Case WX95 & WX125 Wheeled Excavators Operator's Manual 6-82660 - PDF DOWNLOAD

WX95 and WX125 Wheeled Excavators

Operator’s Manual 6-82660 EN

NA North American English

WX95 WX125 Operator’s manual Print No. 6-82660 EN

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WARNING

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Read carefully this chapter before proceeding with the start, use, maintenance, refuelling operations or other interventions.

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This symbol is your alert sign and is specifically intended for safety purposes. It means: WARNING! BE ALERT! YOUR SAFETY IS INVOLVED!

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Read and comply with all precautionary statements following the key-words DANGER, WARNING and CAUTION.

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Machine-mounted safety signs are colour coded yellow with black borders and lettering when they refer to points where special ATTENTION, must be paid as they represent an ACCIDENT DANGER. They are white with red borders and black lettering when they refer to a FORBIDDEN practice.

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IMPORTANT: Data contained in this manual was current at the time of publication. As the Manufacturer improves constantly his products, some information may result as not updated. If variances are observed, contact your Dealer and After-Sales Service.

TABLE OF CONTENTS TABLE OF CONTENTS

PAGE

S - SAFETY PRECAUTIONS SAFETY PRECAUTIONS .............................................................................................................................. S1 SAFETY LABELS ........................................................................................................................................ S35 1 - SPECIFICATIONS Foreword ...................................................................................................................................................... 1-1 Identification data ......................................................................................................................................... 1-2 Noise levels (2000/14/EC) ............................................................................................................................. 1-3 Summary plate for maintenance operations .................................................................................................. 1-5 Wheeled excavator main components ........................................................................................................... 1-6 WX95 Technical specifications ........................................................................................................................... 1-7 WX125 Technical specifications ........................................................................................................................... 1-9 WX95 Operating weights .................................................................................................................................. 1-11 WX125 Operating weights .................................................................................................................................. 1-11 WX95 Digging performance ............................................................................................................................. 1-12 WX125 Digging performance ............................................................................................................................. 1-13 WX95 Transport dimensions ............................................................................................................................. 1-14 WX95 Transport dimensions with clamshell bucket ........................................................................................... 1-15 WX125 Transport dimensions ............................................................................................................................. 1-16 WX125 Transport dimensions with clamshell bucket ........................................................................................... 1-17 WX95 Bucket usefulness depending on arm .................................................................................................... 1-18 WX125 Bucket usefulness depending on arm .................................................................................................... 1-19 2 - OPERATING INSTRUCTIONS Safety precautions for the machine use ........................................................................................................ 2-1 Controls and instruments ............................................................................................................................... 2-2 Safety lever .............................................................................................................................................. 2-3 Upper structure slew locking control ......................................................................................................... 2-4 Start switch .............................................................................................................................................. 2-4 Travel control pedal .................................................................................................................................. 2-5 Left control lever ...................................................................................................................................... 2-5 Right-hand control lever ........................................................................................................................... 2-7 Steering mode selection control (optional) ................................................................................................ 2-9 Steering wheel ....................................................................................................................................... 2-11 Brake control pedal ................................................................................................................................ 2-12 Hydraulik breaker control pedal - optional .............................................................................................. 2-12 Swing /positioner of articulated arm control pedal .................................................................................. 2-13 Steering column panel ............................................................................................................................ 2-14 Monitor panel ......................................................................................................................................... 2-19 Right hand instruments panel ................................................................................................................. 2-29

