTENANCE CHART COOLING SYSTEM LIQUID - LEVEL

WARNING The plug of the cooling system has to be unscrewed at engine shut off and cold.

Never refill with cold liquid while the engine is still hot. The abrupt temperature change could damage the engine components. Let the temperature inside of the engine lower under 50 °C (122 °F) before filling the system with coolant.

If the cooling system is leaking, do not mix sealing additives to the coolant. These could in fact clog the cooling system. In such a case the coolant delivery could cause a engine overheating.

The coolant level has to be checked daily, so as to detect in time liquid leaks and to avoid damages.

Shut off the engine and wait until the engine and the cooling system reach 50 °C (122 °F).

Open the engine compartment cover.

The coolant level must be between notches “min” and “max” of the surge tank (1). If necessary, top up the coolant.

To perform this operation, open with caution the cap (2) of the surge tank of about half of a turn, to allow the pressure to relieve from the cooling system.

Only after pressure relief you can unscrew completely the cap and top up the coolant.

Retighten the plug (2).

Close the engine compartment cover.

15

4-17

SECTION 4 COOLANT TOP UP The coolant must consists in a mixture of 50% of distilled water and 50% of antifreeze.

This mixture offers not only a antifreeze protection up to -30 / -35 °C (-22 / -31 °F), but it protects also the cooling and heating system from corrosion. It prevents also the formation of limestone and increases the boiling point of the cooling system.

Because of this, even during hot season and in hot countries, coolant has not to be diluted with water.

NOTE: the additive quantity to be added to coolant should be about 50%.

If for climate reasons a strong antifreeze is required (for instance in Sweden, Norway, Finland), the antifreeze rate can be increases, but only up to 60% (protection until about -40 °C (-40 °F)).

Otherwise, the antifreeze protection decreases and the cooling effect gets worse (less radiating effect).

Before performing any top up or additive change, ask the After-sales Service about the specifications of the required additive allowed for your machine.

First of all mix the components in a clean container and then pour the mixture into the cooling system. If the mixture components are poured into the cooling system one after the other, it is not possible to obtain the correct mixture ratio. There is also the possibility that components do not mix together in the correct way.

NOTE: do not use not authorized additives. The corrosion produced by this improper use, can cause leaks in the cooling system and serious damages to the engine.

COOLANT LEAKS Leaks of coolant leads to suspect, first of all, to the lack of tightness. In such a case, have the cooling system immediately checked by the After-sales service. The only coolant top up is not sufficient.

If the system is correctly tight, leaks may be found only if the coolant overheats and boils and because of this it is ejected out of the system under pressure.

4-18

SUPPLIES AND MAINTENANCE CHART SCREEN WASHER LIQUID - LEVEL The operation logic and mode of the liquid container have been optimized, because the same has been incorporated in the panel behind the operator’s seat.

The panel is used at the same time as supporting surface for operator’s tools and personal objects.

The liquid container can also be filled outside of the cab by unscrewing cap (1).

Fill the liquid container only with clean drink water, if not the windscreen washer nozzles can get clogged.

In order to obtain the best cleaning of the window panes, you can add to water a commercial detergent.

16

With cold weather, mix antifreeze to the windscreen washer system. Observe the mixing ratio suggested by the Manufacturer.

Remove cap (1) from the back wall of the cab.

Top up liquid up to lower edge of filler neck (2).

Re-tighten the cap (1) and check that the closure is tight.

4-19

SECTION 4 WORKING ATTACHMENT - GREASING Before beginning the greasing operation:

Clean the grease nipple.

- place the working attachment on the ground, completely extended;

Apply the pump nozzle on the grease nipple.

- place the machine in a safe condition.

By means of the greasing pump, grease all lubrication points of the working attachment.

Release the loading area of the articulation joint.

Remove the protection cap from the grease nipple.

Now, pump the grease in such a quantity that the new grease can eject the old one from the articulation points.

Wipe off used grease with a cleaning rag.

After greasing, put protective cap back onto the grease nipple.

17

4-20

SUPPLIES AND MAINTENANCE CHART

Position

Lubrication point

1

Boom cylinder joint (bottom side)

2

Grease nipples block

3

Quantity 2x1

- Handling boom joints

2x1

- Handling boom cylinder joint (rod side)

2x1

- Handling boom cylinder joint (bottom side)

2x1

- Boom cylinders joints (rod side)

2x1

- Monoboom joints

2x1

Clamshell bucket - Joints

10

- clamshell bucket rotation gear

1

- Clamshell bucket joints

2x1

4-21

SECTION 4 TYRES - PRESSURE CHECK

CAUTION Before inflating the tyres, check the tyres, rims and rim parts for damage, penetrated foreign objects and proper fitting.

Check the tyre inflation pressure only when the tyres are cold, as when they are warm, the pressures indicated are higher than usual.

Use inflation equipment with long filling hose, selffixing nozzle and pressure gauge.

Inflate the tyres only with compressed ambient air.

Never use inflammable gases: risk of explosion!

During tyre inflation, do not stand near the tyre and always in the plane of the tyre tread.

Watch the tyre and the pressure gauge of the inflating equipment permanently during the inflation and never exceed the prescribed tyre pressures.

If available, place a safety cage around the wheel.

Make sure that nobody is standing near the tyre when it is being inflated.

Always inflate tyres to the prescribed pressure: - excessive tyres pressure means poor handling properties off the road and a risk of bursting tyres; - insufficient pressure means increased wear on the tyres and inadequate stability of the machine.

Apply the right tyre pressure for each axle and foreseen application.

Do not keep tyres pressure lower than the values due, so as not to overheat the tyres, because this could cause: - tyre breaks; - tread damage; - inner damage; - uneven wear and short life.

18

4-22

SUPPLIES AND MAINTENANCE CHART Do not overinflate the tyres, because if bumped they can break easily and under extreme conditions the rim can get deformed and the tyre can burst.

CAUTION The tyres inflating pressure varies according to the load applied to axles.

Park the machine on level and firm ground with sufficient strength.

Place the working equipment on the ground.

Engage the parking brake.

Shut off the engine.

Attach the self-locking nozzle of the inflating equipment to the tyre filling valve (1).

The device is equipped with a pressure gauge (2), that when connected, allows to check the pressure value.

If the pressure results to be lower than expected, proceed to the inflation.

19

SUGGESTED PRESSURES Tyres

Twin

Single

Manufacturer

Type

Pressure (bar)

Mitas

10.00-20 16 PR

7.50 (109)

Mitas

11.00-20 16 PR

7.00 (102)

Bridgestone

10.00-20 16 PR

7.50 (109)

Bridgestone

11.00-20 16 PR

7.00 (102)

Michelin

18R 22.5 XT

7.80 (113)

Mitas

600/40 - 22.5 TR12

6.00 (87)

The pressures are valid for the types of tyres and equipment listed and to following conditions: - working attachment installed; - bucket empty; - tyres at environment temperature (about 20 °C (68 °F)); - fuel tank full.

4-23

SECTION 4 TYRES - NUTS TIGHTENING Park the machine on a flat surface and lower the equipment to the ground.

Shut off the engine.

Engage the parking brake.

Secure the machine by placing chocks under the wheels to prevent inadvertent movements.

Check if nuts (1) are tighten. Tighten to prescribed torque 450 Nm (331.90 lbf·ft).

20

4-24

SUPPLIES AND MAINTENANCE CHART

WEEKLY SERVICE (50 HOURS)

SERVICE POINTS

Check

Cab - Air filter

S

Cab raising

S

Air filter: Dust discharge valve - Main filter element

S

Air intake system: Intake pipes

S

Level check and top-up

Cleaning

Air bleeding

Water draining

P

2

D

D

Cooler

D

Fuel system

D

Slewing gearbox - Level

V

Battery - Electrolyte

V

Battery - Charge and clamps tightening

Greasing

S

Slewing bearing - Cups

J

Axles floating pins

J

CAB AIR FILTER - CLEANING The heating blower takes air from outside through the rear wall of the cab.

The filter element is accessible by opening the cover (1) on the rear wall of the cab by means of a square-section tool.

Open the cover.

Take out the filter and shake it slightly or blow it with a jet of compressed air without oil, lower than 6 bar (87 psi). Keep the nozzle of the compressed air at a distance of 3 cm (1.18) from the paper.

If dirt is heavy or after 3 cleanings the filter element has to be replaced.

21

WARNING During the cleaning with compressed air, always wear protective goggles.

Do not clean the filter element with blows or strikes, it could get damaged.

Insert the filter element, cleaned or new into the guide and close the cover.

4-25

SECTION 4 CAB RAISING

WARNING Possible maintenance works have to be carried out exclusively with cab lowered.

To ensure the maximum life of the raising device, it is necessary to perform periodical checks: - check the cab raising and lowering operation at least a couple of times; - check for the presence of deformations in the carpentry structure; - check for the presence of leaks in the hydraulic system;

22

- check for the presence of electric faults.

AIR FILTER - CLEANING Besides the scheduled times for cleaning, the air filter must also to be cleaned by means of a electronic vacuum sensor (1), installed on the air filter housing, the indication of this sensor is shown on the multifunction display with a fault message.

23

DUST DISCHARGE VALVE - CLEANING The dust discharge valve (2) collects dust penetrating into the air filter case.

To discharge the dust, compress the dust discharge valve (2) repeatedly.

The dirt is crumbled and comes out from the bottom.

24

4-26

SUPPLIES AND MAINTENANCE CHART AIR FILTER - DISASSEMBLY Open the cover on the left side of the machine.

Open the clamps (4) on the filter housing and remove the cover (3).

Remove the main filter element (5) carefully from the case.

The safety filter (6) remains in place.

Clean the main element (5) of the filter with dry, compressed air with no oil traces, at a pressure below 6 bar.

If damaged, the filter element has to be replaced.

Clean the inside of the filter housing (7).

Assemble the main element (5), checked and cleaned, or possibly a new element.

25

Reassemble the cover (3) and lock it with the clamps (4).

MAIN FILTER ELEMENT - CLEANING Never clean filter elements by beating them against hard objects.

After 3 cleaning cycles or after one year of operation at the latest, the main filter element must be replaced.

Never clean filters with petrol and flammable or hot liquids.

Cleaning with compressed air is suitable if the filter element is to be re-used immediately.

The air pressure at the nozzle must not exceed 6 bars (87 psi).

The compressed air nozzle has to be held at about 3 cm (1.18) from the filter element.

26

Start cleaning the filter surface by blowing dry compressed air diagonally from outside into the filter element.

Continue cleaning by blowing compressed air from inside against the element.

Cleaning is finished when all visible dust has been removed from the element.

CHECKS

4-27

SECTION 4 Checks before installation of the main filter element.

Check the filter paper with the help of a lamp bulb. Filter damage is indicated where the light shines brightly through the paper. If damaged, replace the main filter element immediately.

27 Check the seal visually. If the seal is damaged, replace the main filter element immediately.

28

AIR INTAKE LINE - CHECK Hoses and tubes for air intake damaged or leaking, influence enormously the performance and life of the engine.

Dirt or pieces of the intake air can reach the engine and damage it heavily.

The feeding pressure created by the turbocharger could dissipate with the consequence that the engine does not develop its full power.

The engine must not be allowed to draw in unfiltered air, therefore: - check the tightness of all hoses and pipes of filtered air; - check that all clamps are in place and well tight.

Remove immediately possible damages replace at once the damaged components.

4-28

and

29

SUPPLIES AND MAINTENANCE CHART MULTI-COOLER - CLEANING CAUTION Start the cleaning operation only after the standstill of all moving components, assemblies and after the engine, silencer and cooler have cooled down.

Wear protective gloves and goggles before starting to clean with compressed air.

If the machine is working in a very dusty environment, the cooler has to be cleaned more frequently as prescribed by the service schedule.

Do not use pointed or hard tools to clean the cooler, as for instance, metallic brushes and screwdrivers.

They could damage the cooling fins.

The cooler for the turbocharger air, is installed inside of a hood containing draining holes for condensate.

If the holes are clogged and the condensate accumulated, when it freezes, the cooler could get damaged.

Check periodically, before and during the cold season, that the draining holes are free.

CLEANING The multi-cooler contains radiating elements for the engine coolant (3), for hydraulic oil (2) and for the turbocharger air (1).

Open the cover on the right side of the upper structure.

Now the cooler is accessible.

Disassemble the covers above the cooler.

Brush and suck the dirt from the radiator fins.

Resistant dirt build-ups can be removed with water jets or compressed air jets.

The cooler has to be cleaned by directing the jets from the top to the bottom. Remove the dirt residuals.

30

In case of dirt build-up, clean the hood and the draining holes.

4-29

SECTION 4 FUEL SYSTEM - AIR BLEEDING AND WATER DRAINING CAUTION The fuel vapours are readily flammable. For this reason, avoid any formation of sparkles and use only protected lamps and not open flames like lighter or matches.

If you are to work on the fuel system: - shut off the engine and the additional heating fault; - place the machine in a safe condition.

Fuels can be harmful for health: - do not swallow; - avoid long contact with the skin; - do not inhale vapours; - wear a protective mask and gloves.

Collect escaping fuel and discard without polluting the environment.

Discard the fuel filters and the rags soaked with fuel in the prescribed way for polluting waste.

4-30

SUPPLIES AND MAINTENANCE CHART AIR BLEEDING When components on the fuel delivery line are replaced, the air bleeding from the system is performed automatically.

When the fuel line under high pressure is disassembled or replaced, the air bleeding is not required for engine start-up. The fuel pump during start-up generates high pressure inside of fuel and discharges the air through the injectors at high pressure side.

31 If such an amount of air, plenty exceeding the average required, should penetrate into the system, bleed the fuel system immediately.

Loosen the delivery line on the injection pump (1).

Activate repeatedly lever (2) on the delivery pump, until air is completely bleeded from the system.

Once the air has been completely relieved, connect the fitting again. The fuel pump is activated by the camshaft of the engine block at the side directed towards the cab. The fuel pump is accessible through the rear cover of the panelling right.

If air bubbles are still noticed for several minutes, air is penetrating into the system. Because of breaks or pores in the welding link, fastening the hose to the connector, air can penetrate into the fuel system.

32

Check for the presence of leaks on all hoses and connections, as well as on the fuel filter.

An injector jammed to open position, can generate the return of exhaust gas to the pump, and the presence of too much air into the system. Start the engine and check the hoses. If exhaust gas returns through the hoses, the injector is still open or jammed.

4-31

SECTION 4 WATER AND SLUDGE BLEEDING Dirt and water settle on the bottom of the fuel tank.

This happens especially when the machine refuelling is often or periodically performed with fuel stored into cans or barrels, or when the machine is employed in areas with strong thermal differences between day and night. In such a case there is the formation of condensate, in particular when the tank is not completely full. With temperatures lower than 0 °C (32 °F), the condensate freezes and the draining, through the threaded cap (1), is impossible.

Because of this, bleed water and sludge at the end of the work-shift and then refuel the tank.

Remove the base-plate for maintenance below the fuel tank.

33

Now the drain sleeve is accessible.

Place a collecting container below the tank drain plug (1).

With caution unscrew the drain plug (1) under the fuel tank and drain water and sludge.

Retighten the drain plug (1).

Reinstall the maintenance base-plate.

SLEWING GEARBOX - OIL LEVEL Place the machine in a safe condition.

Open the engine hood.

Check the oil level in the expansion tank, by means of the inspection glass (2).

The oil level should reach the centre of the inspection glass (2). If necessary, top up oil through the hole of the screw plug (1).

34

4-32

SUPPLIES AND MAINTENANCE CHART BATTERIES - LEVEL - CHARGE CHECK AND CLAMPS TIGHTENING

CAUTION Batteries give off explosive gases.

Never handle naked flames and unshielded light sources near batteries, never smoke.

Battery acid is toxic and corrosive.

Avoid any contact with the skin, mouth, eyes and clothing. Avoid spilling battery acid. Avoid inhaling the vapours.

Wear acid-proof gloves, firm protective clothing and goggles.

If the skin is splashed with acid, rinse thoroughly with water and consult a doctor.

Never wear metal necklaces, bracelets or watchstraps when working on the battery. The metal parts may induce a short circuit resulting in burns.

If the eyes are splashed with acid, rinse thoroughly with running water and consult a doctor immediately.

Never set tools down on the battery. They may induce a short circuit, causing irreparable damage to the battery and injuring persons.

Both 12 V batteries are located behind the cabin, under a cover (1). They are connected in series.

Therefore, the system voltage is 24 V. Unscrew the screws (2) and remove the cover (1).

Now the batteries are accessible.

35 CHECKING THE ELECTROLYTE LEVEL Remove the caps (1).

When the undercaps (2) are present: - electrolyte level should reach base of these.

Without undercaps: - electrolyte level should be 10 - 15 mm (0.39 0.59 in) above top of plates.

If necessary, top up with distilled water.

Retighten the caps (1).

36 4-33

SECTION 4 CHARGE CHECK Unscrew caps (1) and undercaps (2) if installed.

Measure electrolyte density of individual cells with commercial hydrometer (3).

Hydrometer reading (see table on following page) indicates battery’s state of charge.

During measurement, temperature of electrolyte should preferably be +20 °C (68 °F).

Electrolyte density in kg/dm3

Charge

Normal

Tropical

1.28 (80)

1.23 (77)

correct

1.20 (75)

1.12 (70)

low: charge

1.12 (70)

1.08 (67)

discharged: recharge immediately

37

CLAMPS CHECK Keep battery clean and dry.

Disconnect dirty clamps.

Clean battery poles (+) and (-) and clamps and grease with acid-free and acid resistant grease.

When reassembling, ensure that clamps make good contact. Tighten the wheel nuts by hand.

38

CHARGE Top up / recharge When the charge is performed with low current intensity (top up charge with small battery charger) it is not necessary to detach the connection cables of the on board net. Respect anyway the prescriptions of the Manufacturer of the battery charger. If the batteries are not installed, use a battery charger with a charging voltage of 24 V (batteries are serial connected).

To recharge the battery, do not exceed the maximum charge current of 10% of the battery rated capacity.

Recharge time maximum 30 hours, in case of battery completely flat.

4-34

SUPPLIES AND MAINTENANCE CHART Quick recharge Respect the prescriptions of the Manufacturer of the battery charger.

Before performing the quick recharge, that is, a recharge with high density voltage, disconnect both connecting cables and disassemble the batteries.

Before performing the battery charge, unscrew the plugs to allow the release of gas from all battery cells.

A flat battery can freeze already at -10 °C (14 °F).

If the battery is frozen, it must absolutely be defrosted before quick recharge; otherwise it could explode.

The battery charger net cable has to be plugged-in to the electric socket, only after the battery charger clamps have been correctly connected to the battery poles. red = positive black = negative Once the recharge is complete, reinstall the battery and perform correct connection (first the positive pole and than the negative).

4-35

SECTION 4 SLEWING BEARING CUPS AND AXLE FLOATING PINS - GREASING Before starting with the greasing operations place the machine in a safe condition.

By means of the greasing pump, grease all lubrication points of the upper structure.

Remove the protection cap from the grease nipple.

Clean the grease nipple.

Apply the pump nozzle on the grease nipple.

Now, pump the grease in such a quantity that the new grease can eject the old one from the articulation points.

Wipe off used grease with a cleaning rag.

After greasing, put protective cap back onto the grease nipple.

SLEWING BEARING CUPS (1) = No. 2 grease nipples Slew the upper structure three times and repeat the greasing procedure.

39

AXLES FLOATING PINS (2) = No. 2 grease nipples

40

4-36

SUPPLIES AND MAINTENANCE CHART

MONTHLY SERVICE (250 HOURS) SERVICE POINTS

Check

Level check and top-up

Greasing

Replacement / Change

Engine oil filter

Q

Fuel filter

Q

Hydraulic oil return filter

Q

Steering axle

V

Rigid axle and gearbox

V

Air conditioning system

S

Blade and stabilizer joint

J

Cardan shaft

J

Steering trunnion pins

J

Axle locking cylinders contact face

J

Stabilizers brackets

J

ENGINE OIL FILTER - CHANGE

WARNING To replace the engine oil filter shut off the engine and wait until it is cool. Collect oil, rags, old filter and discard them without polluting the environment.