I

TABLE OF CONTENTS Heater and air conditioner (optional) ...................................................................................................... 2-33 L.h. Control lever console ...................................................................................................................... 2-36 Radio (optional) ..................................................................................................................................... 2-37 Hour counter .......................................................................................................................................... 2-41 Operator’s seat ........................................................................................................................................... 2-42 Adjusting the operator’s seat .................................................................................................................. 2-42 Cab ............................................................................................................................................................. 2-43 Door ...................................................................................................................................................... 2-43 Front windscreens and windows ............................................................................................................ 2-44 Cab accessories .................................................................................................................................... 2-45 Escape routes ........................................................................................................................................ 2-46 Mirrors ................................................................................................................................................... 2-46 Fastening points ..................................................................................................................................... 2-47 Machine use ............................................................................................................................................... 2-48 Refuelling ............................................................................................................................................... 2-49 Checks before engine start-up .............................................................................................................. 2-50 Start switch ............................................................................................................................................ 2-50 Starting the engine ................................................................................................................................. 2-51 Checks after engine start-up .................................................................................................................. 2-51 Starting the engine after prolonged storage ............................................................................................ 2-52 Warm-up in cold weather conditions ...................................................................................................... 2-52 Starting the engine using booster batteries ............................................................................................. 2-53 Stopping the engine ............................................................................................................................... 2-54 Travel control pedal ................................................................................................................................ 2-55 Travelling instructions .................................................................................................................................. 2-56 Travelling on the road ............................................................................................................................. 2-56 Emergency boom lowering procedure ................................................................................................... 2-61 Excavator removal .................................................................................................................................. 2-62 Speed sensor ......................................................................................................................................... 2-64 Safety lever ............................................................................................................................................ 2-65 Control levers ......................................................................................................................................... 2-66 Machine warm-up .................................................................................................................................. 2-67 Engine speed hand control .................................................................................................................... 2-67 Auto/idle switch ...................................................................................................................................... 2-68 Memory button ....................................................................................................................................... 2-68 Machine operation ...................................................................................................................................... 2-69 Main operating rules .............................................................................................................................. 2-70 Precautions during operation ................................................................................................................. 2-75 Parking the machine .............................................................................................................................. 2-76 Precautions for travelling on slopes ........................................................................................................ 2-77 Manoeuvring of hanging loads ............................................................................................................... 2-79 Reading key for the liftable load table located in the cab ........................................................................ 2-81 Bucket installation .................................................................................................................................. 2-82 Bucket tooth tip ...................................................................................................................................... 2-83 Road transport ............................................................................................................................................ 2-84 Transport rules ....................................................................................................................................... 2-84 Rules for loading/unloading the machine on a trailer .............................................................................. 2-85 Loading the machine on a trailer ............................................................................................................ 2-86 Unloading the machine from the trailer ................................................................................................... 2-88 Sea transport .............................................................................................................................................. 2-89 Craning the machine for sea transport ................................................................................................... 2-89 Precautions in cold weather conditions ....................................................................................................... 2-90 Prolonged machine inactivity ...................................................................................................................... 2-91 Using the machine after prolonged storage ................................................................................................. 2-92 Machine demolition ..................................................................................................................................... 2-92

II

TABLE OF CONTENTS 3 - OPTIONAL VERSIONS

1

Hydraulic breaker ......................................................................................................................................... 3-1 Hydraulic breaker selection and installation ............................................................................................. 3-1 Precautions when using the hydraulic breaker ......................................................................................... 3-1 Hydraulic breaker control ......................................................................................................................... 3-4 Nibbler .......................................................................................................................................................... 3-5 Choiche and assembly of nibbler ............................................................................................................. 3-5 Precautions to be observed when using the nibbler ................................................................................. 3-5 Nibbler control .......................................................................................................................................... 3-7 Hydraulic oil and filter element service interval ......................................................................................... 3-8 Attachment slew system ................................................................................................................................ 3-9 Attachment slew control ........................................................................................................................... 3-9 Clamshell bucket system ............................................................................................................................. 3-10 Clamshell bucket control ........................................................................................................................ 3-10 Cab protection (F.O.P.S.) ............................................................................................................................ 3-11 Fuel transfer pump ................................................................................................................................. 3-12 4 - MAINTENANCE Maintenance precautions .............................................................................................................................. 4-1 General notes ............................................................................................................................................... 4-2 Check hour meter regularly ..................................................................................................................... 4-3 Service reminder plate ............................................................................................................................. 4-3 Prepare the machine for maintenance ..................................................................................................... 4-4 Hood and access covers .......................................................................................................................... 4-5 External visual inspection .............................................................................................................................. 4-6 Engine oil ................................................................................................................................................. 4-7 Checks before starting daily work ................................................................................................................. 4-7 Hydraulic system oil ................................................................................................................................. 4-9 Fuel tank ................................................................................................................................................ 4-10 Windscreen washer tank ....................................................................................................................... 4-11 Fuel pre-filter ......................................................................................................................................... 4-11 Engine cooling system ........................................................................................................................... 4-12 Machine lubrication and maintenance general table .................................................................................... 4-13 After 100 hours of operation ....................................................................................................................... 4-14 Bucket links ........................................................................................................................................... 4-14 Boom and arm ....................................................................................................................................... 4-15 Stabilizers or blade ................................................................................................................................. 4-15 After 500 hours of operation ....................................................................................................................... 4-16 Outer and inner circulation air cleaners ................................................................................................. 4-17 Air cleaner: Outer element ..................................................................................................................... 4-19 Slew reduction gear oil ........................................................................................................................... 4-20 Axle reduction gears oil .......................................................................................................................... 4-21 Front and rear axles oil .......................................................................................................................... 4-22 Transmission oil ..................................................................................................................................... 4-22 Hardware tightening ............................................................................................................................... 4-23 Tyres ...................................................................................................................................................... 4-30 Fuel tank ................................................................................................................................................ 4-31 Hoses, lines and fittings ......................................................................................................................... 4-32 Fuel hoses ............................................................................................................................................. 4-40 Hydraulic oil system reservoir ................................................................................................................ 4-41 Engine oil and filter ................................................................................................................................ 4-42 Fuel filter ................................................................................................................................................ 4-44 Hydraulic system oil filter ....................................................................................................................... 4-46 Slewing ring bearing .............................................................................................................................. 4-48 Slewing ring teeth .................................................................................................................................. 4-49