Remove the base-plate for maintenance below the engine compartment.

Unscrew the filter cartridge (1) and drain old oil into a collecting container.

Discard the filter separately.

Clean the sealing surface on the engine and remove completely possible residuals of the old seal.

41

4-37

SECTION 4 Fill the new filter cartridge with clean oil.

Lightly oil the gasket of the new filter cartridge.

Screw in the new cartridge until the gasket is flush.

At this point tighten the filter by hand.

Fill in engine oil into filler neck (2) until the oil level reaches the “max” mark of dipstick (3).

Start the engine and check that the connection between the filter cartridge and the engine is tight.

Check oil level.

Reassemble the base-plate for maintenance below the engine compartment.

42

FUEL FILTER/S - CHANGE

WARNING For this kind of replacement shut off the engine and wait until it is cool.

Collect fuel, rags and old filters and discard them without polluting the environment.

The fuel filters are installed inside of the engine compartment at the engine side and are accessible through the rear right hood cover.

There is no need to clean these filters, but they have to be replaced according to service schedule.

Unscrew the filter cartridges (1), paying attention not to spill the fuel over, but to collect it in a container.

Discard the old cartridges.

Clean the seal face of the filter head.

Fill the new cartridges with fuel.

Lightly oil the gasket of the new cartridges.

Screw in the new cartridges, until the gasket is flush and then tighten by hand.

After a while, check the tightness of connection between filter head and cartridges.

If the engine does not start, bleed the air from the fuel line.

4-38

43

SUPPLIES AND MAINTENANCE CHART HYDRAULIC OIL RETURN FILTER CHANGE

WARNING Before starting to work on the hydraulic system, make sure that this is not under pressure and relieve any residual pressure from it.

Never let hydraulic oil to come in contact with the skin.

Discard used oil, rags and the old filter without polluting the environment.

Beyond respecting the maintenance intervals for return filter change, replace the same also: - when on display appears the relevant error message. This means that the filter is very dirty; - after a repair on the hydraulic system.

Relieve the pressure from the oil tank.

Unscrew the screws (1) and remove the cover (2) with spring (4) and gasket (3).

Take out the old return filter (5) and replace it with a new one.

Reassemble the cover (2) with a new gasket (3) and spring (4).

44

4-39

SECTION 4 STEERING AXLE - OIL LEVEL

WARNING The axle and the differential box may also be hot after a long journey.

Leave the axle and differential box to cool down and wear working gloves.

The axle and differential may be slightly over pressurized, so turn the control plug carefully, just far enough to release the excess pressure (audible hissing sound).

Collect escaping oil and discard without polluting the environment.

Park the machine on a level and firm surface. Block the wheels of the rigid axle by placing chocks under them.

Raise the machine with the levelling blade or the working equipment until the wheels of the steering axle are clear of the ground and turn freely.

Shut off the engine.

Place the machine in a safe condition.

DIFFERENTIAL - LEVEL Clean the area around screw plug (1).

Unscrew the screw plug slowly, until the inner pressure is completely released.

Only after this operation, unscrew the screw plug (1) completely.

Oil level should be flush with the plug hole.

If necessary, top up oil through the hole.

Screw up the screw plug (1).

45

4-40

SUPPLIES AND MAINTENANCE CHART TRAVEL GEARBOXES - OIL LEVEL Bring the screw plugs (1) and (2) into position depending on the wheel-hub installed.

Screw plug (1) must be above the centreline.

The line under the word “Front” must be in horizontal position.

Clean the area around screw plugs (1) and (2).

Unscrew the screw plug (1) slowly, until the inner pressure is completely released. Only after this operation, unscrew the plug completely.

The oil level must be flush with the hole edge. If necessary, top up oil to level of drilled hole.

46 Screw up the screw plug (1).

Repeat check on other wheel-hub gear.

47

4-41

SECTION 4 RIGID AXLE AND GEARBOX - OIL LEVEL

WARNING The axle and the gearbox may also be hot after a long journey.

Let the axle and the gearshift box cool down and wear working gloves.

The axle and the gearshift box may be slightly over pressurized, so turn the control plug carefully, just far enough to release the excess pressure (audible hissing sound).

Collect escaping oil and discard without polluting the environment.

Park the machine on a level and firm surface.

Block the wheels of the axle by placing chocks under them.

Raise the machine with the levelling blade or the working attachment until the wheels of the rigid axle are clear of the ground and turn freely.

Shut off the engine.

Place the machine in a safe condition.

DIFFERENTIAL AND GEARBOX - OIL LEVEL Clean the area around screw plug (1) of axle and screw plug (2) of gearbox.

Unscrew the screw plugs (1) and (2) slowly, until the inner pressure is completely released. Only after this operation unscrew the plugs completely. The oil level must be flush with the hole edge. If necessary, top up oil through the hole.

Retighten screw plugs (1) and (2).

48

49

4-42

SUPPLIES AND MAINTENANCE CHART TRAVEL GEARBOXES - OIL LEVEL Bring the screw plugs (1) and (2) into position depending on the wheel-hub installed. The line under the word “REAR” or “OIL” must be in horizontal position.

Clean the area around screw plugs (1) and (2).

Unscrew the screw plug (1) slowly, until the inner pressure is completely released. Only after this operation, unscrew the plug completely. The oil level must be flush with the hole edge. If necessary, top up oil through the hole.

Screw up the screw plug (1).

Repeat this check on the wheel-hub at the opposite axle end.

50

Lower the machine.

51

AIR CONDITIONING SYSTEM If the system is not used at least once a month (for instance during winter), it is necessary to perform a visual check of the system status and of its main components.

Moreover, it is necessary to let it run for at least 10-15 minutes.

In this way you avoid that the oil seal on the compressor shaft dries and becomes fragile. In this case coolant leaks may take place. Besides, in this way all compressor components are periodically lubricated.

4-43

SECTION 4 BLADE AND STABILIZERS JOINTS, CARDAN SHAFT, STEERING TRUNNION PINS - GREASING Before starting with the greasing operations place the machine in a safe condition.

By means of the greasing pump, grease all lubrication points.

Remove the protection cap from the grease nipple.

Clean the grease nipple.

Apply the pump nozzle on the grease nipple.

Now, pump the grease in such a quantity that the new grease can eject the old one from the articulation points.

Wipe off used grease with a cleaning rag.

After greasing, put protective cap back onto the grease nipple.

BLADE AND STABILIZERS JOINTS (1) = No. 12 grease nipples

52 CARDAN SHAFT (2) = No. 2 grease nipples

53

4-44

SUPPLIES AND MAINTENANCE CHART STEERING TRUNNION PINS (3) = No. 4 grease nipples (4) = No. 2 grease nipples

54

FLOATING AXLE LOCKING CYLINDERS CONTACT FACES - LUBRICATION The contact faces of floating axle locking cylinder must be lubricated.

If the contact faces are dry, noise is heard during the axle floating.

The pistons rounded ends can not glide, therefore their motion generates friction and strikes.

The contact faces can get seized.

Clean the pistons ends and the upper faces of the gliding element.

Spray some lubricant between the cylinder rod and the gliding element.

Repeat this operation also with the other cylinder of the floating axle.

55

4-45

SECTION 4

SERVICE EVERY 12 MONTHS (500 HOURS) Check

Cleaning

Engine - revolutions sensor

S

D

Engine - Drive belt

S

SERVICE POINTS

Replacement / Change

Oil change

Greasing

V

Engine oil Slewing bearing - Screws tightening

S

Slewing bearing - Teeth Slewing gearbox - Screws tightening

J

S

ENGINE REVOLUTIONS SENSOR CLEANING

WARNING Injuries hazard, because of the motion of blower blades, belts and of hot components of the engine and silencer.

Shut off the engine and let it cool down, before opening the engine compartment.

Place the machine in a safe condition.

Shut off the engine.

Open the engine compartment cover. The engine revolutions sensor (1) is fitted on the flywheel case and is accessible from the bottom, after dismantling the panels, that are placed under the pumps and engine compartment.

Disconnect the connector of the sensor linkage cable.

Loosen the lock-nut (2) and unscrew the sensor (1).

Clean the front side of the sensor.

Check the electric contacts of connector. If necessary, clean them and remove rust, if present.

To reassemble the sensor, carry out following operations: Screw up sensor (1) manually in the fly-wheel case, until a certain hardness is felt. Now the front face of sensor is going to lean against the fly-wheel tooth.

Now unscrew the sensor of half a turn. In this way the correct distance of the fly-wheel is set.

Tighten the lock-nut (2), paying attention not to modify the sensor tightening depth.

Connect again the connector of the linking cable.

4-46

56

SUPPLIES AND MAINTENANCE CHART DRIVE BELTS - CHECK

WARNING Accidents hazard, caused by the blower blades and by the belts in motion.

Shut off the engine before opening the engine hood.

Risk of burns caused by engine, silencer and coolers hot components.

Start the maintenance works and repair only after the engine, the silencer and the radiators are cool.

Place the machine in a safe condition.

Shut off the engine.

57

Open the engine compartment cover.

Carry out a visual check of all engine belts, after the opening of the side door, at the right in travel direction.

Check that the belts have no cracks crossing over.

Transversal cracks (1), parallel to the belt width are allowed. Cracks parallel to the belt length (2), crossing the transversal ones (1) are not allowed.

In this case the belt has to be replaced. The belt must be replaced also in case of frayed edges or if it is losing pieces.

Check that the belts have no shiny or worn out spots. In this case the belt is loose or it slips.

4-47

SECTION 4 ENGINE OIL - CHANGE

WARNING Risk of burns caused from hot engine oil.

Collect escaping oil and discard without polluting the environment.

DRAINING HOSE FOR OIL CHANGE The engine is equipped with a special filler neck (1) for oil discharge.

In this way the oil change can be performed in a clean and not polluting way.

Perform the oil change in this way: - place under the drain sleeve a collecting container for old oil; - take from the equipment available the relevant draining hose; - unscrew the blanking plug (3) from the oil drain sleeve (1); - screw up the hose (2). The sleeve (1) opens automatically and oil is discharged;

58

- once oil has been drained, unscrew the hose (2).

The drain sleeve (1) closes independently; - retighten the protection cover (3).

OIL DRAINING Bring engine oil to operating temperature.

Park the machine on a level surface, and secure it against inadvertent movements.

Shut off the engine.

Disassemble the base-plate for maintenance below the engine compartment. Now the oil drain sleeve (1) is accessible.

Drain the engine oil through the drain sleeve. For this operation, use the proper hose.

59

4-48

SUPPLIES AND MAINTENANCE CHART OIL FILLING Screw up the hose.

Reassemble the base-plate for maintenance below the engine compartment.

Engine oil filter change.

Carry out the oil filling by unscrewing the plug (4), until you reach the reference “max” of the dipstick (5).

60

61

SLEWING BEARING - SCREW TIGHTENING CHECK The fastening screws of the slewing bearing (1) and undercarriage (2) are tightened to the prescribed tightening torque.

The loosen screws have to be unscrewed first and then tightened by means of a dynamometric key or another tightening tool (electric / hydraulic) at the prescribed tightening torque.

WX 210 Industry - WX 240 Industry = 560 Nm (405 lbf·ft)

62

4-49

SECTION 4 SLEWING BEARING TEETH GREASING

WARNING Perform the upper structure slewing only after ensuring that nobody is staying in the slewing range.

The slewing bearing teeth and the slewing gearbox pinion, are enclosed into a housing filled with grease.

Disassemble the cover (2) by untightening the screws (3).

Check the presence of possible damages on the pinion teeth.

Check the grease filling.

The height of the grease filling in the tank must be of about 20 mm (0.79 in) on WX 210 Industry and WX 240 Industry excavators. If this is not the case, add grease.

63

Check that water is not penetrated. You can recognize this event by the fact that grease becomes lighter. Great quantities of water create some bags, that have absolutely to be cleared, by draining or sucking the water.

Check the teeth coating and the seal of the upper structure rotor. If there are leaks or damages, water could penetrate or cause breaks or grease leaks.

These troubles have to be cleared immediately.

Replace the gasket (1) and reinstall the cover (1) by fixing it with screws (3).

SLEWING GEARBOX - SCREWS TIGHTENING CHECK The fastening screws (1) of the slewing gearbox (2) on the upper structure are tightened at prescribed tightening torques.

The loose screws have to be completely loosened and then tightened at the prescribed tightening torque by means of a torque wrench.

WX 210 Industry - WX 240 Industry = 250 Nm (184.39 lbf·ft)

64

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SUPPLIES AND MAINTENANCE CHART

SERVICE AFTER 1000 HOURS SERVICE POINTS

Check

Cleaning

Oil change

Replacement / Change

Cab - Air filter

Q

Windscreen wiper - Blades

Q

Engine brackets - Screws tightening

S

Engine - Belt tensioner

S

Air filter: Main and safety filter elements

Q

Hydraulic system - Bleeding valve

Q

Steering axle

W

Rigid axle and gearbox

W

Service brake - Plates

S Q

Pilot control filter Counterweight - Screw tightening Air conditioning system

S SD Q

Compressor belt Heat exchanger - Evaporator - Condenser

D

Filter and panel

D

CAB AIR FILTER - CHANGE The filter element is accessible by opening the cover (1) on the rear wall of the cab by means of a square-section tool.

Open the cover (1).

Withdraw the old filter element and discard it without polluting the environment.

Install the new filter.

Close the cover (1).

65

WINDSCREEN BLADES - CHANGE For a good visibility from the operator’s side a good cleaning of the cab windows is required.

In order to maintain this status, the good condition and operation of the windscreen wiper blades is crucial.

Change the blades for safety reasons.

4-51

SECTION 4 ENGINE BRACKETS - SCREWS TIGHTENING CHECK Place the machine in a safe condition.

Place the working attachment on the ground.

Engage the parking brake.

Shut off the engine and wait that it cools down.

Check that rubber pads and the screws of the engine brackets are not damaged or missing.

If some components are broken or weakened or cracked, the dampers have to be replaced. The damaged screws have to be changed and the missing ones, replaced.

Check the tightening of the screws with a torque wrench checking that the torques are the prescribed ones.

66

Torques (Nm) Position

Screw

1

M12

104 (76.71)

2

M16

250 (184.39)

3

M20

490 (361.40)

WX 210 Industry

WX 240 Industry

ENGINE BELT TENSIONER - CHECK

WARNING Danger of injuries caused by blower and belts in motion.

Risk of burns caused by engine, silencer and coolers hot components.

Shut off the engine and wait that it cools before opening the hood.

Make sure that the belt tensioner bracket (1) does not touch neither the upper point nor the lower one of the crankcase stop.

If one of the stop points is touched, the belt (2) must be changed.

If replacement is necessary, pay attention to use a belt with the proper length.

Check that the belt tensioning roller (3) and the crankcase do not show brakes.

If damaged, the belt tensioner (1) has to be replaced. Address in this case to an authorized workshop.

Check the belt tensioner (1) for dirt build-ups. In case of dirt build-ups, disassemble it and clean it with steam jets.

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67

SUPPLIES AND MAINTENANCE CHART Check that the spring seat, the belt tensioner and the cranckase are one above the other. If they are remarkably spaced or tilted one against the other, the belt tensioner has to be replaced.

Check for signs that the tensioner bracket touches the spring seat. If they touch each other, this means that the bracket bushing is faulty and that the belt tensioner has to be changed.

A worn belt tensioner, showing some backlash, or a belt slipping from the pulley, indicate the possibility of a wrong pulley alignment.

The maximum allowable pulley alignment is of 3°.

The measurement can be performed by means of a blade scale and a goniometer.

AIR FILTER - REPLACEMENT OF MAIN FILTER ELEMENT AND OF SAFETY ELEMENT Place the machine in a safe condition.

Place the working attachment on the ground.

Engage the parking brake.

Shut off the engine and wait that it cools down.

Open the cover on the left side of the machine.

Open the clamps (2) on the filter housing and remove the cover (1).

Remove the main filter element (3) carefully from the case (5).

Remove from the case (5) also the safety element (4).

NOTE: beyond respecting the maintenance interval of the safety element (4), this has to be replaced after the main element (3) has been cleaned three times.

Clean the inside of the filter case (5) and the cover (1) accurately, by means of a vacuum cleaner.

68

Install the new safety element (4) and then the main new element (3).

Reassemble the cover (1) and lock it with the clamps (2).

4-53

SECTION 4 HYDRAULIC SYSTEM BLEEDING VALVE - CHANGE The air bleeding and sucking valve (1) ensures this operation inside of the hydraulic oil tank (2), so as to compensate the hydraulic oil level floating.

This valve maintains a pressure of about 0.3 bar (4 psi) inside of the tank.

The valve (1) contains a filter element (4), that cannot neither be cleaned nor replaced. This is the reason why the valve has to be replaced completely.

The filter head is connected to the lower side, so as to be free to turn. In this way, you avoid that the valve is removed without authorization.

69 To unscrew the valve, insert laterally the locking pin (3), that is delivered with the new valve. Now the old valve has to be unscrewed with great care (the pressure inside of the hydraulic oil tank is released).

Insert the locking pin (3) inside of the new valve and tighten the valve manually.

Take out the locking pin and store it (for instance in the keys bunch) for a future use.

70

STEERING AXLE - OIL CHANGE

WARNING The axle and the differential box may also be hot after a long journey.

Leave the axle and differential box to cool down and wear working gloves.

The axle and differential may be slightly over pressurized, so turn the control plug carefully, just far enough to release the excess pressure (audible hissing sound).

Collect the escaping oil and discard it without polluting the environment.

Park the machine on a level and firm surface.

Block the rigid axle wheels by placing chocks under them.

Raise the machine with the levelling blade or the working equipment until the wheels of the steering axle are clear of the ground and turn freely.

Shut off the engine.

Place the machine in a safe condition.

4-54

SUPPLIES AND MAINTENANCE CHART DIFFERENTIAL - OIL CHANGE Clean the area around screw plugs (1) and (2).

Place a container under the screw plug (2) to collect old oil.

Unscrew the screw plug (1) slowly, until the inner pressure is completely released. Only after this operation, unscrew the plug (1) completely.

Unscrew the screw plug (2).

Oil flows out of the screw plug (2).

Screw up the screw plug (2).

Fill new oil through the screw plug (1) hole. The oil level must be flush with the hole lower edge.

Screw up the screw plug (1).

71

TRAVEL GEARBOXES - OIL CHANGE According to the type of wheel-hub, set screw plugs (2) for oil drain into the shown positions.

Screw plug (1) must be above the centreline.

The line under the word “Front” must be in horizontal position.

Clean the area around the screw plugs (1) and (2).

Place a container under the screw plug (2) to collect old oil.

Unscrew the screw plug (1) slowly, until the inner pressure is completely released.

Only after this operation, unscrew the screw plug (1) completely.

72

Unscrew the screw plug (2). Oil flows out of the screw plug (2).

Screw up the screw plug (2).

Fill new oil through the screw plug (1) hole.

The oil level must be flush with the hole lower edge.

Screw up the screw plug (1).

Perform the oil change in the same way also for the other travel gearbox.

73

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SECTION 4 RIGID AXLE AND GEARBOX - OIL CHANGE

WARNING The axle and the gearbox may also be hot after a long journey.

Let the axle and the gearshift box cool down and wear working gloves.

The axle and the gearshift box may be slightly over pressurized, so turn the control plug carefully, just far enough to release the excess pressure (audible hissing sound).

Collect escaping oil and discard without polluting the environment.

Park the machine on a level and firm surface.

Block the steering axle wheels by placing chocks under them.

Raise the machine with the levelling blade or the working attachment until the wheels of the rigid axle are clear of the ground and turn freely.

Shut off the engine.

Place the machine in a safe condition.

GEARSHIFT BOX - OIL CHANGE Clean the area around screw plugs (1) and (2).

Place a container under the gearshift box screw plug (1) to collect old oil.

Unscrew the screw plug (2) slowly, until the inner pressure is completely released. Only after this operation, unscrew the screw plug (2) completely.

Unscrew the screw plug (1).

Oil flows out from the plug (1) hole.

Screw up the screw plug (1).

Fill new oil through the plug (2) hole.

The oil level must be flush with the hole lower edge.

Screw up the screw plug (2).

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74

SUPPLIES AND MAINTENANCE CHART DIFFERENTIAL - OIL CHANGE Clean the area around the plugs (1) and (2).

Place a container under the screw plug (2) to collect old oil.

Unscrew the screw plug (1) slowly, until the inner pressure is completely released. Only after this operation, unscrew the screw plug (1) completely.

Unscrew the screw plug (2).

Oil flows out of the screw plug (2).

Screw up the screw plug (2).

Fill new oil through the screw plug (1) hole.

The oil level must be flush with the screw plug (1) lower edge.

75

Screw up the screw plug (1).

TRAVEL GEARBOXES - OIL CHANGE Bring the screw plugs (1) and (2) into position depending on the gearbox installed. The line under the word “REAR” or “OIL” must be in horizontal position.

Clean the area around screw plugs (1) and (2).

Place a container under the screw plug (2) to collect old oil.

Unscrew the screw plug (1) slowly, until the inner pressure is completely released. Only after this operation, unscrew the screw plug (1) completely.

Unscrew the screw plug (2).

Oil flows out of the screw plug (2).

76

Screw up the screw plug (2).

Fill new oil through the screw plug (1) hole.

The oil level must be flush with the hole lower edge.

Screw up the screw plug (1).

Perform the oil change in the same way also for the other travel gearbox.

4-57

SECTION 4 SERVICE BRAKE - PLATES CHECK The check to carry out is the thickness of coatings.

To purchase the measurement device address to your Dealer.

WX 210 Industry Measurement of maximum gap (mm)

WX 240 Industry

4.5 (0.18 in)

The measurement has to be carried out on all wheels and by following this procedure.

Park the machine on a level and firm surface.

Move the machine so that the plugs (1) set to shown position.

Place the working attachment on the ground.

Place the machine in a safe condition.

Shut off the engine.

Unscrew the screw plug (1).

Lock the service brake.

77 Screw the measuring device (2) in the screw plug.

Loosen the lock-nut (4) of measuring device.

Screw the threaded shaft (5) up to stroke end by means of star knob.

Bring the scaled ring nut (3) to “0” and then lock the lock-nut (4).

Release the service brake.

Screw the threaded shaft (5) up to stroke end by means of star knob.

During the tightening determine the quantity of full turns (see “0” reference of the graduated scale) and the value of the last half-turn. A complete turn corresponds to 1 mm (0.039 in) of shaft stroke, while each notch of the graduated scale corresponds to 0.1 mm (0.0039 in).

Perform the measurement and check the value detected with the reference one.

If the value detected is higher or equal to the reference value, replace the brake plates. In such cases, contact the After-sales service.

Unscrew the measuring device (2) and tighten the screw plug (1).

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78

SUPPLIES AND MAINTENANCE CHART PILOT CONTROL FILTER - CHANGE Park the machine on a level and firm surface.

Place the working attachment on the ground.

Activate the parking brake.

Place the machine in a safe condition.

Shut off the engine.

Relieve the pressure from the hydraulic system.

The filter of the pilot control is built-in in the valves block (1), installed in the frame between the cab and the engine compartment.

79 Unscrew the case (2) and move it downward as far as possible. Do not let hydraulic oil flow out.

Remove the filter (3) with one turn.

Clean the filter case (2) and the seal surfaces on the filter head.

Fit the new filter (3) with one turn.

Tighten the case (2) in the filter head.

Once the hydraulic system is operating, check the tightness of the filter case.

Discard used filters according to environment legislation.

80

COUNTERWEIGHT - SCREW TIGHTENING CHECK Place the machine in a safe condition.

Place the working attachment on the ground.

Engage the parking brake.

Shut off the engine.

Check the tightening of the screws (1) fastening the counterweight by using a torque wrench and checking that the tightening torque is the prescribed one.

WX 210 Industry - WX 240 Industry = 2250 Nm (1659.51 lbf·ft)

81

4-59

SECTION 4 AIR CONDITIONING SYSTEM CLEANING AND OPERATION CHECK COMPRESSOR BELT CHANGE

WARNING Shut off the engine and let it cool down before carrying out any maintenance work.

Disconnect the blower from electric power supply.

In this case possible injuries caused by the accidental activation of the blower are avoided.

Some parts of the air conditioning system (e.g. the heat exchanger and the resistor of the blower) may still be hot after shutdown. Risk of scalding! Let them cool before restart working.

Avoid any skin contact with the coolant.

Wear goggles to protect your eyes. If, although you wear goggles, some coolant gets in contact with your eyes, seek medical advice immediately.

SYSTEM COMPONENTS The air conditioning system consists of: - blower (1); - heat exchanger (2); - evaporator (3); - panel filter (4); - heating valve (5); - draining sleeve for condensate discharge (6); - motor for air re-circulation and outer air intake (7); - thermostat, electronic control unit (8); 82 - feet area air outlets (9); - air outlet on front and rear window (10); - coolant inlet (11); - coolant outlet (12); - connection of air conditioning hoses (13); - air from outside (14) inlet; (these elements are accessible by removing the upper cover) - condenser (15) and coolant container with dehumidifier (16) located in front of the multi-cooler; 83

4-60

SUPPLIES AND MAINTENANCE CHART - compressor (17): it is installed in the engine compartment on the front; - compressor belt (18);

84 - heating valve (19): it is installed on the right side of the heater/air conditioner.

85

4-61

SECTION 4 OPERATION CHECK AND CLEANING Perform a general check of the system and of its components.

Check the coolant level.

Check hoses and connections for tightness and proper laying.

Check the good conditions and the correct fastening of connectors and of electric wires.

Check that evaporator fins (3) are not bent: if this is the case, straighten them again.

Check that the antifreeze probe is not bent or shows leaks.

Check if the condensate of the sleeve (6) is able to drain.

86

Clean the panel filter (4).

Check the operation of the heating valves (5).

Clean the heat exchanger (2), the evaporator (3) and the blower (1).

Clean the condenser (15).

When the condenser is dirty, its performance is poor. Clean with compressed air or with a sprayer (do not use high-pressure jet cleaners). Possible bent fins must be straightened again.

87 Check the operation of the compressor (17). Check the tightening of the fastening screws.

Check the condition and the tension of belt (18).

88

4-62

SUPPLIES AND MAINTENANCE CHART Check the operation of the selector for temperature adjustment (20).

If the selector is hard to move, check that the tie-rod is not bent or rusted, eventually replace it.

89 COMPRESSOR BELT - REPLACEMENT

WARNING Risk of injury from hot or rotating parts in the engine compartment.

Shut off the engine before opening the engine hood.

After operation, even the compressor can be hot.

Let it cool down before performing any work.

IMPORTANT: if the belt tension is not correct, the compressor performance may be impaired.

This can also cause damages to the belt and to the compressor.

The compressor (1) is fastened to the engine block.

Open the engine hood.

Loosen the lock screw (3).

Loosen the belt tension (2), by shifting the compressor (1) toward the engine with swinging movements.

Replace the damaged belt (2) with a new one.

By shifting the compressor (1) to the right with swinging movements, tension the belt (2).

Tighten the lock screw (3) again.

Check belt tension.

Press with the thumb the belt in the centre between the pulleys. It must flex of about 10 mm (0.39 in). If the tension does not correspond to this parameter, you must loosen or tension the belt accordingly.

90

Check that the fastening screws (4) of compressor (1) to the support and to the engine support, are tightened correctly. tighten them, if necessary.

After some hours of operation, check the belt (2) condition and tension.

4-63

SECTION 4

SERVICE AFTER 3000 HOURS SERVICE POINTS

Check

Oil change

Cleaning

W

D

Oil tank Engine - valves clearance

Air bleeding Replacement / Change P

S

Cooling system liquid

Q

D

Fuel tank Slewing gearbox

W

HYDRAULIC OIL TANK - CLEANING AND OIL CHANGE

WARNING Never let hydraulic oils to come in contact with the skin.

Wear protective gloves.

Collect escaping oil and discard without polluting the environment.

HYDRAULIC OIL DRAIN

WARNING Do not start the engine if hydraulic oil has been drained.

91

By turning dry, the hydraulic pumps get damaged or broken.

Bring engine oil to operating temperature (about 50 °C (122 °F)).

Park the machine on a level and firm surface.

Retracting the cylinders as much as possible and lay the working attachment on the ground.

Shut off the engine.

Release the pressure from the hydraulic oil tank.

Place a collecting container under the hydraulic oil tank (1) and the multi-cooler.

Drain the hydraulic oil from the tank (1) by means of proper hose.

The oil drain sleeve (2) of the tank is accessible from the bottom though an opening on the counterweight.

4-64

92

SUPPLIES AND MAINTENANCE CHART To drain the oil from the cooler, unscrew the filling cap (3) cautiously, to allow that the pressure contained in the oil cooling system, can be released.

Only after this operation, unscrew the plug completely.

Disassemble the cover panel under the multi-cooler.

Drain the hydraulic oil from the multi-cooler by means of the specially provided hose.

93 The oil drain sleeve (4) of the multi-cooler is accessible from the bottom though an opening in the bottom of the undercarriage.

Collect the hydraulic oil in the container at disposal.

94

4-65

SECTION 4 HYDRAULIC OIL TANK - CLEANING

WARNING Do not use petroleum, paraffin oil or other solvents to clean the tank.

This can cause the formation of gas easy flammable and explosive.

Use therefore only hydraulic oil or paraffin oil for the special detergent for cleaning and washing the tank.

Discard hydraulic oil and dirty rags according to environment legislation.

Unscrew all screws (1) and remove the cover (2).

Place a container to collect detergent oil under the hydraulic oil tank.

Clean the tank (3) inside with hydraulic oil or detergent oil.

Remove all deposits and detergents residuals.

Replace the gasket under the cover (2).

Reassemble the cover (2) and fasten it with screws (1).

95 HYDRAULIC OIL FILLING Remove the return filter cover.

Loosen the bleeding plug on the hydraulic oil tank (1).

Fill hydraulic oil inside of filter chamber, until oil comes out from the bleeding plug (1). Tighten the bleeding plug.

Carry on with the hydraulic oil filling, until the level on the gauge (2) reaches the “max” reference.

Bleed air from the hydraulic system.

Check the oil level on the gauge (2) inside of the hydraulic oil tank (3).

96

97 4-66

SUPPLIES AND MAINTENANCE CHART HYDRAULIC SYSTEM - AIR BLEEDING Beyond respecting the maintenance intervals, air must be bled from the hydraulic system after each oil change: pumps, engines and cylinders have to be accurately bled of air. If this is not the case, their performance during intake and operation will be seriously affected.

Unscrew the breather plugs (1) on the working pump and the breather plugs of the slewing pump (2) on the regulator side, in front of the flange.

Hydraulic oil flows from the tank into the pumps, by releasing the air outside.

Tighten again the bleeding plugs (1) and (2), as soon as hydraulic oil starts to flow out from the hole without air bubbles.

98

Start the engine and let it run idle and middle speed for about two minutes.

Extend and retract all hydraulic cylinders repeatedly, until their movements stop to knock.

Slew the upper structure repeatedly by reversing the slewing direction.

ENGINE - CHECK AND ADJUSTMENT OF VALVES CLEARANCE Consult your Dealer.

4-67

SECTION 4 COOLING SYSTEM LIQUID - CHANGE

WARNING Drain the coolant only after it has cooled down sufficiently.

Discard used coolant according to environment legislation.

Park the machine on a level and firm surface.

Place the working attachment on the ground.

Activate the parking brake.

Place the machine in a safe condition.

99 Shut off the engine.

Open the cover of the engine compartment and the door in front of the multi-cooler.

Prepare a collecting container for the coolant.

Unscrew plug (1) of expansion tank (2).

Using the oil drain hose, which must be clean, drain the coolant from the cooler.

The drain sleeve (3) of the cooler coolant can be accessed from the front, on the left.

Collect the coolant in the previously prepared container.

Fill the new liquid inside of the expansion tank, until the level sets between references “min” and “max”.

Tighten the plug (1) again.

After a short test, check again the liquid level and, if necessary, top up.

4-68

100

SUPPLIES AND MAINTENANCE CHART FUEL TANK - CLEANING

WARNING Do not use petroleum, paraffin oil or other solvents to clean the tank.

This can cause the formation of gas easy flammable and explosive.

Use therefore only hydraulic oil or detergent oil specially suited for the tank cleaning.

Follow the operator’s manual for detergent oil.

Do not spill fuel or detergent oil into the soil.

Store these products to reuse or to discard them, according to environment legislation.

Empty the tank beforehand by using up as much fuel as possible.

Check the residual quantity of fuel inside of the tank and place a container, sufficiently big, under the drain plug (3) of the tank (4) to collect fuel.

Remove the base-plate for maintenance below the fuel tank. Now the drain plug (3) is accessible.

Unscrew the drain plug (3), located under the fuel tank (4) and drain the fuel.

Place the container under the tank (4) to collect the detergent liquid.

Unscrew the cover of the filling neck (1).

101

Remove the little filter (2).

Clean the tank by means of the proper device and wash it.

Screw the drain plug (3).

Reinstall the maintenance base-plate.

Refit the little filter (2) into the filler neck.

Refuel through the little filter (2) installed inside of the filler neck.

Tighten the plug (1) again.

4-69

SECTION 4 SLEWING GEARBOX - OIL CHANGE

WARNING Collect escaping oil and discard without polluting the environment.

Perform the oil change with the machine at operation temperature; hot oil drains more easily.

DRAINING HOSE FOR OIL CHANGE The gearbox is equipped with a special sleeve (1) for oil discharge.

In this way the oil change can be performed in a clean and not polluting way.

Perform the oil change in this way: - place under the drain sleeve a collecting container for old oil; - take from the equipment available the relevant draining hose; - unscrew the blanking plug (3) from the oil drain sleeve (1); 102 - screw up the hose (2). The sleeve (1) opens automatically and oil is discharged; - once oil has been drained, unscrew the hose (2).

The drain sleeve (1) closes independently; - retighten the protection cover (3).

OIL CHANGE Prepare a collecting container for used oil.

Unscrew the screw plug (3).

Unscrew the protective cap (2) from the drain sleeve (1).

Drain oil through the drain hose.

103

Once the used oil has been drained, fill in the new oil through the hole of the screw plug (3), until the level reaches the centre of the inspection glass (4).

The time taken to fill in the prescribed oil quantity depends on the temperature of the environment.

Tighten the screw plug (3).

After a short time, check the level through the inspection glass (4). If necessary, top up the oil.

104

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SUPPLIES AND MAINTENANCE CHART

SERVICE WHEN NECESSARY SERVICE POINTS

Check

Pressure release

Cleaning

Air bleeding Replacement

D

Machine Windscreen wiper

S

D

Engine - Drive belt

Q

Engine - Injectors

Q

Hydraulic system

O

Tyres

Q

Service brake

P

Steering axle - Steering adjustment

S

Axle floating locking cylinders

P

Fuses

Q

Lights - Floodlamps - Bulbs

Q

Batteries

Q

Clamshell - Wear

S

MACHINE - CLEANING A periodical cleaning, correctly executed, allows the machine to maintain its performances.

It can moreover be one of the reason for claiming a guarantee service, if corrosion damages take eventually place.

The necessary products for machine care can be required from the After-sales service or from the Spares Parts Department. The use instructions printed on the packages must be strictly observed.

WARNING If used in the wrong way, the machine cleaning products may become harmful for health. They have to be stored always with the outmost care and safely.

The machine cleaning products residuals have to be disposed of according to the environment legislation.

The best protection for the machine against the harmful influences of the environment, can be achieved only by washing it frequently and by treating it with proper preservatives. How often the machine must undergo to the above mentioned treatment, depends also by the operative conditions, by the seasons and weather and environment conditions.

The greater is the time, resin of the trees, road powders, yards and industries powders, tar spots, soot deposits, antifreezing salt and other aggressive liquids stick to the varnish, the greater and persistent is their destructive effect. High temperatures, due for instance to intensive solar radiations, increase the corrosive effect. It can therefore happen, that the machine washdown is daily necessary, as well as that a monthly washdown with the relative preservative treatment, is sufficient. When performing the washdown, wash accurately also the part below the machine.

4-71

SECTION 4

WARNING To protect the environment, wash the machine only at washing stations, duly equipped for this job, and possibly also equipped with oil and grease collecting tanks for disposal. To wash the machine outside these stations, could in some territories and nations even be forbidden.

IMPORTANT: when washing the machine, do not direct the water jet toward electric or electronic components or assies or on ports. The water sprays and jets can cause misfunctioning or damage of the whole electronic system.

DAMAGES TO THE VARNISH Small damages to the varnish, like scratches, grooves or stone blows, have to be covered immediately with stick, spray or touch up varnish, before the formation of rust. In case of a light formation of rust, this should be accurately eliminated. Finally, on the concerned spot, apply a anticorrosion base and then the varnish coat.

CAB GLASSES AND MIRRORS

WASHING OF THE MACHINE BY HAND

Snow and ice have to be removed from glasses and mirrors with rubber blades. To avoid the scratches caused by dirt, do not move the blades forward and back but let them only slide. Clean the glasses also inside.

With plenty of water soften first all dirt and rinse as well as possible.

Residuals of rubber, oil, wax, grease or silicone can be removed with a detergent for glasses or silicone.

Clean up the machine at last with a sponge or a suitable brush.

Finally wash the wheels, the undercarriage and the stabilizers. For this operation use, if possible, a second sponge or brush.

Use shampoo only in case of hard dirt.

If the machine is sprayed with a hose, the water jet should not be directed toward the locks and hinges of doors and hatches or toward other openings. In winter they could freeze.

WASHING THE MACHINE WITH HIGH PRESSURE CLEANER Strictly observe the manufacturer operator’s manual of the cleaner, particularly for what it concerns the pressure and jet distance.

Do not use rotary nozzles or the so-called “dirt-eating nozzles”.

The water temperature should not exceed 60 °C (140 °F).

POLISHING Polishing is necessary only if the varnish has become opaque and if even with the use of preservatives the brilliance cannot be achieved.

NOTE: the components coated with opaque varnishes and plastic have not to be treated with polishers and hard waxes.

4-72

PLASTIC AND IMITATION LEATHER COMPONENTS The outer plastic components have to be cleaned up with water, while the inner ones with a humid cloth.

If this is not sufficient, the plastic components and the leather imitation ones have to be treated only with specific products without solvents, suitable for the cleaning and care of plastic.

PADDINGS AND FABRIC UPHOLSTERING The paddings and the fabric upholstering of the operator’s seat and cab roof, have to be cleaned with specific detergents of with dry-chemical foam and with a soft brush.

SEAT BELT CLEANING Keep seat belt clean! Dirty belts have to be cleaned only with soaped water, without to take them apart.

RIMS The wheels rims have to be cleaned accurately during the machine wash. You avoid in this way the dirt and aggressive materials build-up. Very hard dirt build-ups can be removed with an industrial cleaner.

Damaged varnish has to be reworked, before the formation of rust.

SUPPLIES AND MAINTENANCE CHART WINDSCREEN WIPER - CHECK AND CLEANING For a good visibility from the operator’s side a good cleaning of the cab windows is required.

In order to maintain this status, the good condition and operation of the windscreen wiper blades is crucial.

For a perfect visibility, a long glasses life and a correct operation, it is absolutely necessary to use quality blades. To avoid the formation of scratches, the windscreen wiper blades, should be cleaned periodically with a specific detergent. With hard dirt, the blades cleaning has to be performed with a sponge or a rag.

After the cleaning, activate the screen wiper to check the reaction on the glasses.