III

TABLE OF CONTENTS Front axle .................................................................................................................................................... 4-50 Iengine cooling system .......................................................................................................................... 4-51 Accumulators charge ............................................................................................................................. 4-52 Brake and power controls oil filter .......................................................................................................... 4-53 Air conditioner - optional ........................................................................................................................ 4-54 After 1000 hours of operation ..................................................................................................................... 4-55 Air filter: Outer element .......................................................................................................................... 4-55 After 1500 hours of operation ..................................................................................................................... 4-56 Fuel pre-filter ......................................................................................................................................... 4-56 Alternator - fan belt ................................................................................................................................ 4-58 After 2000 hours of operation ..................................................................................................................... 4-59 Slew reduction gear oil ........................................................................................................................... 4-59 Transmission oil, axles oil ....................................................................................................................... 4-61 Engine cooling system ........................................................................................................................... 4-63 Air cleaner: Inner element ...................................................................................................................... 4-65 After 2500 hours of operation ..................................................................................................................... 4-66 Hydraulic system oil ............................................................................................................................... 4-66 After 3000 hours of operation ..................................................................................................................... 4-72 Engine valves ......................................................................................................................................... 4-72 Filling chart MODEL WX95 ......................................................................................................................... 4-73 Filling chart MODEL WX125 ....................................................................................................................... 4-74 5 - TROUBLESHOOTING Engine .......................................................................................................................................................... 5-1 Electrical system ........................................................................................................................................... 5-6 Controls ........................................................................................................................................................ 5-8 6 - ELECTRICAL SYSTEM General notes ............................................................................................................................................... 6-1 Batteries .................................................................................................................................................. 6-2 Fuses ....................................................................................................................................................... 6-4

IV

S - SAFETY PRECAUTIONS

S SAFETY PRECAUTIONS Assess exact paths of gas ducts, water mains, telephone lines, sewers, overhead and underground electric lines and all other possible obstacles.

Such paths should be opportunely defined by competent Authorities. If necessary, require that the service is interrupted or said installations are moved prior to starting the work.

You must know the working capacity of the machine.

Define the rear superstructure swing area and provide for opportune barriers to prevent access into it.

Never exceed machine lifting capacity.

Remain within the limits shown in the loading capacity chart located on the machine.

SAFETY PRECAUTIONS GENERAL NOTES Read the Operation and Maintenance Instruction Manual carefully before starting, operating, maintaining, fuelling or servicing the machine.

Carefully read the explanation to each and all safety signs in the special section of this Manual before starting, operating, maintaining, fuelling or servicing the machine.

Machine-mounted safety plates are colour coded yellow with black borders when they refer to points where special ATTENTION must be paid and failure to observe them may cause a serious DANGER to the integrity of machine operators.

They are white with red borders and black lettering when they refer to a FORBIDDEN practice.