NOTE: with ice, before setting the machine in operation for the first time, check that blades are not frozen.

DRIVE BELT - CHANGE

WARNING Danger of injuries caused by blower and belts in motion.

Before opening the hood, shut off the engine.

Risk of burns caused by engine, silencer and coolers hot components.

Open the cooler side cover on the right side of the upper structure.

Now the drive belt is accessible.

Activate the automatic belt tensioner (3) with a special wrench (1) and remove the old drive belt (2) from the alternator, from the pumps and the pulley.

Place the new drive belt (2) to correct position on the pulley, pumps, alternator and idle rollers.

Restore the tensioning operation of the automatic belt tensioner (3).

Other kinds of adjustment are not required.

105

4-73

SECTION 4 INJECTORS - REPLACEMENT Consult your Dealer.

HYDRAULIC SYSTEM AND TANK PRESSURE RELEASE

WARNING Only unpressurized hydraulic systems may be opened. Even if the machine is parked in horizontal position, with its attachment supported on the ground and the engine shut off, there may still be substantial residual pressure in parts of the hydraulic system: - the primary pressure of the last hydraulic movements, before the machine stop.

- the secondary pressure, produced by the machine own weight or by the attachment single elements. The secondary pressure is present, until the component creating the pressure is set to rest position, for instance by means of mechanical supports, that allow to clear off the supporting function of the hydraulic system.

HYDRAULIC SYSTEM PRESSURE RELEASE Place the working attachment on the ground.

Shut off the engine.

Turn the ignition key to position “I” (ignition ON).

Activate the pilot control.

Activate both hydraulic control levers or pedals in both directions required for the works at hand.

Set the ignition key to position “0” (ignition OFF).

Disconnect the pilot control.

Before activating the cylinders, equipped with break protection valves, pay particular attention, because after the activation of the hydraulic control lever or pedals, some residual pressure may be present inside of the cylinder.

- On lifting cylinders with break protection valve at bottom side. This residual pressure can be discharged by lifting the undercarriage of about 10 cm (3.94 in).

During this operation the machine leans on the cylinder head side allowing the cylinder bottom to release the pressure.

4-74

- On adjusting cylinders with break protection valve at cylinder head side. This residual pressure may release, by retracting nearly completely the concerned cylinder and by lifting the undercarriage of about 10 cm (3.94 in) with the attachment completely extended. During this operation the machine leans on the cylinder bottom side allowing the cylinder head to release the pressure.

SUPPLIES AND MAINTENANCE CHART PRESSURE RELEASE FROM HYDRAULIC OIL TANK For this operation fit the locking pin (2) laterally into the bleeding valve (1) and air intake. Now unscrew the valve (1) with care, until the bleeding hole opens (you hear a hissing).

Now the residual pressure inside of working attachment and of hydraulic pilot control has been released.

106 Tighten the valve (1) manually and take out the locking pin (2).

107

4-75

SECTION 4 TYRES - CHANGE Park the machine on a level and firm surface.

Engage the parking brake.

Loosen the wheel nuts (1) of the wheel (2) by approximately 1 full turn.

Raise the axle with the defective wheel slightly, until the wheels come clear of the ground. For this operation the machine can be lifted at the concerned side either with the working equipment or with the stabilizers.

Place wooden chocks under the lifted axle, to avoid that it lowers.

Place the machine in a safe condition.

Relieve the pressure from the tyres.

Unscrew nuts (1) from the concerned wheel (2) and the middle ring (optional).

Mark the inner wheel and the outer one. Do not lose the centering rings, the spring washers and the wheel nuts. They have to be reused for reassembly.

Fit the new tyres and inflate both of them at about 1 bar.

Observe the assembly sequence: - inner wheel (rims with greater camber angle); - intermediate ring (optional); - outer wheel (rims with minor camber angle).

Observe the sequence absolutely, because in case of wrong assembly of the wheels, the maximum allowable with of the machine can be exceeded; - pay attention to the tread position; - do not damage the threads of the wheel studs; - centre the intermediate ring; - no foreign body must be stuck between the tyres and the intermediate ring.

Tighten the nuts (1) of the wheel (2) by hand.

Remove the wooden chocks under the raised axle and lower it.

Tighten the nuts (1) of the wheel (2) to the prescribed torque.

Inflate the tyres to the correct pressure.

Check, after some service hours, the tightening of the wheel nuts by means of a torque wrench.

4-76

108

SUPPLIES AND MAINTENANCE CHART WHEELS TREAD POSITION Observe the tread position when fitting the wheels.

(A) = Shows the tread position recommended for allwheel driven machines which must have the same traction power for both driving directions.

109 (B) = Shows the tread position of the tyres when the all-wheel-driven machine needs especially good traction in one direction, e.g. during work with the levelling blade.

110

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SECTION 4 SERVICE BRAKE - AIR BLEEDING The braking system of this machine consists of two braking circuits. One circuit is designed for the pair of wheels of the steering axle, while the other circuit is designed for the pair of wheels of the rigid axle.

If works have been performed on the braking system, causing the penetration of air inside of the system, for instance during a hose replacement, once these works have been completed, bleed the air from the concerned circuit.

Secure the machine so that it cannot move accidentally.

Link a hose on the connection (1) of a multi-plate brake.

Connect the other end of the hose with a container, previously filled with hydraulic oil.

Start the engine.

Depress the pedal and hold, until hydraulic oil, flows out from the hose without air bubbles.

Repeat this operation also with the other brake of the same axle. In this way air is bleeded from one braking circuit.

111

STEERING ADJUSTMENT To ensure the correct travel and steering operation, the steering stop has to be adjusted according to machine type. According to the axle and tyres type, also the steering stop changes.

At each axle or tyres change, adjust correctly the steering stop and keep it constantly under control.

Through the axle joint rotation (4), the steering force are transferred to the wheel, which on its turn, is steered by the stub axle. The steering stop is limited by a spacer (1), fastened to the joint by means of a screw (2) and a thrust stop (3), placed on the axle body. In this way the steering wheels can turn safely without coming in touch with other elements, even when they are completely steered and the axle is fully inclined.

112

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SUPPLIES AND MAINTENANCE CHART AXLE FLOATING LOCKING CYLINDERS - AIR BLEEDING Park the machine on a level and firm surface.

Place the working attachment on the ground.

Shut off the engine.

Place chocks under the wheels.

Unscrew the plugs (2) on both cylinders.

Push the pistons down, until they lean on the thrust block of the axle.

Fill both cylinders with hydraulic oil and retighten the plugs (2).

Unscrew both breather screws (1) and fill the ports with hydraulic oil.

113

Screw up the breather screws (1) without tightening them.

Start the engine and release the brake.

Disconnect the floating axle lock by depressing push-button (3), the lamp and the symbol turn off.

When the flowing out oil is without air bubbles, tighten the bleeding screws (1).

114

4-79

SECTION 4 FUSES - REPLACEMENT Shut off the engine and turn the ignition key to position “0”, before removing the fuses.

Replace faulty fuses only with fuses of the same amperages.

The fuses are placed in two fuse boxes (A) and (B): a box (A) under the seat on the left side and the other (B) on the right side of the cabin under the control panel.

Remove the transparent cover (2) of the fuse holder, after prior removal of the two side clamps (1).

Now you can have access to fuses.

115

116 If an electric control does not react, check the relevant fuse as first thing.

Take out the fuse from the fuse holder. A suitable tool for this operation is located in the fuse box.

YES

NO

Check the fuse. Nearly always it is possible to check visually if a fuse is burnt out. In case of doubt, check with an Ohmeter or replace the burnt fuse with a new one.

If the fuse is burn out, fit in the fuse holder another fuse with the same amperage.

If the fuse is still intact, check the relevant electric unit, the connectors and cables.

4-80

117

SUPPLIES AND MAINTENANCE CHART FUSES LEGEND Cab - Fuse box (A) FA.1

5A

Power-Relay (main switch function), electronic control unit, engine stop solenoid shrinkage coil

FA.2

5A

Start-Relay, optional: Grid-Heater-Controller

FA.3

5A

Free

FA.4

2A

Sensors earthing

FA.5

15A

Optional: Filling system

FA.6

5A

Electric-hydraulic pilot control safety switch, Relay for main unit voltage supply, work pilot control lamp, travel pilot control lamp

FA.7

5A

Box Voltage Supply - Power Control System

FA.8

5A

Parking brake switch, brake lamp (lamp), alternator (energizing voltage)

FA.9

10A

Optional: seat compressor, additional heating gauge

FA.10

5A

Optional: stabilizers/blade

FA.11

10A

Main beams

FA.12

1A

Voltage supply for left and right hydraulic control levers

FA.13

2A

Voltage supply - Electro-Hydraulic Controller

FA.14

30A

Voltage supply - Electro-Hydraulic Controller

FA.15

1A

Voltage supply for travel pedal and key-pad module on flywheel

FA.16

5A

Optional: lubrication pump voltage supply

FA.17

15A

Optional: Additional heating

FA.18

5A

Optional: Additional heating

FA.19

7.5A

FA.20

5A

Optional: quick coupler

FA.21

5A

Optional: heating filter relay, Grid-Heater-Controller

FA.22

30A

Optional: heating filter

FA.23

25A

Stop solenoid shrinkage coil

FA.24

5A

Diagnostics electric socket

FA.25

10A

Voltage supply for 24 V/12 V radio and socket transformer

FA.26

2A

Relay for cab inner light

FA.27

2A

Power-Relay (main switch operation)

FA.28

15A

Ignition start lock

FA.29

5A

Emergency direction indicators

FA.30

15A

Blower / compressor for air conditioner

FA.31

-

Free

FA.32

-

Free

Optional: blower level 1 for additional heating

4-81

SECTION 4 Cab - Fuses box (B) FB.1

10A

Optional: rotary light

FB.2

10A

Optional: cab rear working floodlamps

FB.3

10A

Front cab working floodlamps

FB.4

10A

Screen wiper and glasses wash pump

FB.5

5A

Cab inner light

FB.6

7.5A

Voltage supply for 24 V/12 V radio and socket transformer

FB.7

2A

Voltage supply for display and key-pad module in the cab

FB.8

5A

Optional: frequency switching valve

FB.9

5A

Lights and switches function

FB.10

-

Free

FB.11

-

Free

FB.12

-

Free

FB.13

-

Free

FB.14

-

Free

FB.15

-

Free

FB.16

-

Free

Engine compartment F20

4-82

125A

Grid-Heater

SUPPLIES AND MAINTENANCE CHART BULBS - REPLACEMENT Burnt bulbs have to be replaced with bulbs of same power.

Before installing a new bulb, remove all traces of corrosion from the holder and the electrical contacts.

This helps avoid contact problems and high contact resistances.

Never touch new bulbs with bare fingers. Finger marks and dirt will burn in when the bulb is hot and may reduce the service life of the bulb.

Because of this, wrap a clean rag or a piece of the packing around the bulb and fit the same into the bulb holder.

CAB LIGHT Unlock and remove the light cover (1).

Now the bulbs are accessible and can be replaced.

Refit the cover (1) and lock it.

118

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SECTION 4 FRONT WORKING FLOODLAMPS Remove the light from the cab roof.

With your fingers, compress the safety bracket (arrows) on connector (2) and remove the connector.

Unscrew the nut (1) with a spanner.

Remove working floodlamp (4) with the cap (3).

Holding the working floodlamp (4) still, turn the cap (3) to the left and remove it.

Press one side of the safety bracket (6) and move it upwards.

Replace the lamp (5).

Assemble by following procedure in reverse order.

119

120 BOOM WORKING FLOODLAMP Unscrew the fastening screws (1) of the covering glass (2).

Open the locking clamp (3) and replace the bulb (4).

121

122 4-84

SUPPLIES AND MAINTENANCE CHART TRAVEL FLOODLAMP Unscrew the screws (1) and remove the floodlamp (2) from the upper structure frame.

Remove the large rubber cap (6) from the floodlamp back.

Disconnect the electric connector (4).

Remove the protection cap (3) from the bulb holder.

Open the lock bracket (5) of the bulb.

Replace the bulb.

123

124 TURN SIGNAL LIGHTS Unscrew the fastening screws (1) of the covering glass (2).

The bulb (3) is fitted inside a plug-in bulb holder (4): - press the bulb (3) and turn it to the left; - take out the bulb (3); - lock the new bulb (3) firmly inside of the bulb holder (4).

Reassemble the covering glass (2) and fasten it with screws (1).

125

126 4-85

SECTION 4 REAR FLOODLAMPS Unscrew the fastening screws (1) of the covering glass (2) of the lamps.

Remove the covering glass (2) of the lamps.

The bulbs are fitted inside a plug-in bulb holder.

Press the bulb and turn it to the left.

Remove the bulb.

Insert and correctly block a new lamp into the bulb holder.

Screw in the covering glass of the lamps.

A. Tail light B. Rear fog lights

127

C. Turn lights D. Stop light

128

4-86

SUPPLIES AND MAINTENANCE CHART BATTERIES - REPLACEMENT

WARNING Shut off the engine before removing batteries, to prevent damaging the alternator and regulator or the electronic modules.

Disconnect clamps from poles in the correct sequence.

A sequence error can cause a short-circuit.

Park the machine on a level and firm surface.

Set the ignition key to position “0” (start OFF).

Shut off the engine.

Place the machine in a safe condition.

The batteries are located behind the cabin under the cover (1).

Unscrew the screws (2) and remove the cover (1).

129 Unscrew the screws (5) and remove the locks (4).

Remove the cap (6).

Disconnect the clamp of the battery negative pole (-).

Disconnect the clamp of the battery positive pole (+).

Insulate the clamps.

Remove the batteries (3).

Before installing the new batteries, polish the contact faces of the battery poles and clamps.

Install the new batteries (3).

Connect the clamp to the battery positive pole (+).

130

Connect the clamp to the battery negative pole (-).

Tighten the clamps screw firmly.

Avoid to overtighten the screws so as not to damage them.

Finally apply grease or non-corrosive Vaseline to the battery poles and clamps.

The presence of loosen or corroded clamps generates overloads on the generator and regulator.

Reassemble the cover (6) and the locks (4) and fasten them with screws (5).

Reassemble the cover (1) and fasten it with screws (2).

4-87

SECTION 4 CLAMSHELL - WEAR CHECK When the normal wear of the clamshell blades and end stroke stops exceeds the allowed value, the clamshell cylinder may get damaged. In such a case the allowed cylinder stroke is exceeded; cylinder piston and liner bump one against the other at stroke end.

To verify the wear status on clamshells for trenches, reference marks are applied in the factory: - on the guide rod (1) by means of a punch; - on the cylinder rod (2) by means of a tool.

Repair the bucket prior that the cylinder rod (2) aligns with one of the marks on the guide rod (1).

The lower mark indicates the clamshell blades wear, while the upper mark indicates the wear of the end stroke stops of the clamshell clams.

131

4-88

SECTION 5 TROUBLESHOOTING Faults are often due to the machine not having been operated or serviced properly.

When dealing with faults, it is therefore necessary to read the corresponding chapter of the operating instructions once again.

If you cannot find the cause of a fault or rectify it, contact the After-sales service.

Describe the fault and the accompanying circumstances as precisely as possible when contacting our After-sales service. Exact information helps to locate and to rectify faults as fast as possible.

Never do work for which you are not qualified.

The present fault table lists the faults reported to date, their possible causes and the remedial action.

In exceptional cases, a described fault may also have another cause.

FAULT The fault is described as a result of an observation or of a preceding activity.

Observe the machine carefully.

Examine the problem thoroughly.

Ask yourself the following questions: - Which warning signs preceded the fault?

- Which repair and servicing work had been performed beforehand?

- Has this defect already been noticed in the past?

- Are we faced with one or with several defects occurring at the same time?

POSSIBLE CAUSES This column describes the possible causes of the fault observed. The causes are listed in the order of their probability of occurrence, the possible cause applying in most of the cases is mentioned in first place.

CORRECTION This column informs about how to detect the causes of faults and how to remedy them.

5-1

SECTION 5 ERRORS INDICATION ON THE DISPLAY When a fault occurs, the multi-function display shows on the upper section an error code (for instance # 7004), at the same time two lamps one yellow (2) and one red (3) light up; according to the fault they can light up either singularly or together.

According to the fault seriousness, also an acoustic warning can be released.

RED

Serious fault

+

The persons safety and/or the operation of the machine’s main assemblies are endangered.

CONTINUOUS SOUND

ERROR CODE Error explanation (rows of 25 digits)

1

YELLOW + SINGLE SOUND

Fault insignificant for the safety of persons and for machine operation.

These faults have to be cleared as soon as possible. In the majority of cases though, the full machine functionality remains unchanged.

WARNING The serious faults have to be cleared immediately.

Shut off the machine immediately.

Beyond the error code, in the lower section of the multi-function display, appears a short explanation of the error code.

In some particular cases, some faults can occur concurrently.

In such a case, the relevant error codes are indicated, by alternating one after the other in the usual visualization.

5-2

TROUBLESHOOTING

ENGINE PROBLEM

POSSIBLE CAUSE

The engine does start at all or Improper starting procedure. starts only with difficulty.

CORRECTION Revise the starting procedure.

Starting temperature too low.

Perform preheating.

Troubles at start-up.

Consult your Dealer.

Fuel unsuitable.

Drain fuel tank and refill with fuel of correct type.

Dirty or contaminated fuel.

Drain fuel tank and refill with clean fuel.

Lack of fuel.

Add fuel. Perform air bleeding.

Air filter dirty or clogged.

Clean or replace the filtering elements.

Fuel filter dirty or clogged.

Replace fuel filter.

Batteries defective or discharged.

Charge or replace batteries.

Starter motor faulty.

Consult your Dealer.

Cable for starter connection loose or Check and replace the cable. oxidized.

The engine starts but it does not run.

The engine runs irregularly or fails.

Starter fuse or relay faulty.

Replace.

Defective wiring connections.

Clean and tighten battery and starter motor terminals.

Stop solenoid locked or seized.

Consult your Dealer.

Engine stop solenoid wiring faulty.

Check and/or repair wiring connections.

Wrong valves clearance.

Consult your Dealer.

Air in the feeding system.

Bleed the feeding system.

Injector/s dirty or faulty.

Consult your Dealer.

Injection line leaks.

Check for leaks and rectify.

Inside mechanics blocked.

Consult your Dealer.

Engine coupling side locked.

Consult your Dealer.

Fuel system contaminated.

Clean the system.

Fuel injector/s faulty.

Consult your Dealer.

Leaks in the feeding system.

Check system hoses and fittings.

5-3

SECTION 5 PROBLEM The engine runs irregularly or fails.

The engine overheats.

Engine output is poor.

The engine does not run with all cylinders.

Engine oil pressure is nonexistent or excessively low.

Engine oil consumption excessive.

5-4

POSSIBLE CAUSE

CORRECTION

Fuel unsuitable.

Drain fuel tank and refill with fuel of correct type.

Air filter dirty or clogged.

Clean or replace the filtering elements.

Fuel filter dirty or clogged.

Replace fuel filter.

Multi-cooler dirty.

Clean cooler.

Cooler fan faulty.

Check and replace the cable.

Low coolant level.

Add coolant.

Wrong valves clearance.

Consult your Dealer.

Injector/s dirty or faulty.

Consult your Dealer.

Injection line leaks.

Check for leaks and rectify.

Oil level too high.

Top up oil level.

Fuel unsuitable.

Drain fuel tank and refill with fuel of correct type.

Air filter dirty or clogged.

Clean or replace the filtering elements.

Fuel filter dirty or clogged.

Replace fuel filter.

Leaks in the feeding system.

Check system hoses and fittings.

Wrong valves clearance.

Consult your Dealer.

Injector/s dirty or faulty.

Consult your Dealer.

Injection line leaks.

Check for leaks and rectify.

Wrong valves clearance.

Consult your Dealer.

Injection line leaks.

Check for leaks and rectify.

Injector/s dirty or faulty.

Consult your Dealer.

Engine oil level low.