It is fundamental that all machine operators know very well the meaning of each safety plate as this considerably decreases operating hazards and accidents.

Do not allow unauthorised personnel to operate or service this machine.

Do not wear rings, wrist watches, jewellery, loose or hanging garments, such as ties, torn clothing, scarves, unbuttoned or unzipped jackets that can get caught in moving parts. Wear certified safety clothes such as: hard hat, no-slip footwear, heavy gloves, ear protection, safety glasses, reflector vests, respirators every time the job requires it.

Ask your employer about safety regulations in force and protective equipment.

Always keep the operator’s compartment, step plates, grab-rails and handles clean and clear of foreign objects, oil, grease, mud or snow to minimise the danger of slipping or stumbling. Remove mud or grease from your shoes before operating the machine.

Do not jump on or off the machine. Always keep both hands and one foot, or both feet and one hand in contact with steps and/or grab rails.

Do not use controls or hoses as hand holds. Hoses and controls are movable parts and do not provide solid support. Besides, controls may be inadvertently moved and cause unexpected movement of the machine or its attachments.

Never operate the machine or its attachments from any position other than sitting in the driver’s seat.

Keep head, body, limbs, hands and feet inside the operator’s compartment at all times to reduce exposure to external hazards.

Be careful of possible slippery conditions of the steps and hand rails as well as of the ground around the machine. Wear protective boots or shoes with the soles made of highly no-slip rubber.

Do not leave the machine until it has come to a complete stop.

Always check height, width and weight limitations which may be encountered in the working site and ensure the machine does not exceed them.

START UP Never start up or set in motion a failed machine.

Before getting on, walk around the machineto inspect it. Before operating the machine, make sure that any possible dangerous condition has been properly removed.

Before starting machine, check that steering and attachment controls are in the neutral position and the safety lever is in the LOCK position.

Immediately report any malfunction of parts or systems to the maintenance managers for proper action.

Prior to starting the engine, check, adjust and lock the driver’s seat for maximum riding comfort and control accessibility.

Prior to operating the machine and/or its attachments, check that bystanders are outside the machine operating range. Sound horn.

Obey all hand signals, safety indications and signs.

Due to the presence of flammable fluids, never check fuel level, refuel, charge the batteries or use the starting fluid in the presence of smoking materials, open flames or sparks.

Ensure that nobody is within the excavator operating area before starting the machine, swinging the upper structure or moving in any direction.

Adjust all rear-view mirrors for maximum visibility of the area behind the machine.

Ensure that engine speed is appropriate to the job to be carried out.

If any hydraulic control or system exhibits erratic performance or responds abnormally, have the machine checked for air in the system.

Air in these circuits may cause incorrect movements with consequent accident hazard.

Refer to the Operation and Maintenance Instruction Manual about corrective action to be taken.

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SAFETY PRECAUTIONS Operators must know the performance of the machine they are driving.

When working on slopes or near sudden level drops in the terrain, pay attention not to lose adherence and avoid loose soft ground since overturn or loss of machine control could result.

If noise level is high and exceeds 90 dB(A) over 8 hours at the operator’s ear, wear approved ear protection in compliance with local regulations.

Do not operate the machine if you are extremely tired or feel ill.

Be especially careful towards the end of the working shift.

Where removable counterweights are provided, do not operate the machine if they have been removed.

When operating the machine, keep in mind height limits of overhead doors, arches, overhead cables and lines as well as width limits of corridors, roads and narrow passages. Also, get to know load limits of the ground and paving type of the ramps you are to work on.

Beware of fog, smoke or dust that obscure visibility.

Check constantly the work areas to find out the dangerous points. Some examples of dangerous work areas are: inclines, overhangs, trees, demolition rubble, fires, ravines, steep slopes, rough terrain, ditches, crowns, ridge trenches, diggings in traffic areas, crowded parking lots, crowded service areas, fenced zones. In such conditions, proceed with extreme care.

Whenever possible, avoid crossing over obstacles such as very rough terrain, rocks, logs, steps, ditches, railroad tracks. When obstructions must be crossed, do so with extreme care and at a square angle, if possible.

Slow down. Ease up to the break-over point, pass the balance point slowly and ease down the other side also using the attachment, if necessary.