Top up oil in correct quantity.

Engine oil not suitable.

Drain and refill with correct engine oil.

Excessive inclination of engine.

Check and modify the engine position.

Engine oil level too high.

Decrease oil level.

Excessive inclination of engine.

Check and modify the engine position.

Engine oil not suitable.

Drain and refill with correct engine oil.

TROUBLESHOOTING PROBLEM Exhaust smoke: blue.

POSSIBLE CAUSE

CORRECTION

Engine oil level too high.

Decrease oil level.

Excessive inclination of engine.

Check and modify the engine position.

Air filter dirty or clogged.

Clean or replace the filtering elements.

Defective head gasket.

Replace the gasket.

Oil level too high.

Decrease oil level.

Starting temperature too low.

Engine preheating.

Fuel unsuitable.

Drain fuel tank and refill with fuel of correct type.

Injector/s dirty or faulty.

Consult your Dealer.

Defective head gasket.

Replace the gasket.

Air filter dirty or clogged.

Clean or replace the filtering elements.

Leaks in the feeding system.

Check for leaks and rectify.

Wrong valves clearance.

Consult your Dealer.

Injector/s dirty or faulty.

Consult your Dealer.

Engine cannot be shut off, lamps extinguished.

Stop solenoid locked or seized.

Consult your Dealer.

Engine power lowering.

Fuel unsuitable.

Drain fuel tank and refill with fuel of correct type.

Air filter dirty or clogged.

Clean or replace the filtering elements.

Fuel filter dirty or clogged.

Replace fuel filter.

Charge-air line leaking.

Check for leaks and rectify.

Injection line leaks.

Check for leaks and rectify.

Injector/s dirty or faulty.

Consult your Dealer.

Control system not operational.

Consult your Dealer.

Fuel unsuitable.

Drain fuel tank and refill with fuel of correct type.

Air cleaner dirty or clogged.

Clean or replace the filtering elements.

Wrong valves clearance.

Consult your Dealer.

Engine temperature low.

Engine heater.

Injector/s dirty or clogged.

Consult your Dealer.

Exhaust smoke: white.

Exhaust smoke: black.

Excessive fuel consumption.

5-5

SECTION 5

STEERING SYSTEM PROBLEM

POSSIBLE CAUSE

CORRECTION

Steering not operational.

Air in the hydraulic system of the steering.

Bleed the system.

Steering wheel hard.

Double pump without frictional connection.

Consult your Dealer.

Steering wheel hard to turn when travelling on level ground.

Oil level too low.

Top up hydraulic oil in correct quantity.

Defective valves.

Consult your Dealer.

Tyres pressure too low.

Check and inflate tyres at correct pressure.

Air in the hydraulic system of the steering.

Bleed the system.

The steering floats (needs constant adjustments).

Internal leaks in the power steering or Consult your Dealer. cylinders.

Steering wheel easy to turn at limit stop.

Internal leaks in the power steering or Consult your Dealer. cylinders.

Steering wheel turns fast and uneven during steering action (steering discontinuous).

Air in the hydraulic system of the steering.

Bleed the system.

Internal leaks in the power steering or Consult your Dealer. cylinders.

Oil supply rate insufficient.

5-6

Consult your Dealer.

TROUBLESHOOTING

BRAKES SYSTEM SERVICE BRAKE PROBLEM

POSSIBLE CAUSE

Insufficient braking action or no Brake pedal valve faulty. braking action at all.

CORRECTION Consult your Dealer.

Air in the accumulator.

Consult your Dealer.

Air in the hydraulic braking system.

Check for leaks and rectify.

Brake discs worn out.

Replace the plates.

Air in the braking system.

Bleed the system.

Brake valve faulty.

Consult your Dealer.

Insufficient braking action or no Brake valve faulty. braking action at all.

Consult your Dealer.

PARKING BRAKE PROBLEM The parking brake does not release.

Parking brake not breaking.

POSSIBLE CAUSE

CORRECTION

Malfunction of the parking brake valve.

Consult your Dealer.

Brake release pressure too low.

Consult your Dealer.

Switch defective.

Consult your Dealer.

Gearbox blocked.

Consult your Dealer.

Malfunction of the parking brake valve.

Consult your Dealer.

5-7

SECTION 5

HYDRAULIC SYSTEM PROBLEM Working and slewing movements not operational.

Working operation too slow.

Power losses in working hydraulics.

POSSIBLE CAUSE

CORRECTION

Pilot control lever not in working position.

Check and position lever correctly.

Pilot control lever defective.

Consult your Dealer.

Hydraulic oil level too low.

Top up hydraulic oil in correct quantity.

Pilot control pressure limiting valve faulty.

Consult your Dealer.

Pilot control pump defective.

Consult your Dealer.

Pumps drive coupling defective.

Consult your Dealer.

Pressure relief valve defective.

Consult your Dealer.

LOW IDLE too low.

Check and adjust.

Fuel filter dirty or clogged.

Clean or replace fuel filter.

Engine lacks power.

Consult your Dealer.

Hydraulic oil temperature too high.

Check.

Dirty oil cooler.

Clean oil cooler.

Coolant temperature too high.

Consult your Dealer.

Malfunction of pilot control valve.

Consult your Dealer.

Pilot control pressure limiting valve faulty.

Consult your Dealer.

Pilot control pump defective.

Consult your Dealer.

Malfunction of primary and secondary Consult your Dealer. pressure limiting valves.

Independent working movement after hydraulic control lever activation.

Boom not operational.

Pilot valve defective.

Consult your Dealer.

Malfunction of pilot control valve.

Consult your Dealer.

Pilot control pressure limiting valve faulty.

Consult your Dealer.

Malfunction of primary and secondary Consult your Dealer. pressure limiting valves.

Boom lifting and lowering not operational.

Right hydraulic control lever defective.

Consult your Dealer.

Pilot control pressure limiting valve faulty.

Consult your Dealer.

Malfunction of primary and secondary Consult your Dealer. pressure limiting valves.

Right hydraulic control lever defective.

5-8

Consult your Dealer.

TROUBLESHOOTING PROBLEM Dipper not operational.

POSSIBLE CAUSE Pilot control pressure limiting valve faulty.

CORRECTION Consult your Dealer.

Malfunction of primary and secondary Consult your Dealer. pressure limiting valves.

Left hydraulic control lever defective. Consult your Dealer.

Dipper extension and retraction not operational.

Pilot control pressure limiting valve faulty.

Consult your Dealer.

Malfunction of primary and secondary Consult your Dealer. pressure limiting valve.

Left hydraulic control lever defective. Consult your Dealer.

Bucket cylinder (clamshell) extends without control.

Switching valve from standard bucket Consult your Dealer. to clamshell does not close completely.

Clamshell opens and closes too slowly.

Pilot control pressure limiting valve faulty.

Consult your Dealer.

Malfunction of primary and secondary Consult your Dealer. pressure limiting valve.

LOW IDLE too low.

Check and adjust.

Fuel filter dirty or clogged.

Clean or replace the fuel filter.

Engine lacks power.

Consult your Dealer.

Malfunction of pilot control valve.

Consult your Dealer.

5-9

SECTION 5

TRAVEL PROBLEM Machine does not move: no forward travel, nor reversing.

POSSIBLE CAUSE

CORRECTION

Hydraulic oil level too low.

Top up hydraulic oil in correct quantity.

Pilot control pump defective.

Consult your Dealer.

Pumps drive coupling defective.

Consult your Dealer.

Travel fuse faulty.

Replace fuse.

Parking brake blocked.

Release parking brake.

Storage pressure too low.

Consult your Dealer.

Control spool faulty.

Consult your Dealer.

Travel direction pedal valve defective. Consult your Dealer.

Maximum speed not reached.

Malfunction of pilot control valve.

Consult your Dealer.

Travel direction lever faulty.

Check and/or replace lever.

Travel direction pedal valve defective. Consult your Dealer.

Travel motor operation and adjustment incorrect.

Consult your Dealer.

Low engine speed.

Consult your Dealer.

Malfunction of pilot control valve.

Consult your Dealer.

Wheels brake setting incorrect.

Check and adjust.

Insufficient engine power.

Check and adjust.

Tyres pressure too low.

Inflate tyres at correct pressure.

Hydraulic oil temperature too high.

Cool oil.

Coolant temperature too low.

Engine preheating.

Travelling power is insufficient. Pilot control pump defective.

Consult your Dealer.

Travel direction pedal valve defective. Consult your Dealer.

5-10

Malfunction of pilot control valve.

Consult your Dealer.

Wheels brake setting incorrect.

Check and adjust correctly.

Travel motor operation and adjustment incorrect.

Consult your Dealer.

TROUBLESHOOTING

SLEWING PROBLEM Slewing not operational.

POSSIBLE CAUSE

CORRECTION

Pilot control lever not in working position.

Check and position lever correctly.

Pilot control lever defective.

Consult your Dealer.

Hydraulic oil level too low.

Top up hydraulic oil in correct quantity.

Pilot control pressure limiting valve faulty.

Consult your Dealer.

Pilot control pump defective.

Consult your Dealer.

Pumps drive coupling defective.

Consult your Dealer.

Slewing pump supply system defective.

Consult your Dealer.

Upper structure parking brake locked. Check and release the brake.

Upper structure locking pin jammed.

Remove the locking pin.

Upper structure slewing fuse faulty.

Replace fuse.

Solenoid defective.

Replace the solenoid.

Hydraulic control lever not operational.

Consult your Dealer.

Switch defective.

Replace switch.

Slewing left or right not operational.

Pump adjustment slewing wrong.

Check and adjust correctly.

Slewing power insufficient.

Pilot control pressure limiting valve faulty.

Consult your Dealer.

Slewing pump supply system defective.

Consult your Dealer.

Slewing high pressure system defective.

Consult your Dealer.

Slewing motor leaking excessive.

Consult your Dealer.

Display setting wrong.

Perform correct display setting.

Slewing pump adjustment incorrect.

Check and adjust correctly.

Air in the system.

Bleed the air.

Pilot control pressure limiting valve faulty.

Consult your Dealer.

Brake discs worn out.

Replace the brake plates.

Spontaneous slewing.

Upper structure brake not operational.

5-11

SECTION 5

FLOATING AXLE BLOCKING PROBLEM Floating-axle support not blocking.

Floating-axle not blocking.

Floating-axle blocking not stable.

Noises during floating of axle.

5-12

POSSIBLE CAUSE

CORRECTION

Floating-axle blocking valve faulty.

Consult your Dealer.

Pilot valve faulty.

Consult your Dealer.

Floating-axle blocking valve faulty.

Consult your Dealer.

Pilot valve faulty.

Consult your Dealer.

Switch in blocked position.

Check and remove switch from blocking position.

Floating-axle blocking valve faulty.

Consult your Dealer.

Blocking valve not vented.

Vent blocking valve.

Contact faces of blocking cylinder not Lubricate contact faces of cylinders. lubricated.

TROUBLESHOOTING

STABILIZERS PROBLEM Stabilizer not operational.

POSSIBLE CAUSE

CORRECTION

Pilot control lever not in working position.

Check and position lever correctly.

Pilot control lever defective.

Consult your Dealer.

Hydraulic oil level too low.

Top up hydraulic oil in correct quantity.

Pilot control pressure limiting valve faulty.

Consult your Dealer.

Pumps drive coupling defective.

Consult your Dealer.

Primary pressure limiting valve defective.

Consult your Dealer.

Pilot control valve operation defective.

Consult your Dealer.

Engine inner leaks.

Consult your Dealer.

Non-return valves of cylinders defective operation.

Consult your Dealer.

Stabilizer legs not operational. Pilot control lever not in working position.

Check and position lever correctly.

Pilot control lever defective.

Consult your Dealer.

Hydraulic oil level too low.

Top up hydraulic oil in correct quantity.

Pilot control pressure limiting valve faulty.

Consult your Dealer.

Pumps drive coupling defective.

Consult your Dealer.

Primary pressure limiting valve defective.

Consult your Dealer.

Pilot control valve operation defective.

Consult your Dealer.

Engine inner leaks.

Consult your Dealer.

Non-return valves of cylinders defective operation.

Consult your Dealer.

Storage pressure of brake system too Check and increase the braking low. pressure.

Selection of individual stabilizer leg cylinders not possible.

Non-return valves of cylinders defective operation.

Consult your Dealer.

Storage pressure of brake system too Check and increase the braking low. pressure.

Switch defective.

Replace the switch.

Cylinders switching valve defective.

Replace the valve.

5-13

SECTION 5 PROBLEM Cylinder extends without control.

Stabilizers cylinders retract without control.

Blade cylinders extend or retract without control.

The blade lays only one side.

Stabilizer legs lay only on one side.

5-14

POSSIBLE CAUSE

CORRECTION

Non-return valves of cylinders defective operation.

Consult your Dealer.

Cylinders internal leaks.

Consult your Dealer.

Non-return valves of cylinders defective operation.

Consult your Dealer.

Cylinders internal leaks.

Consult your Dealer.

Non-return valves of cylinders defective operation.

Consult your Dealer.

Cylinders internal leaks.

Consult your Dealer.

Non-return valves of cylinders defective operation.

Consult your Dealer.

Cylinders internal leaks.

Consult your Dealer.

Non-return valves of cylinders defective operation.

Consult your Dealer.

Cylinders internal leaks.

Consult your Dealer.

TROUBLESHOOTING

CLAMSHELL BUCKET PROBLEM Clamshell rotation not operational.

POSSIBLE CAUSE

CORRECTION

Clamshell rotation pump defective.

Consult your Dealer.

Hydraulic oil level too low.

Top up with hydraulic oil in correct quantity.

Malfunction of clamshell-rotation pressure-limiting valve.

Consult your Dealer.

Clamshell rotation valve defective.

Consult your Dealer.

Button on hydraulic control lever defective.

Consult your Dealer.

Clamshell rotation solenoid defective. Consult your Dealer.

Clamshell rotates very slowly.

Clamshell rotation motor defective.

Consult your Dealer.

Pinion and ring gear worn.

Replace pinion and ring gear.

Malfunction of clamshell-rotation pressure-limiting valve.

Consult your Dealer.

Clamshell rotation solenoid defective. Consult your Dealer.

At cylinders stroke end the clamshell does not rotate.

Clamshell rotation motor defective.

Consult your Dealer.

Malfunction of clamshell-rotation pressure-limiting valve.

Consult your Dealer.

Clamshell blades or limit stops worn out.

Replace.

5-15

SECTION 5

AXLES PROBLEM Ring gear teeth broken outside.

POSSIBLE CAUSE

CORRECTION

Excessive gear load compared to the Replace bevel gear. one foreseen.

Gear adjustment wrong (excessive backlash).

Follow carefully the recommended operations for the adjustment of bevel gear set backlash.

Pinion nut loose.

Tighten pinion nut.

Ring gear teeth broken inside. Load bump.

Replace bevel gear.

Gear adjustment wrong (insufficient backlash).

Follow carefully the recommended operations for the adjustment of bevel gear set backlash.

Pinion nut loose.

Tighten pinion nut.

Ring gear teeth or pinion teeth Insufficient lubrication. damaged or scored.

Contaminated oil.

Incorrect lubrication or depleted additives.

Use proper lubrication, fill up to right level and replace at recommended intervals.

Worn out pinion bearings that cause Replace bevel gear. an incorrect pinion axle backlash and wrong contact between pinion and ring.

Overheated ring and pinion teeth.

Prolonged functioning at high temperatures.

Replace bevel gear.

Incorrect lubrication.

Low oil level.

Contaminated oil.

Use proper lubrication, fill up to right level and replace at recommended intervals.

Excessive use.

Replace bevel gear.

Insufficient lubrication.

Use proper lubrication, fill up to right level and replace at recommended intervals.

Axle beam body bent.

Vehicle overloaded.

Damaged vehicle.

Load bump.

Replace axle beam body.

Bearings worn or pitted.

Insufficient lubrication.

Contaminated oil.

Use proper lubrication, fill up to right level and replace at recommended intervals.

Excessive use.

Replace bearings.

Pinion nut loose.

Tighten pinion nut.

Drive pinion teeth pitted.

5-16

TROUBLESHOOTING PROBLEM Oil leakage from gaskets and seals.

POSSIBLE CAUSE

CORRECTION

Prolonged functioning at high temperature of the oil.

Replace the gasket or seal and matching surface if damaged.

Oil gasket assembled incorrectly.

Replace.

Damaged or worn gasket lip.

Replace.

Contaminated oil.

Use correct lubricants and replace at recommended intervals.

Excessive wear of input flange Excessive use. spline.

Replace the flange.

Pinion nut loose.

Tighten pinion nut.

Excessive pinion axial backlash.

Check and adjust the backlash.

Pinion teeth cracked because of the fatigue.

Excessive use or continuous overload.

Replace bevel gear.

Break of pinion and ring gear teeth.

Crash load of differential components.

Check and/or replace other differential components.

Side gear spline worn out.

Excessive use.

Replace differential gear assy.

Replace axle beam, if necessary.

Thrust washer surface worn out or scratched.

Insufficient lubrication.

Incorrect lubrication.

Contaminated oil.

Use a correct lubricant, top up to correct level and replace washers.

Inner diameter of tapered roller Excessive use. bearings worn out.

Replace bearing.

Excessive pinion axial backlash.

Check pinion axial backlash.

Insufficient lubrication.

Contaminated oil.

Use proper lubrication, fill up to right level and replace at recommended intervals.

Bent or broken axle beam.

Vehicle intensively operated or overloaded.

Replace.

Axle beam broken at wheel side.

Wheel support loose.

Replace.

Axle beam body bent.

Ensure that wheel support is not worn out or wrongly adjusted.

5-17

SECTION 5

CENTRALIZED LUBRICATION PUMP If the tank pump operates correctly can be checked from outside, by checking the rotation of the mixing blade (for instance by opening the connection of an additional lubrication assy or by checking the lamps of the control board).

2

3

PROBLEM If the pump motor in the tank does not rotate.

POSSIBLE CAUSE

CORRECTION

Power supply cut out.

Check the electric power supply for the tank pump and, if necessary, clear the trouble.

Cut out of electric power supply for control board.

Check that the wire from tank pump connector is linked to the control board. If power supply is present, the left lamp is alight.

Cut out of electric power supply from Start additional lubrication. If power control board to starter motor. supply is present, the right lamp (3) remains alight during the working time.

Control board defective.

5-18

Replace control board. Before assembling the new board, you have to set the time-outs and working times as on the old board. Have these setting performed by the Aftersales service.

TROUBLESHOOTING PROBLEM The right lamp (3) blinks.

Different lubricant quantity on lubrication points.

POSSIBLE CAUSE

CORRECTION

One of the two selectors (1) and (2) is Set both selectors on position 3. positioned to 0.

Signals: 4-times flickering.

Short-circuit on button (4).

Signals: 3-times flickering.

Check if the short-circuit is occurred on the control board. Replace the board if necessary.

Wrong quantity.

Check the quantity according to lubrication diagram.

The relevant valve body has been assembled without locking ring.

Remove the valve and fit the locking ring.

Wrong setting of working and timeout times.

Check the times setting.

Excess or lack of lubrication on Wrong setting of working and timethe lubrication point. out times.

Check the setting of the working and time-out time on control units, control boards or controls.

System locking downhill.

Articulation points, pipes or distribution manifold clogged.

Detect and clear the locking cause as described hereunder:

The trouble can be determined from following signals:

Activate the tank pump.

On the main distribution manifold (B) - grease output from pressure relief detach one by one all high pressure valve; hoses (G) leading to the sub- the checking plugs, installed on the manifolds. If, for instance, grease manifold pistons (if installed), do comes out under pressure from output 1 of main distribution manifold not move.

(B), this means that the clogging has to be searched in the lubrication circuit of the sub-manifold (D).

Let the tank pump operate.

Detach one by one all high pressure hoses (E) of the sub-manifold (D). If, for instance, grease comes out under pressure from output 3 of subdistribution manifold (D), this means that the clogging has to be searched in the piping of connector 3 or in the articulation point connected to the same.