To overcome deep trenches or sinking ground, place the machine perpendicular to the obstacle, drastically reduce ground speed and start crossing using also the attachment if necessary, only after assessing that ground conditions allow the traverse safely and without risks.

The gradient you may attempt to overcome is limited by factors such as ground conditions, load being handled, machine type and speed, and visibility.

There is no substitute for good judgement and experience when working on slopes. Avoid operating the attachment too close to an overhang or high wall, either above or below the machine. Beware of caving edges, falling objects and landslides.

Remember that such hazards are likely to be concealed by bushes, undergrowth and such.

Avoid faggots, bushes, logs and rocks. Never drive over them, nor over any other surface irregularities that discontinue adherence or traction with the ground, especially near slopes or drop-offs.

Be alert to avoid changes in adherence conditions

OPERATION Do not run the engine of this machine in closed buildings without proper ventilation capable to remove harmful exhaust gases which concentrate in the air.

Keep the driver’s seat free from foreign objects, especially if these are not secured. Never use the machine to transport objects, unless proper securing points are provided.

Do not carry riders on the machine.

Study and familiarise with escape routes alternative to normal exit routes.

For your personal safety, do not climb on or off the machine while it is in motion.

Make sure that bystanders are clear of the machine operating range before starting the engine and operating the attachment. Sound horn.

Obey all hand signals, safety indications and signs.

When backing, always look to where the machine is to be moved.

Be alert of the position of bystanders. Should someone enter the work area, stop the machine.

Maintain a safe distance from other machines or obstacles to ensure required visibility conditions.

Always give way to loaded machines.

Maintain a clear vision of the surroundings of the travel or work area at all times.

Keep cab windows clean and repaired.

When pulling loads or towing through a cable or chain, do not start suddenly at full throttle. Take-up slack carefully. Avoid kinking or twisting chains or cables.

Carefully inspect cables or chains for flaws or problems before proceeding.

Do not pull through a kinked chain or cable as the high anomalous stresses existing in this condition may induce failures in the kinked portion. Always wear heavy gloves when handling chains or cables.

Chains and cables should be securely anchored using suitable hooks. Anchor points should be strong enough to withstand the expected load.

Keep anyone clear of anchor points and cables or chains. Do not pull or tow unless the operator’s compartments of the machines involved are properly protected against possible backlash in case of cable or chain failure or detachment.

Be alert of soft ground conditions close to newly constructed walls. The fill material and machine weight may cause the wall to collapse under the machine.

In darkness, check area of operation carefully before moving in with the machine. Use all lights provided.

Do not move into low visibility areas.

If the engine tends to slow down and stall for whatever reason under load or at idle, immediately report this problem to the maintenance managers for proper action. Do not operate the machine until this condition is corrected.

Regularly check all exhaust system components, as exhaust fumes are toxic for the operator.

S2

S SAFETY PRECAUTIONS Always ensure that slings and chains used for lifting are adequate to the load and in good condition.

All loading capacities are referred to the machine on a level surface and should be disregarded when working on a slope.

Avoid travelling across slopes. Proceed from uphill downhill and vice-versa.

If machine starts slipping sideways when on a slope, lower the bucket and thrust bucket teeth into the ground.

Working on slopes is dangerous. Grade the working area if possible. Reduce work cycle time if it is not possible to grade the working area.

Do not move full bucket or a load from uphill downhill as this would reduce machine stability.

Do not work with the bucket turned uphill as counterweights protruding downhill would reduce machine stability on the slope and increase risk of overturning.

We recommend to work on slopes with the bucket downhill, after checking machine stability with the bucket empty and attachment retracted, by slowly swinging the upper structure by 360°.

Position the carriage at a right angle relative to slopes, hanging walls, etc. to exit the working area easily. Be aware when the upperstructure is turned by 180°, steering and travel controls are reversed.

Properly judge ground conditions with particular attention to consistency of the area you are going to work on. Keep the machine sufficiently far from the digging border.

Never dig under the machine.

Should it be necessary to dig under the machine, always ensure that digging walls are opportunely propped up against landslide to prevent the machine from falling into the trench.

Do not slew the upper structure, raise the load or brake abruptly if not required. This may cause accidents.