By means of a manual pump clear all clogged pipes of articulation points.

Distribution manifold clogged.

Replace the distribution manifold or have it cleaned by the After-sales service.

5-19

SECTION 5

HEATING/AIR CONDITIONING SYSTEM SYSTEM PROBLEM System very noisy.

POSSIBLE CAUSE

CORRECTION

Belt loose or worn.

Retension belt or replace.

Clutch noisy.

Repair clutch.

Compressor supporting bracket loose Repair bracket, replace compressor. or internal compressor parts worn out.

5-20

Blower motor excessively worn.

Replace the blower.

System overfilled.

Evacuate coolant until the high pressure reading is normal again.

Not enough coolant in the system.

Check for leaks, refill the system.

TROUBLESHOOTING COOLING SYSTEM PROBLEM Compressor not working.

POSSIBLE CAUSE

CORRECTION

Open circuit in compressor solenoid. Check power supply to the clutch.

Faulty thermostat.

Replace thermostat.

Belt loose or broken.

Adjust belt tension, replace belt.

Belt pulley not turning although magnetic clutch is engaged.

Check compressor and replace, if necessary.

Compressor clutch slipping.

Repair clutch or replace compressor.

Evaporator flooded.

Expansion valve jammed or stuck in open position.

Replace expansion valve (block).

Evaporator frozen.

Thermostat sensor in wrong position. Install sensor in another place.

Evaporator clogged up.

Dirty fins.

Clean evaporator.

Coolant leaking.

Refrigerant line defective.

Check all lines for defects caused by external influences or chafing.

Leaks in the system.

Evacuate the system, refill, check for leaks and repair.

Air filter (recirculation).

Panel filter clogged.

Clean or replace the panel.

Air filter (recirculation).

Filter element clogged.

Clean or replace the filter element.

Heating operating.

Tie rod for heating valve not set correctly or faulty.

Set the tie rod or replace it.

5-21

SECTION 5 BLOWER PROBLEM Blower not working.

POSSIBLE CAUSE Fuse blown or loose.

CORRECTION Check fuse contact, if necessary plug in correctly. Replace defective fuse.

Reappearance of the defect after a short time indicates a short-circuit.

Check blower for blocking or other faults. Eliminate the cause.

Connector loose.

Check that connector at machine side is firmly in place and correct, if necessary.

Check connection of blower switch.

Open the machine and check the electrical connections inside.

Connecting cable damaged or ripped Replace cable, observing correct off. cable run and connection.

Electrical connections interchanged.

Check connecting cables and reconnect properly, if necessary.

Defective blower switch.

Replace by new original spare switch.

Blower unit locked.

Eliminate the cause of the blockage, e.g. by removing foreign object from rotor. If necessary, install a new blower.

Defective blower motor.

Replace the blower.

Blower cannot be switched off. Defective blower switch.

Replace blower switch.

The blower operates at low performance.

Rated supply voltage incorrect.

Rated voltage of conditioner and of vehicle system must be identical.

Replace the blower.

Dirty clamps.

Clean connector contacts. Proceed with care to avoid short-circuits.

Heat exchanger heavily contaminated.

Clean carefully, to avoid causing damage that might result in consequential leaks.

Blower ducts obstructed.

Check for no obstructions on the ports or air outlets. Eliminate the cause.

5-22

SECTION 6 STORAGE MACHINE STORAGE

ENGINE STORAGE

If the machine is to be set out of operation for longer periods, the following measures are recommended:

If the engine is to remain idle for an extended period of time, it is necessary to take protective measures to prevent rusting. The preservative measures described here will protect the engine for up to 6 months.

Inspect the machine. Repair damaged or worn parts. Install new parts, if necessary.

Park the machine on a level and firm surface.

Lay the working attachment on the ground, retracting the hydraulic cylinders as much as possible.

If not, coat the exposed cylinder rods with grease.

Shift all control levers to position “0”.

Make sure that the cab is placed to its lowest position.

Clean the machine.

Lubricate all grease points.

Protect all pieces against rust and dirt with a grease coat.

Drain coolant. If the system is filled with antifreeze mixture, draining is not necessary.

Release alternator and fan belts.

Paint parts needing it to prevent rust formation.

Carry out preservation of the engine.

Remove the batteries and store them in a dry protected place after full charging.

If not removed, disconnect battery negative cable from the terminal (-).

The procedure will have to be reversed before the engine is recommissioned.

Anti-corrosion oils to specification: - MIL-L-21260B. - TL 9150-037/2.

- Nato Code C 640 / 642.

Anti-corrosion media for exterior protection only to specification: - Nato Code C 632.

Recommended cleaning agent to remove preservatives: - Petroleum benzine (hazardous materials class A3).

To store the engine, perform following operations: Clean the engine.

Clean engine with high-pressure equipment.

Run engine up to operating temperature, then switch off.

Drain engine oil and fill with anticorrosion oil.

Protect the machine against unauthorized starting:

Drain fuel from tank.

- pull out the ignition key from the block - close and lock the windows

Prepare fuel mixture from 90% diesel and 10% anticorrosion oil and fill up tank.

- lock the cab door

Run engine for approximately 10 minutes.

- lock and ensure all covers

Shut off the engine.

- cover all ports.

Race engine repeatedly by hand for cylinder and combustion chamber preservation.

Store the machine in a dry protected place. If the machine is parked outside, cover it with a tarpaulin arranged so to allow ventilation. If not, humidity harmful to the machine may result.

If the machine is to be stored for a prolonged period of time, operate some times the travel, swing and digging hydraulic operations at least once per month to guarantee proper lubrication.

Dismantle V-belts and store in packaged form.

Spray V-belt pulley grooves with anti-corrosion agent.

Close intake and exhaust ports.

6-1

SECTION 6 BATTERIES STORAGE For extended outage periods, remove battery/batteries and store them on dry, well ventilated premises at approximately 20 °C (68 °F).

Observe the following points: Clean battery.

Check acid density and battery fluid level once a fortnight.

RECOMMISSIONING THE MACHINE AFTER PROLONGED STORAGE Before recommissioning the machine after a prolonged storage, observe the following points: Remove engine preservation. Fill in new engine oil.

Install batteries and reconnect them to the electrical system. Check batteries charge, if necessary recharge them. Check electrolyte density.

Charge batteries when acid density has fallen to 1.23 kg/dm3 (85.71 lb/ft3) or earlier.

Check the hydraulic oil level in the tank.

Keep batteries clean and dry externally.

Degrease piston rods of hydraulic cylinders.

Check tyre pressure.

Check operation of the electrical system.

Check operation of braking and steering systems.

Check fuel level in the tank and top up if necessary.

Commission engine.

DANGER Do not run the engine in confined spaces without proper ventilation and/or a suitable system capable to remove harmful exhaust gases.

Bring machine into driving position and engage the parking brake.

Bleed air from the hydraulic system.

IMPORTANT: if the machine has not been used for a long time, oil layers on the sliding surfaces may have deteriorated.

Operate travel, swing and digging hydraulic systems 2 or 3 times to lubricate sliding surfaces.

6-2

STORAGE DECOMMISSIONING OF THE MACHINE

WARNING Dismantle the machine according to the general safety rules.

The machine dismantling must be carried out exclusively by trained personnel, qualified and authorised to perform such operation.

Start the hydraulic system components disassembly, only after such components, hydraulic oil and lubricants have completely cooled down and after releasing any residual pressure.

To decommission the machine, it is necessary to have access to specific equipment (hoist, hydraulic presses, containers for liquids, etc.) and special tools described in the Operator’s Manuals and Repair Manuals, available from Dealers.

This is in order to avoid that during disassembly operations dangerous situations arise both for the personnel involved and the environment.

The machine contains: - fluids under pressure (hydraulic system, cooling system, etc.); - gases (air conditioning system and accumulator, as applicable); - acid (batteries); - components of the machine with remarkable weight (booms, buckets, etc.).

IMPORTANT: handle and dispose of fluids according to current regulations. Use only authorised disposal procedure and, in case of doubt, contact the appropriate authorities.

6-3

SECTION 6 NOTES:

6-4

SECTION 7 ATTACHMENTS CLAMSHELL BUCKET SAFETY INSTRUCTIONS The hazard zone of the clamshell must be kept clear of all persons.

Never try to change the clamshell position or its support with your hands.

The bucket link when blocked should not be use to lift weights.

The safety pin could get bent or break.

Use the safety hook or the clamshell lifting eyes or remove the safety pin, until you have to move loads.

CLAMSHELL BUCKET ASSEMBLY

WARNING Before performing the assembly, check if the clamshell bucket and the machine are filled with the same hydraulic oil or with oil mixed.

Otherwise, drain oil from the hydraulic system of the clamshell bucket.

Disassemble the clamshell rotation.

Retract the bucket cylinder or assemble the safety pin for the bucket link (1).

NOTE: after installation of the safety pin, the bucket cylinder should not be extended, because this operation could damage the pin and also the bucket link.

1 Shut off the engine, turn the ignition key to position “I”.

Relieve the pressure from the hydraulic hoses of the clamshell.

Press to the left and hold the right hydraulic control lever (3).

Depress button “Clamshell turning” (4) and button (5).

Press to the right the right hydraulic control lever (3).

Release buttons (4) and (5) and right hydraulic control lever (3).

Turn ignition key to position “0” and disconnect the pilot control with lever (6).

2

7-1

SECTION 7 Set to horizontal position the marker grooves on the valves’ squares (7).

3 Clean and grease bearing pins and bushes.

Drive the machine towards the clamshell.

Insert dipper into grab bearing, push bearing pin (2) home and secure it.

4 Shut off engine and relieve hydraulic pressure from clamshell hoses as described.

Clean quick couplers on clamshell and dipper.

Connect hydraulic hoses to clamshell cylinder (8) and to clamshell rotation motor (9). Check that quick couplers are perfectly engaged.

Grease all nipples on clamshell and gearing of clamshell rotating mechanism.

Start the engine and lift the clamshell from the ground.

Bleed clamshell hydraulic system by opening and closing the clamshell repeatedly and by turning it clockwise and counter-clockwise.

7-2

5

ATTACHMENTS CLAMSHELL BUCKET DISASSEMBLY Open clamshell completely and set clamshell down on the ground.

Shut off the engine, turn the ignition key to position “I”.

Relieve the pressure from the hydraulic hoses of the clamshell.

Press to the left and hold the right hydraulic control lever (3).

Depress button “Clamshell turning” (4) to the right and button (5) to the left.

Press to the right the right hydraulic control lever (3).

Release buttons (4) and (5) and right hydraulic control lever (3).

6

Turn ignition key to position “0” and disconnect the pilot control (6).

Disconnect hydraulic hoses (8) and (9) and quick couplers.

Protect quick couplers of clamshell and dipper from dirt by applying the dust cups.

7 Unscrew safety device of bearing pin (2) and take out the pin.

Start the engine.

Lift working attachment carefully to release the clamshell.

8

7-3

SECTION 7 PARAMETERS SETTING ATTACHMENT CLAMSHELL BUCKET REDUCED LOAD CARRYING CAPACITY

CLAMSHELL BUCKET SPEED

CLAMSHELL BUCKET SPEED

OPENING:

OPENING:

CLOSING:

CLOSING:

Save changes?

F34185

9 The opening/closing speed reduction of clamshell is optional.

SWITCHING OVER FROM STANDARD TO CLAMSHELL BUCKET To switch over the working attachment from standard bucket to clamshell, two valves located on the bucket cylinder have to be switched.

The valves have to be switched only if the pressure has been released from the hydraulic system, otherwise, the seals may get damaged.

STANDARD BUCKET OPERATION Set to horizontal position the marker grooves on the valves’ squares (1).

10

7-4

ATTACHMENTS CLAMSHELL BUCKET OPERATION Set to vertical position the marker grooves on the valves’ squares (1).

11 SWITCHING OVER OF VOLUME FLOW FROM STANDARD BUCKET TO CLAMSHELL By means of switch (2) the machine can be switched over from backhoe operation with unlimited volume flow in the working pumps, to grab operation with presettable independent volume flow rates for opening and closing of the clamshell.

12 Standard bucket

Depress the blank face of the switch (2).

Clamshell bucket

Depress the symbol face of the switch (2).

The display shows the clamshell symbol (3).

The volume flow rates/speeds for opening and closing of the clamshell can be set via the display independently of one another.

13

7-5

SECTION 7

CRANING HOOK SAFETY INSTRUCTIONS The machine can be used to carry loads only if equipped and approved for this task.

The machine must be equipped with overload warning system and pipe break protection valves.

Before starting the work, activate the overload warning system.

During the lifting or transfer of a load, the personnel must stay or walk near the machine in such a way to be off the danger area.

The operator must keep visual contact with other persons in the working area.

Use only tested and efficient lifting gear with an adequate load capacity.

During transfer do not hang a load over a person but transfer the same by keeping it as close as possible to the ground to avoid its swinging.

The machine must never be driven with a slung load unless the road surface is even and the roadway is clearly visible. The visibility in the passage area can be improved, by shifting the boom and by turning the upper structure to the right. Once the upper structure is turned, block the floating axle.

If the craning hook is installed on the bucket link pay particular attention to following: the bucket link components must be connected with a safety pin, if an attachment other than the standard bucket is installed (e.g. the clamshell).

In this case the craning hook cannot be used to lift loads.

The pin is not designed for such situations, therefore it could bend or break abruptly. In this case the bucket link and the hanging load start suddenly to swing.

USE OF THE CRANING HOOK In order to use the hydraulic excavator for the craning operation, bucket links with welded craning hook are available (optional).

The maximum load carrying capacity of the craning hook is indicated on the hook.

7-6

ATTACHMENTS

OVERLOAD WARNING SYSTEM

WARNING The overload warning system sends exclusively acoustic and visual indication but thanks to them the machine overturning is avoided.

When the warning system sounds: - lower the load immediately; - reduce the working radius or the load.

Hydraulic excavators used for lifting operations or for transporting loads must be equipped with an overload warning system and pipe break protections in the lifting cylinders of the working equipment.

During these operations the overload warning system must be activated.

OVERLOAD!

When the admissible load moment is exceeded, the red warning lamp (1) lights up. The buzzer sounds at the same time. The display shows the “overload” symbol (2) and the OVERLOAD text (3).

The admissible load moment is exceeded if too heavy a load is to be lifted with the working radius of the equipment being too great.

14

SETTING THE OVERLOAD WARNING SYSTEM INTO OPERATION The overload working system can be used optionally in two different operation modes: Press button (1) once, the left lamp (2) lights up when the machine is used as a crane, without stabilizers.

Press button (1) twice, the right lamp (3) lights up when the machine is used as a crane, with stabilizers (stabilizers/blade).

Before using the machine for lifting operations, activate the overload warning system: With button (1) set the overload warning system to required operation mode.

The button lamp lights up.

15

Check that the overload warning system works correctly.

7-7

SECTION 7 MALFUNCTIONING OF THE OVERLOAD WARNING SYSTEM If a fault occurs in the overload warning system, lamps (2) and (3) on button (1) are both flashing.

In this case, too, the red warning lamp lights up and the “Overload” message is displayed on the screen.

IMPORTANT: have the overload warning system repaired immediately by our Service Department.

16 OVERLOAD WARNING SYSTEM CHECK The overload warning system has to be ckecked: - every day before beginning the work; - every time before using the machine for lifting.

Raise the boom to the highest position and move against block.

OVERLOAD!

Warning lamp (1) lights up and an acoustic warning is sounded. The display shows the “overload” symbol (2) and the relevant text (3).

If a fault occurs, have the overload warning system checked and repaired immediately by our Service Department.

OVERLOAD WARNING SYSTEM DEACTIVATION

17

If the machine has to be used exclusively for digging and not for craning, the overload warning system can be deactivated.

Depress repeatedly button (1) until lamps (2) and (3) turn off.

Now the overload warning system is deactivated.

18

7-8

ATTACHMENTS

“MOZELT” MAGNET SAFETY INSTRUCTIONS The presence of a lifting magnet on the machine is a special working system which implies an increase in safety risks. Other than when working with traditional clamshells, the magnet, when engaged, immediately attracts all accessible ferromagnetic materials. The quantity of this material is often higher than the quantity allowed by the carrying capacity of the machine.

For line system repair, only employ authorized technical personnel.

Similarly, when the magnet is disengaged due to a cable breaking or a short circuit, it immediately releases the held material. This behaviour can lead to dangerous situations well beyond the working area, if the material falling down, due to a levering effect, throws other objects far away. Furthermore, it cannot be excluded that, while slewing, scrap metal in the lower part of the collected material heap releases from the magnet.

Never slew the working equipment nor change the position of the machine with the magnet engaged without load.

The power rating of the machine must necessarily be coordinated with the power rating of the magnet.

The maximum carrying capacity of the machine must not be exceeded.

Never open the boxes of the connection terminals and the 230 V connectors on the generator and the lifting magnet with the machine engine running.

Never disengage the magnet from the system with the engine running.

Due to the levering effect, accidentally attracted materials may cause injuries to persons or the overturn of the machine.

Electric power cables must be efficiently protected.

Only use suitable electric power systems or accessories authorized by the magnet manufacturer. Continuously check that the high-strength chains holding the magnet do not show signs of wear or damage.

Contact with live parts can cause injuries and, in some cases, even death.

When releasing the load, the magnet may swing considerably! Therefore, it is strongly recommended to fix the magnet in a mechanically safe manner, by using the appropriate special coupler on the front boom of the machine!

In case of failure, such voltage may remain active even if the system has been disengaged.

It is forbidden to persons with pacemakers to stay in the area of operation of the magnet.

Connect only lifting magnets to the system. For different electric users, their use is not only dangerous, but absolutely forbidden.

The magnet reaches operating temperatures above 200 °C (392 °F).

After use, do not touch the magnet without appropriate protection devices.

The electric power supply system has an operating voltage of 230 V.

Before starting any operation on the 230 V line system, it is necessary to stop the engine of the machine.

In case of trouble, immediately stop working. If you are not able to recognize and solve the trouble of the system components, immediately contact the After-sales Service.

7-9

SECTION 7 SYSTEM The most important parts of the magnet are: 1. Generator 2. Multi-function display 3. Activation buttons 4. Switch line 5. Control line 6. Magnet line (230 V) 7. Connection box with 7 terminals 8. Magnet connection line 9. Magnet for load lifting with Ø 900 mm (35.43 in) - Ø 1500 mm (59.05 in) 19 The electric power supply systems have a rated power of 13.0 kW with output voltage adjustment of 220 V DC. The relative operation time of the system is 100%. In this way, a 24 h continuous operation is made possible.

The systems are designed for self-propelled machines, in particular for handling ferromagnetic materials such as heavy scrap metal, ingots, raw iron, scrap cast iron and scrap cuts, as well as swarf and dross. The electric power of the magnets connected to the system must not exceed 10% of the rated power of the systems. All types of load-lifting magnets may be connected to the system.

The generator is actuated by a hydraulic motor. The assy is located on a common frame, mounted with welded sections on the right side of the machine, above the tank.

20

7-10

ATTACHMENTS The generator needs a constant operating speed of 3000 rpm. Its operating speed range is about ± 10% of this, and therefore between 2700 rpm and 3300 rpm. In case of actuation through hydraulic motors, when disengaging the magnet, speed peaks up to 4000 g/min are allowed, provided that they do not exceed a duration of 0.5 seconds. In case of speeds above 3400 rpm and below 2700 rpm, magnet operation is totally or partially impossible.

Operating and connection conditions are shown on a multi-function display located in the cab. The function display is fitted in a holder next to the machine’s multi-function display. This display shows following indications: - ready for operation (a); - magnet ON (b); - magnet OFF (c); - 220 V line interrupted (d); - generator revolution problem (e); - relative operation time between 50% and 100% (f).

21

WARNING Any intervention inside the magnet system, both during and after the warranty period, is strictly forbidden. If any such intervention is performed, it automatically leads to a malfunction or break of the system. In such cases, any right to free-of-charge replacement during the warranty period is immediately lost, and also the possibility of having the generator replaced with a generating set within an exchange program, which is cheaper.

7-11

SECTION 7 OPERATION

WARNING When working with magnets for load lifting, all prescriptions and regulations regarding occupational safety and accident prevention must be strictly complied with. Furthermore, magnets for load lifting must be used only by operators perfectly familiar with the relevant instructions and safety regulations.

Before turning on power supply, the operator must check that the system of the 230 V line is in a visually perfect state. The operator must check that all connectors and fixed connections are correctly fastened and that the voltage limiting device of the magnet connection line operates as prescribed.

The magnet system is engaged by means of switch (1).

22 Once the system has been engaged, the system sets power level 4.

If a higher power level had been previously set, it remains unchanged. When all system components are ready for operation, the display of the machine shows the symbol of the magnet system (3). Furthermore, on the magnet display, located in the cab, the yellow “Ready for operation” lamp lights up (a).

The generator moves now to its working rpm range.

This lamp stays on during operation and turns off only if a malfunction is signalled.

Engagement and disengagement of electric power supply, i.e. of the magnet for load lifting, is performed through the button (2) on the right hydraulic control lever.

When the engagement control is activated, the generator conveys the voltage to the magnet without contact. When the disengagement control is activated, the generator automatically starts demagnetization. During the demagnetization stage, which enables the magnet to disengage the load (about 1.5 seconds), no new engagement control may be activated. After 10 minutes of magnet operation, the system multi-function display also shows, time after time, the operation time reached by the magnet.

7-12

23

ATTACHMENTS MAGNET ENGAGEMENT Press the button (2) on the left hydraulic control lever only once. Further to the yellow “Ready for operation” lamp, a green “Magnet ON” lamp lights up on the system multi-function display.

MAGNET DISENGAGEMENT Press the button (2) on the left hydraulic control lever only once. The green “Magnet ON” lamp now turns off and a red “Magnet OFF” lamp lights up.

Once the load has been released, the lamp turns off. The yellow “Ready for operation” lamp, which remained on during the whole process, signals that it is possible to start a new engaging phase.

Problems are signalled by red lamps, which remain constantly on.

24

CORRECT OPERATION Lay the first magnet onto the material and engage it.

Once disengaged, move the magnet by slewing it backwards.

DISPLAY The operation availability of the generator is enabled only when it reaches its working rpm range.

With hydraulic actuation, this occurs automatically, when the rpm of the hydraulic motor reaches a minimum of 2700 and a maximum of 3400 rpm. The consequently available engagement control is activated, when the 230 V line system between the generator and the load-lifting magnet closes and does not have problems.

Operating and connection conditions are shown on a multi-function display located in the cab. The function display is fitted in a holder next to the machine’s multi-function display. This display shows following indications: - ready for operation (a); - magnet ON (b); - magnet OFF (c); - 220 V line interrupted (d); - generator revolution problem (e); - relative operation time between 50% and 100% (f).

25

7-13

SECTION 7 TROUBLE DISPLAY The generator moves in its working rpm range.

- (a) yellow lamp: system ready for operation.

26 After activating the engagement control through the button on the left hydraulic control lever: - (a) yellow lamp: system ready for operation.

- (b) green lamp: magnet ON; - (f) green lamp: relative working time 70%.

27 After activating the engagement control through the button on the left hydraulic control lever: - (a) yellow lamp: system ready for operation; - (b) green lamp: magnet ON; - (e) red lamp: revolution trouble; - malfunction: the generator moves below its working rpm range. The normal operation of the magnet is only partially possible (minimum power); - action: bring the machine engine to its maximum rpm (increase power level), adjust the rpm of the hydraulic motor.

28 After activating the engagement control through the button on the left hydraulic control lever: - (a) yellow lamp: all lamps off; - malfunction: broken cable on switch line, defective button; - action: replace switch line or check/replace the button.

29

7-14

ATTACHMENTS After activating the engagement control through the button on the left hydraulic control lever: - (a) red lamp: 230 V line interrupted; - malfunction: line interruption on 230 V circuit.

No load. Defective magnet. Connector not ok; - action: stop the machine engine, remove line interruption, have the magnet checked, check connection and connector conditions.

30 After activating the engagement control through the button on the left hydraulic control lever: - (a, b, c, d, e) lamps: all lamps flash intermittently; - malfunction: short circuit in the 230 V line system.

Total earth leakage of magnet; - action: stop the machine motor, remove the short circuit and replace the line, check the line and the connection, replace the magnet.

31 The generator moves in its working rpm range: - indicator: no lamp on; - malfunction: broken cable/control line interruption; - action: replace control line.

32

7-15

SECTION 7

BREAK PROTECTION VALVES The break protection valves prevent the working attachment from lowering in case of a hydraulic hose breaking on the head side of the boom cylinders.

The hydraulic connection of boom cylinder head is cut out, so that hydraulic oil can flow back from this point only if the “boom lowering” control is activated.

Also the upper and dipper cylinders can be equipped with pipe break protection valves.

If an hydraulic pipe breaks: Set hydraulic control lever for “Boom lowering”, or the pedal for “Boom lowering” to idle position.

Alert people nearby with the horn.

The working attachment area with lifted load has to be ensured so as nobody can stay under the working attachment or under the load or in proximity of the hydraulic hose broken.

When the working attachment and the load are lowered to the ground, oil comes out from the broken spot of the pipe.

Place the working equipment and the load carefully on the ground.

Replace the broken hydraulic hose.

Only after replacement, resume the work.

Escaping hydraulic oil and possible rags have to be discarded without polluting the environment.

7-16

ATTACHMENTS

REAR FLOODLAMPS The rear working floodlamps (1) are positioned on the rear side of cab, under the roof.

33 SWITCHING THE FLOODLAMPS ON AND OFF The rear floodlamps can only be switched on, if the ignition key is set to position “I” (ignition ON).

Switch on the working floodlamps by depressing face without symbol of button (2), the lamp inside the button lights up.

Switch off the working floodlamps by depressing face with symbol of button (2), the lamp inside the button lights off.

34

7-17

SECTION 7

ROTARY LIGHT SINGLE LIGHT Rotary lights are fitted on a mounting stud and secured with a retaining screw. The electrical connection is incorporated in the stud. In this way a connecting cable is not required.

DOUBLE LIGHT In some countries, two rotary lights are mandatory.

1st rotary light: installed as described for the single light.

2nd rotary light: this second rotary light is attached by means of a magnetic base (electrical connection via coupling) or it is installed as the 1st light.

SWITCHING ON AND OFF SWITCHING ON THE ROTARY LIGHT/LIGHTS Connect switch (1).

Depress switch face without symbol, the lamp goes out.

WARNING The rear floodlamps can only be switched on, if the ignition key is set to position “I” (ignition ON).

SWITCHING OFF THE ROTARY LIGHT/LIGHTS Disconnect switch (1).

Depress switch face with symbol, the lamp goes out.

35

7-18

ATTACHMENTS

FUEL TRANSFER PUMP

DANGER Fuel and its steams are easy flammable and can generate explosions. For this reason refuel by keeping far from open flames, cigarettes, alight matches, particularly hot areas and sparkles generating areas.

DANGER Fuels can be harmful for health. They must not be swallowed. Avoid long contact with the skin.

If the machine is refuelled often or regularly with fuel from cans or barrels, there is an increased risk of foreign matter and water getting into the fuel system.

In this case:

36

- always refuel through a fine mesh filter; - user only intake hoses with a fine mesh filter; - drain off water from the fuel filter more often than specified in the maintenance schedule.

NOTE: refuel only with decanted fuel. We suggest to refuel at the end of each working day, condensation will so be avoided during overnight down-time.

Do not let the tank run out of fuel because air could penetrate inside of the supply circuit and would require the air bleeding.

By means of the refuelling system, fuel can be pumped from a large spare container into the machine tank.

The refuelling system is installed on the left side of the machine, close to the fuel tank.

The refuelling system consists of: the intake hose, the electric pump and the tank filling hose.

The intake tube is winded and stored in the tools compartment. The filling hose (5) remains connected to the pump and fuel tank.

WARNING Before refuelling, the tank cap must be opened to avoid overpressure in the tank and risks of dangerous fuel leaks.

7-19

SECTION 7 Open the tank cover.

Protect the tank filler from penetration of dirt.

Disassemble cover (1) of maintenance opening, placed under the refuelling system.

Connect intake hose (2) to large spare container.

Turn the ignition key to position “I”.

Activate the pump with green button (3) on the same pump.

37 The pump deactivates by means of red button (4) on the same pump.

The pump disconnects automatically when the fuel tank is full.

If the pump runs dry for a long time, it could get damaged or broken.

For this reason insert the pump only when you need to refuel.

38

CAB PROTECTIONS When you work in areas where there is the danger of rocks or debris falling the use of following cab protections is unavoidable.

- (1) FOPS (Falling Object Protective Structure), tubular structure to install over the cab roof.

- (2) FGPS (Front Guard Protective System), tubular structure to install on the front side of the cab.

NOTE: usually the FOPS protection (1) can be supplied either alone or coupled with the FGPS protection (2).

39

7-20

ATTACHMENTS

CENTRALIZED LUBRICATION SAFETY INSTRUCTIONS Place the machine in a safe condition.

The centralized lubrication system, connected to the pump tank is secured through the pressure limiting valve (1). The whole system can be checked visually on the pressure limiting valve. If during the flow rate the pressure limiting valve is releasing fuel, the system is somewhere clogged.

Danger of injuries caused by the escape of fuel under high pressure.

An improper treatment can cause damages due to the lack or excess of lubrication on bearings and articulation points.

Modifications or application of the system have to be carried out only after agreement and Manufacturer approval.

40

OPERATION OPERATION VISUAL CHECK The distribution manifolds can be equipped with checking plug (1). The checking plug is connected to a little piston inside of the distribution manifold and during the delivery phase it moves fore and back. If the system gets clogged, the checking plug remains stuck.

41

7-21

SECTION 7 LUBRICANTS The tank pump can operate with standard grease types available on the market up to class NLGI 2.

Class NLGI indicates exclusively the static density of grease, but not the dynamic behaviour of grease while pumped. The characteristics of fluidity of grease of same class NLGI may differ remarkably between them.

WARNING The Manufacturer is not liable for damages to the centralized lubrication system, caused by chemical or biological alterations of the lubricant used, or by grease not allowed or to be used only in a limited way.

During the handling of grease care for maximum cleanliness. The dirt inside of grease remains suspended and cannot settle. This creates problems to the system and as a consequence also damages to the articulation points.

Lubricants with solid residuals higher than 3% cannot be used for the centralized lubrication system.

TANK PUMP The tank pump (1) is secured behind the cab and is accessible through the left side door. The lubrication processes are handled according to the machine service hours. When the ignition key is set to “I”, the centralized lubrication system activates and lamp (2) lights up.

A lubrication cycle consists of a down-time and a work time. The lubrication system is repeated continuously after machine start. During the working time, the tank pump delivers lubricant to the different points to be lubricated, flowing through the distribution manifolds.

42 The down-time defines the frequency of the lubrication periods inside of the operation time. The working time defines the quantity of lubricant delivered. A longer working time means an higher quantity of lubricant, a shorter working time means a lower quantity of lubricant. When the machine is shut off, the down-times and working times already passed are summarized and memorized on an unlimited time. When the ignition cylinder is activated again, the control restarts from the point of disconnection.

43

7-22

ATTACHMENTS TIMES SETTING To check the down-time and the working time, remove cover (1) from the case of the tank pump.

The down-time can be set by means of blue selector (3), while the working time can be set by means of red selector (2). Each one of them must be set on 15 different levels.

IMPORTANT: in the work is set a down-time of 3 hours [position 3 of selector (3)] and a working time of 6 minutes [position 3 of selector (2)]. The downtimes and working times can be modified and reset from the After-sales service or by an authorized workshop.

44 After resetting and checking the down-time and working time, replace and tighten the closing cover (1).

45

OPERATION TEST Turn the ignition key to position “I”.

As soon as the control board of the tank pump receives voltage, lamp (3) lights up.

Hold button (4) of control board depressed, so that lamp (2) remains alight over 2 seconds.

During this operation the down-time shortens. Now a normal lubrication process takes place.

At any time additional lubrications can be performed. The grease coming out from the lubrication points has to be collected and discarded according to environmental legislation.

46

7-23

SECTION 7 FILLING OF THE TANK PUMP The filling of the tank pump is performed through fittings (1) or (2).

47

MANUAL FILLING PUMP ASSEMBLY Remove both cartridge caps (1).

Prior to the assembly of the manual filling pump, pay attention to insert also the gasket (2).

By means of the plunger, fill grease into the tank pump through the fitting. Repeat this operation until grease reaches the maximum level. If an overfilling takes place, grease comes out from the overflow opening.

After the filling of the tank pump, replace the cap (5) and the cover (4).

48 REUSE OF THE MANUAL PUMP It is possible to fill the manual pump by taking the grease from a barrel. Pay attention not to twist the lip of the seal pack (6).

49

7-24

ATTACHMENTS MOTORIZED FILLING PUMP Fill grease into the tank pump through the fitting (1) or (2) and by means of the filling hose. Repeat this operation until grease reaches the maximum level. If an overfilling takes place, grease comes out from the overflow opening.

50 After the filling of the tank pump, replace the cap (5) and the cover (4).

51

52

7-25

SECTION 7 NOTES:

7-26

SECTION 8 DATA AND TECHNICAL SPECIFICATIONS DIMENSIONS - OPERATING WEIGHTS WX 210 Industry MODELS

1

2 mm (in) Dipper

A

B

C

D

E

F

G

H

I

L

L1

M

M1

N

O

P

3800 (149.60)

2185 10110 3130 3200 2750 2750 2500 (86.02) (398.03) (123.23) (125.98) (108.26) (108.26) (98.42)

1235 (48.62)

307 (12.08)

2500 2750 4145 4355 2300 (98.42) (108.26) (163.18) (171.46) (90.55)

1138 (44.80)

1018 (40.07)

5200 (204.72)

3200 10040 3130 3200 2750 2750 2500 (125.98) (395.27) (123.23) (125.98) (108.26) (108.26) (98.42)

1235 (48.62)

307 (12.08)

2500 2750 4145 4355 2300 (98.42) (108.26) (163.18) (171.46) (90.55)

1138 (44.80)

1018 (40.07)

L-M = dimensions with standard undercarriage L1-M1= dimensions with wide undercarriage

8-1

SECTION 8 WX 240 Industry MODELS

1

2 mm (in) Dipper

A

3800 (149.60)

2185 (86.02)

5200 (204.72)

8-2

B

C

D

E

F

G

H

I

10110 3130 3200 2750 2750 (398.03) (123.23) (125.98) (108.26) (108.26)

2500 (98.42)

1235 (48.62)

307 (12.08)

3200 10040 3130 3200 2750 2750 (125.98) (395.27) (123.23) (125.98) (108.26) (108.26)

2500 (98.42)

1235 (48.62)

307 (12.08)

L

M

N

O

P

2750 4360 (108.26) (171.65)

2300 (90.55)

1138 (44.80)

1018 (40.07)

2750 4360 (108.26) (171.65)

2300 (90.55)

1138 (44.80)

1018 (40.07)

DATA AND TECHNICAL SPECIFICATIONS

DIGGING PERFORMANCE WX 210 Industry MODELS

3

Dipper

mm

in

5200

204.72

3800

149.60

A Maximum loading height

mm

in

10600

417.32

9400

370.07

C Maximum depth

mm

in

6700

263.78

5300

208.66

F Maximum outreach

mm

in

11800

464.56

10500

413.38

H Front swing radius

mm

in

2800

110.24

2100

82.67

K Minimum loading height

mm

in

1500

59.05

2700

106.30

8-3

SECTION 8 WX 240 Industry MODELS

4

Dipper

mm

in

5200

204.72

3800

149.60

A Maximum loading height

mm

in

10600

417.32

9400

370.07

C Maximum depth

mm

in

6700

263.78

5300

208.66

F Maximum outreach

mm

in

11800

464.56

10500

413.38

H Front swing radius

mm

in

2800

110.24

2100

82.67

K Minimum loading height

mm

in

1500

59.05

2700

106.30

8-4

DATA AND TECHNICAL SPECIFICATIONS

LIFTING CAPACITIES WX 210 Industry MODELS

5

9.0 9.0 9.0 9.0 4.5 6.0 7.5 9.0 4.5 6.0 7.5 4.5 6.0 7.5 4.5 6.0 7.5 4.5 6.0 7.5 (14.76) (19.68) (24.61) (29.53) (14.76) (19.68) (24.61) (29.53) (14.76) (19.68) (24.61) (29.53) (14.76) (19.68) (24.61) (29.53) (14.76) (19.68) (24.61) (29.53)

A (m) (ft) Z2

5.8 3.8 2.8 (19.03) (12.47) (9.19)

LD = 3.8 m 4.6 3.1 2.3 Z1 (12.47 ft) (15.09) (10.17) (7.55) Z3

3.1 2.3 (10.17) (7.55)

Z2

5.7 4.1 2.9 (18.70) (13.45) (9.51)

2.1 6.2 4.8 3.5 2.6 6.2 6.0 4.6 3.5 6.2 6.0 4.8 4.5 5.2 3.4 2.5 (6.89) (20.34) (15.74) (11.48) (8.53) (20.34) (19.68) (15.09) (11.48) (20.34) (19.68) (15.74) (14.76) (17.06) (11.15) (8.20)

1.8 (5.90)

1.8 6.1 4.1 3.0 (5.90) (20.01) (13.45) (9.84)

2.4 7.1 5.1 4.1 3.0 7.1 5.1 4.2 3.0 4.0 2.7 (7.87) (23.29) (16.73) (13.45) (9.84) (23.29) (16.73) (13.78) (9.84) (13.12) (8.85)

2.0 (6.56)

1.6 (5.25)

1.9 (6.23)

2.4 (7.87)

2.0 (6.56)

1.6 (5.25)

2.1 5.7 5.1 3.6 2.7 5.7 5.4 4.7 3.6 5.7 5.4 4.8 3.8 5.7 3.7 2.6 (6.89) (18.70) (16.73) (11.81) (8.85) (18.70) (17.72) (15.42) (11.81) (18.70) (17.72) (15.74) (12.47) (18.70) (12.14) (8.53)

1.9 (6.23)

4.1 3.0 (13.45) (9.84)

5.1 4.1 3.0 (16.73) (13.45) (9.84)

5.1 4.2 3.0 (16.73) (13.78) (9.84)

2.7 (8.85)

LD = 5.2 m 4.4 3.0 Z1 (17.06 ft) (14.44) (9.84)

2.2 (7.22)

1.7 5.9 3.9 2.9 (5.57) (13.36) (12.79) (9.51)

2.3 8.0 5.5 4.0 3.1 8.0 6.7 5.2 4.0 3.8 2.6 (7.55) (26.24) (18.04) (13.12) (10.17) (26.24) (21.98) (17.06) (13.12) (12.47) (8.53)

1.9 (6.23)

1.5 (4.92)

4.4 2.9 (14.44) (9.51)

2.2 (7.22)

1.7 5.9 3.9 2.9 (5.57) (13.36) (12.79) (9.51)

2.3 6.5 4.1 3.3 3.1 6.5 4.1 3.3 3.3 3.8 2.5 (7.55) (21.32) (13.45) (10.83) (10.17) (21.32) (13.45) (10.83) (10.83) (12.47) (8.20)

1.9 (6.23)

1.5 (4.92)

Z3

8-5

SECTION 8 WX 240 Industry MODELS

6

9.0 9.0 9.0 9.0 4.5 6.0 7.5 9.0 4.5 6.0 7.5 4.5 6.0 7.5 4.5 6.0 7.5 4.5 6.0 7.5 (14.76) (19.68) (24.61) (29.53) (14.76) (19.68) (24.61) (29.53) (14.76) (19.68) (24.61) (29.53) (14.76) (19.68) (24.61) (29.53) (14.76) (19.68) (24.61) (29.53)

A (m) (ft) Z2

7.3 4.8 3.4 2.6 7.3 5.9 4.2 3.2 7.3 7.1 5.5 4.2 7.3 7.1 5.6 5.3 6.5 4.3 3.1 2.3 (23.95) (15.74) (11.15) (8.53) (23.95) (19.35) (13.78) (10.50) (23.95) (23.29) (18.04) (13.78) (23.95) (23.29) (18.37) (17.39) (21.32) (14.11) (10.17) (7.55)

LD = 3.8 m 5.8 3.9 2.9 Z1 (12.47 ft) (19.03) (12.79) (9.51) Z3 Z2

3.9 2.9 (12.79) (9.51)

2.3 7.6 5.0 3.7 2.9 8.4 6.0 4.9 3.5 8.4 6.0 4.9 3.5 5.2 3.5 2.6 (7.55) (24.93) (16.40) (12.14) (9.51) (27.56) (19.68) (16.07) (11.48) (27.56) (19.68) (16.07) (11.48) (17.06) (11.48) (8.53)

2.1 (6.89)

2.3 (7.55)

2.1 (6.89)

5.0 3.7 3.0 (16.40) (12.14) (9.84)

6.0 4.9 3.5 (19.68) (16.07) (11.48)

6.0 4.9 3.5 (19.68) (16.07) (11.48)

3.5 2.6 (11.48) (8.53)

6.7 5.1 3.6 2.7 6.7 6.3 4.4 3.3 6.7 6.4 5.7 4.3 6.7 6.4 5.7 4.5 6.7 4.7 3.3 2.4 (21.98) (16.73) (11.81) (8.85) (21.98) (20.67) (14.43) (10.83) (21.98) (20.99) (18.70) (14.11) (21.98) (20.99) (18.70) (14.76) (21.98) (15.42) (10.83) (7.87)

LD = 5.2 m 5.6 3.8 2.8 Z1 (17.06 ft) (18.37) (12.47) (9.19)

2.2 7.4 4.9 3.6 2.9 9.8 6.6 4.9 3.8 9.8 7.8 6.2 4.8 5.0 3.4 2.5 (7.22) (24.28) (16.07) (11.81) (9.51) (32.15) (21.65) (16.07) (12.47) (32.15) (25.59) (20.34) (15.74) (16.40) (11.15) (8.20)

2.0 (6.56)

5.6 3.8 2.8 (18.37) (12.47) (9.19)

2.2 7.4 4.8 3.6 2.8 7.7 4.8 3.9 3.8 7.7 4.8 3.9 3.9 5.0 3.3 2.5 (7.22) (24.28) (15.74) (11.81) (9.19) (25.26) (15.74) (12.79) (12.47) (25.26) (15.74) (12.79) (12.79) (16.40) (10.83) (8.20)

2.0 (6.56)

Z3

8-6

DATA AND TECHNICAL SPECIFICATIONS

HYDRAULIC SYSTEM PUMPS The hydraulic system is controlled by 3 pumps, 2 main ones and an independent one for slewing. The engine and the pumps are monitored by the “Power Limit Control” system.

Up to 7 power levels can be selected for digging and lifting, included the levelling mode for fine works. The power level can be increased automatically with “Drive” mode.

Main pumps ........................................................................... No. 3 at variable displacement, at axial pistons.

WX 210 Industry

WX 240 Industry

l/min (gal/min)

2 x 200 + 112 (2 x 52.70 + 29.50)

2 x 215 + 130

Attachment / travel

bar (psi)

340 / 345 (4929 / 5002)

Power Boost

bar (psi)

370 (5364)

Slewing pump

bar (psi)

390 (5654)

Pilot pump

bar (psi)

45 (652)

Maximum displacement

CYLINDERS (ø for stroke) WX 210 Industry

WX 240 Industry

Monoboom lifting cylinder

mm (in)

135 x 985 (5.31 x 38.78)

145 x 985 (5.71 x 38.78)

Handling boom cylinder

mm (in)

115 x 1130 (4.53 x 44.49)

125 x 1130 (4.92 x 44.49)

SLEWING The slewing function is actuated by a closed hydraulic circuit, driving a mechanical gearbox with built-in automatic static brake, with 3 possibilities of calibration.

WX 210 Industry Slewing speed Slewing moment (SAE J1371)

rpm kNm (lbs·ft)

WX 240 Industry 9.5

60 (43397)

70 (50630)

WX 210 Industry

WX 240 Industry

TRAVEL Transmission with clutch pack.

Maximum travel speed at job site

km/h (mph)

8 (4.97)

Maximum travel speed on the road

km/h (mph)

20 (12.43)

kN (lbf)

130 (29225.2)

Maximum drawbar pull (field)

8-7

SECTION 8 TYRES Tyre

Twin

Single

Manufacturer

Type

Pressure (bar) V (max) (psi) [km/h] (mph)

Mitas

10.00-20 16 PR

7.50 (109)

30 (18.64)

Mitas

11.00-20 16 PR

7.00 (102)

30 (18.64)

Bridgestone

10.00-20 16 PR

7.50 (109)

30 (18.64)

Bridgestone

11.00-20 16 PR

7.00 (102)

30 (18.64)

Michelin

18R 22.5 XT

7.80 (113)

30 (18.64)

Mitas

600/40 - 22.5 TR12

6.00 (87)

30 (18.64)

BRAKES SERVICE BRAKE Wet, actives on all wheels.

PARKING BRAKE Mechanical brake at springs actuation, active on transmission.

STEERING WX 210 Industry Turning circle diameter (with twin tyres 10.00.20)

m (ft)

WX 240 Industry

16.3 (53.48)

POWER STEERING WX 210 Industry - WX 240 Industry Model

OSPQ80/200 LS cm3/rev (in3)

80 / 200 (4.88)

Maximum steering pressure

bar (psi)

190 / 195 (2755 / 2827)

Shock valve adjusting

bar (psi)

240 / 260 (3480 / 3769)

Displacement

8-8

DATA AND TECHNICAL SPECIFICATIONS

ELECTRICAL SYSTEM Service voltage ........................................................................................................................................... 24 V Batteries................................................................................................................................................ 2 x 12 V Batteries rating........................................................................................................................................ 100 Ah Alternator .................................................................................................................................................... 70 A Starter motor ......................................................................................................................... 4 kW (2963 ft·lb/s)

TIGHTENING TORQUES WX 210 Industry

WX 240 Industry

Wheels nuts

M22

Nm (lbf·ft)

450 (331.90)

Slewing bearing

M16

Nm (lbf·ft)

560 (413.03)

M12

Nm (lbf·ft)

104 (76.71)

M16

Nm (lbf·ft)

250 (184.39)

M20

Nm (lbf·ft)

490 (361.40)

Slewing gearbox

M16

Nm (lbf·ft)

250 (184.39)

Counterweight

M30

Nm (lbf·ft)

2250 (1659)

Axles

M20

Nm (lbf·ft)

520 (383.53)

Engine supports

CENTRALIZED LUBRICATION PUMP (OPTIONAL) Service temperature..................................................................................... - 40 °C at 70 °C (-40 °F at 158 °F) Allowable service pressure ................................................................................................... 350 bar (5074 psi) Flow rate: ....................................................................................................................................... 2 l (0.50 gal) Service voltage ........................................................................................................................................... 24 V Maximum current consumption..................................................................................................................... 3 A Revolutions ........................................................................................................................................ at 17 rpm Delivery ...........................................................................................................................2.8 cm3/min. (0.17 in3) Set working time ........................................................................................................................................6 min Down-time set ............................................................................................................................................... 3 h

FUEL SYSTEM WX 210 Industry System capacity / tank

litres (gal)

WX 240 Industry

325 (85.60)

8-9

SECTION 8

ENGINE WX 210 Industry Type

WX 240 Industry

F4GE9684G*J601

Operation

4-stroke diesel

Cylinders number

6

Cylinders arrangement

in V-line

Valves per cylinders

2

Boring

mm (in)

104 (4.09)

Stroke

mm (in)

132 (5.20)

Displacement

dm3

Power Maximum torque

3

(in )

5.9 (360.04)

kW (ft·lb/s)

129 (95556)

Nm - rpm (lbf·ft)

690 at 1400 (508.92)

Rated rpm

rpm

2025

Maximum rpm

rpm

2161

Minimum rpm

rpm

800

Pump

rotary

Alternator - voltage

V

24

- current

A

70

- power

kW (ft·lb/s)

4 (2963)

- voltage

V

24

kg (lb)

506 (1113)

Starter motor

Weight

8-10

SEZIONE 9 ALPHABETICAL INDEX Symbols “MOZELT” Magnet .............................................7-9 A Air conditioning ............................. 2-45, 4-43, 5-20 Air filter - Change ............................................. 4-53 Air filter - Cleaning ...........................................4-26 Air filter cleaning ..............................................4-26 Air filter safety element change ........................4-53 Auto Idle ...........................................................3-29 Auxiliary socket ................................................ 2-40 Axle floating locking cylinders - Air bleeding ....4-79 Axle floating locking cylinders air bleeding ...... 4-79 Axles ................................................................ 5-16 Axles floating pins - Greasing .......................... 4-36 Axles floating pins greasing ............................. 4-36 B Basic position ................................................... 3-16 Batteries - Charge check ................................. 4-33 Batteries - Level ...............................................4-33 Batteries - Replacement ..................................4-87 Batteries Level ................................................. 4-33 Battery .............................................................. 3-48 Biodegradable hydraulic oil ................................4-4 Blade ................................................................ 3-45 Blade and stabilizers joints ..............................4-44 Blade and stabilizers joints greasing ................ 4-44 Blower .....................................................4-60, 5-22 Blower cleaning ................................................ 4-62 Brakes system ...................................................5-7 Bucket .............................................................. 3-57 Bulbs - Replacement ........................................4-83 Buzzer ................................................................2-7 C Cab ..................................................................2-33 Cab air filter - Change ...................................... 4-51 Cab air filter - Cleaning .................................... 4-25 Cab air filter change ......................................... 4-51 Cab air filter cleaning ....................................... 4-25 Cab at variable height .............................1-12, 3-13 Cab lighting ...................................................... 2-39 Cab protections ................................................ 7-20 Cab raising ....................................................... 4-26

C Cab windows .................................................... 2-35 Cardan shaft .................................................... 4-44 Cardan shaft greasing ......................................4-44 CE-Mark ........................................................... 1-28 Centralized lubrication .....................................7-21 Clamshell assembly ........................................... 7-1 Clamshell bucket ............................. 3-57, 5-15, 7-1 Clamshell bucket disassembly ........................... 7-3 Clamshell wear ................................................ 4-88 Code .................................................................. 3-4 Components identification plates .....................1-27 Compressor belt - Change ...............................4-60 Compressor belt change ..................................4-60 Condenser - Cleaning ......................................4-60 Condenser cleaning .........................................4-62 Controls and instruments ................................... 2-1 Coolant - Level ................................................. 4-17 Coolant level .................................................... 4-17 Cooling system ................................................ 5-21 Cooling system liquid - Change ....................... 4-68 Cooling system liquid change .......................... 4-68 Craning hook ...................................................... 7-6 Creep speed .................................................... 3-23 Cylinders ............................................................ 8-7 D Decals .............................................................. 1-30 Digging performance .......................................... 8-3 Dimensions ........................................................ 8-1 Documents storage box ................................... 2-38 Door open ........................................................ 2-34 Drive belt - Change .......................................... 4-73 Drive belt change ............................................. 4-73 Drive belts - Check ........................................... 4-47 Dust discharge valve - Cleaning ......................4-26 Dust discharge valve cleaning .........................4-26 E Electrical system ................................................ 8-9 Emergency exit ................................................ 2-36 Engine .......................................................5-3, 8-10 Engine brackets - Screws tightening check .....4-52 Engine brackets screws tightening ..................4-52 Engine oil .........................................................4-13 9-1

SEZIONE 9 E Engine oil - Change ......................................... 4-48 Engine oil - Level ............................................. 4-13 Engine oil change ............................................ 4-48 Engine oil draining ........................................... 4-48 Engine oil filter - Change .................................. 4-37 Engine oil filter change ..................................... 4-37 Engine oil level ................................................. 4-13 Engine revolutions sensor - Cleaning .............. 4-46 Engine revolutions sensor cleaning ................. 4-46 Engine shut off ................................................. 3-12 Evaporator - Cleaning ...................................... 4-62 Evaporator cleaning ......................................... 4-62 F Fine levelling .................................................... 3-42 Fire extinguisher .............................................. 2-38 First-aid kit ....................................................... 2-38 Floating axle ..................................................... 3-26 Floating axle blocking ...................................... 5-12 Floating axle locking cylinders contact faces ... 4-45 Floating axle locking cylinders contact faces - Lubrication ..................................................... 4-45 FOPS ............................................................... 7-20 Foreword ............................................................ 1-1 Front working floodlamps ................................. 2-37 Fuel .................................................................... 4-2 Fuel - Level ...................................................... 4-15 Fuel filter/s - Change ........................................ 4-38 Fuel filter/s change ........................................... 4-38 Fuel level .......................................................... 4-15 Fuel system ........................................................ 8-9 Fuel system water draining .............................. 4-30 Fuel tank - Cleaning ......................................... 4-69 Fuel tank - Level .............................................. 4-15 Fuel tank cleaning ............................................ 4-69 Fuel transfer pump ........................................... 7-19 Fuses - Chart ................................................... 4-81 Fuses - Replacement ....................................... 4-80 Fuses chart ...................................................... 4-81 G Gearbox - Gears change ................................. 3-23 H Hand signals .................................................... 1-38 Heat exchanger - Cleaning .............................. 4-60 Heat exchanger cleaning ................................. 4-62 Heating ....................................................2-44, 5-20 9-2

H Heating system ................................................ 5-20 Hydraulic damping ........................................... 3-43 Hydraulic oil ....................................................... 4-3 Hydraulic oil - Change ...................................... 4-64 Hydraulic oil - Level .......................................... 4-13 Hydraulic oil change ......................................... 4-64 Hydraulic oil level ............................................. 4-13 Hydraulic oil return filter - Change ................... 4-39 Hydraulic oil return filter change ...................... 4-39 Hydraulic oil tank - Cleaning ............................ 4-66 Hydraulic oil tank cleaning ............................... 4-66 Hydraulic system .........................................5-8, 8-7 Hydraulic system - Pressure release ............... 4-74 Hydraulic system air bleeding .......................... 4-67 Hydraulic system bleeding valve - Change ...... 4-54 Hydraulic system bleeding valve change ......... 4-54 Hydraulic system pressure release .................. 4-74 I Ignition key ....................................................... 2-30 J Jump-starting ................................................... 3-10 L Levelling ........................................................... 3-41 Lifting capacities ................................................ 8-5 Lights ............................................................... 4-12 Lubricants ........................................................ 7-22 Lubrication pump ......................................7-22, 8-9 M Machine - Cleaning .......................................... 4-71 Machine cleaning ............................................. 4-71 Machine general inspection ............................. 4-10 Machine main components .............................. 1-24 Machine recovery and towing .......................... 3-52 Machine transport ............................................ 3-53 Main air filter element change .......................... 4-53 Main filter element - Change ............................ 4-53 Main filter element - Cleaning .......................... 4-27 Maintenance intervals ........................................ 4-6 Maintenance intervals - Chart ............................ 4-7 Maintenance intervals chart ............................... 4-7 Multi-cooler - Cleaning ..................................... 4-29 Multi-cooler cleaning ........................................ 4-29 Multi-function display ................................2-12, 5-2

ALPHABETICAL INDEX N Noise ..................................................................1-4 O Operating the machine .......................................3-1 Operating the machine with cold weather ........3-48 Operating weights ..............................................8-1 Operator’s seat ................................................ 2-49 Overload indicator ..............................................7-7 P Parking brake ........................... 2-48, 4-11, 5-7, 8-8 Parking the machine ..........................................3-3 Pilot control filter - Change ...............................4-59 Pilot control filter change ..................................4-59 Pneumatic seat ................................................ 2-49 Position of decals ............................................. 1-31 Power Boost .....................................................3-39 Power levels .....................................................3-30 Power steering ...................................................8-8 R Radio ................................................................ 2-32 Rear working floodlamps ........................2-38, 7-17 Refrigerating agent .......................................... 2-46 Rigid axle and gearbox - Oil change ................ 4-56 Rigid axle and gearbox - Oil level .................... 4-42 Rigid axle and gearbox and oil level ................ 4-56 Rigid axle and gearbox oil level ....................... 4-42 Running-in period ...............................................3-2 S Safety element - Change ................................. 4-53 Safety instructions ..............................................1-2 Screen washer liquid - Level ............................ 4-19 Screen washer liquid level ...............................4-19 Seat belt ...........................................................2-54 Secure the machine ......................................... 3-53 Service brake ........................... 2-47, 4-11, 5-7, 8-8 Service brake - Air bleeding ............................. 4-78 Service brake - Plates check ...........................4-58 Service brake air bleeding ...............................4-78 Service brake plates - Check ...........................4-58 Slewing bearing - Cups greasing .....................4-36 Slewing bearing - Screw tightening check ....... 4-49 Slewing bearing - Teeth greasing .................... 4-50 Slewing bearing cups greasing ........................4-36 Slewing bearing screw tightening .................... 4-49 Slewing bearing teeth greasing ........................4-50

S Slewing gearbox - Level ................................... 4-32 Slewing gearbox - Oil change .......................... 4-70 Slewing gearbox oil change ............................. 4-70 Slewing gearbox oil level ................................. 4-32 Slewing power ..................................................3-37 Stabilization of the machine ............................. 3-45 Stabilizers ...............................................3-45, 5-13 Starting the engines .........................................3-11 Start-up .......................................................3-4, 3-9 Start-up - Immobilizer ......................................... 3-4 Steering .............................................................. 8-8 Steering axle - Oil change ................................ 4-54 Steering axle - Oil level .................................... 4-40 Steering axle oil change ................................... 4-54 Steering axle oil level ....................................... 4-40 Steering column ...............................................2-41 Steering system ................................................. 5-6 Steering trunnion pins - Greasing .................... 4-44 Storage .............................................................. 6-1 Sunblind ........................................................... 2-38 Supplies - Chart ................................................. 4-1 Supplies summarizing chart ............................... 4-1 T Tightening torques - Chart ................................. 8-9 Time ................................................................. 2-24 Travel ..................................... 3-16, 3-20, 5-10, 8-7 Travel with load applied to craning hook .......... 3-25 Troubleshooting ................................................. 5-1 Trunnion pins greasing .................................... 4-45 Tyres .................................................................. 8-8 Tyres - Change ................................................ 4-76 Tyres - Nuts tightening .....................................4-24 Tyres - Pressure .............................................. 4-22 Tyres nuts tightening ........................................ 4-24 U Upper structure holding .................................... 4-12 Upper structure holding brake .......................... 4-12 Upper structure slew ....................... 3-33, 5-11, 8-7 V Vibrations ........................................................... 1-5 W Warm-up ............................................................ 1-7 Warning triangle ...............................................2-38 Washing the machine ......................................4-72 9-3

SEZIONE 9 W Waste disposal ................................................. 1-23 Windscreen blades change .............................. 4-51 Windscreen wiper .....................................2-5, 4-51 Work ................................................................. 3-28 Working attachment greasing .......................... 4-20 Working equipment arm ................................... 3-56 Working hours .................................................... 4-6

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CNH ITALIA S.p.A. - Viale delle Nazioni, 55 - 41100 MODENA - Italy TECHNICAL SUPPORT - Technical Information Print No. 87618263 - 1st Issue - 06 - 2007

COPYRIGHT BY CNH ITALIA S.p.A. All rights reserved. No part of the text or illustrations of this publication may be reproduced.

CASE policy is one of continuous improvement and the right to change prices, specification or equipment at any time without notices is reserved.

All data given in this publication is subject to production variations. Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your CASE Dealer.