Prior to beginning the work near gas distribution mains or other public utilities: • Contact the Company Owner of the gas mains or its nearest branch before starting the work. Look up the number in the telephone directory.

• Define together which precautions should be taken to guarantee work safety.

• Decrease work speed. Reaction time could be too slow and distance evaluation wrong.

• When working near gas mains or other public utilities installations, appoint a person in charge of signalling duties. This person will have the responsibility of observing the machine, any part of it and/or the load approaching the electric line from a better standpoint with respect to the Operator’s position.

This signal-man shall directly communicate with the Operator and the Operator must pay special attention to any signals supplied.

• The gas distributing Company, if previously advised and involved in the work, as well as machine Operator, Owner and/or any natural person or legal entity

that could cause loss of control. Work with extreme care on ice or frozen ground and on stepped slopes or near drop-offs.

The word “bulldozing” generally refers to work in virgin rough terrain, characterised by the presence of all the perils and risks listed above. We emphasise the danger represented in these conditions by large tree limbs and large roots,which may act as a leverage under the machine when up-rooted and cause their overturn. Position the machine according to the loading and unloading areas in order to slew leftwards to load and to obtain best visibility.

Never use the bucket or attachment to lift persons or carry riders on the machine.

Never use the machine as a work platform or scaffolding. The machine must not be improperly used for works not consistent with its features (such as pushing railway cars, trucks or other machines).

Always pay attention to people within the machine operating range.

Never move or stop the bucket, other loads or the attachment above ground personnel or truck cabs.

Before loading a truck make sure that the driver finds a safe place. Load trucks from side or rear. Use only the type of bucket recommended considering machine type, materials to be handled, material piling up and loading characteristics, ground type and other typical conditions of the work to be performed. When travelling with a loaded bucket, keep it as rolled-back as possible.

Ground speed should be adequate to the load and ground conditions. The load must always be properly arranged in the bucket. Move with extreme care when transporting oversize loads.

Do not lift and move the bucket overhead where persons are standing. When working on slopes avoid travelling with bucket downhill because this could reduce the machine stability. Load the bucket from uphill side. Loads to be raised using the machine should be exclusively hooked to the hitch specially provided.

The excavator is no lifting and transportation means, therefore it should not be used to position loads accurately. Should it be exceptionally used to lift and lay building components, special caution must be taken as follows: • The machine should necessarily be equipped with the special option supplied by Dealer. Besides, follow carefully safety rules for the excavator used as lifting means.

• Secure the loads to be raised using cables or chains fastened with appropriate hooking mechanisms.

• Nobody should be allowed to remain under the raised load or within the excavator operating range for any reason whatever.

Never exceed specified loading capacity. Incorrect fastening of slings or chains may cause boom/arm failure or failure of the lifting means with consequent bodily injuries and even death.

S3

S

SAFETY PRECAUTIONS • When digging near recently formed trenches filled with filling materials.

• When digging in bad ground conditions.

• When digging trenches subject to vibration from railroads, working machines or highway traffic.

having rent or leased the machine or being responsible at the time by contract or by law, are liable for the adoption of the necessary precautions.

Working near electric lines can be very dangerous, therefore some special precautions must be observed. Within this Manual, “work near electric lines” means when the attachment or load raised by the excavator (in any position) may reach the minimum safety distance established by local or international Safety Regulations.

To work without risks, keep maximum possible distance from electric lines and never trespass minimum safety distance.

Ensure that local or national safety regulations concerning work near electric lines are observed.

Prior to beginning the work near electric lines: • Contact the Company Owner of the electric lines or its nearest branch before starting the work. Look up the in the telephone directory.

• Define together with the Company representative which precautions should be taken to guarantee work safety.

• All electric lines should be considered as operative live lines even though it might be well known that the line in question is out of work and visibly connected to the ground.

• The Electric Power Company, if previously advised and involved in the work, as well as machine Operator, Owner and/or any natural person or legal entity having rent or leased the machine or being responsible at the time by contract or by law, are liable for the adoption of the necessary precautions.

• Decrease work speed. Reaction time could be too slow and distance evaluation wrong.

• Warn all ground personnel to keep clear of the machine and/or load at all times. If the load has to be guided down for laying, consult the Electric Power Company to know which precautions should be taken.

• Appoint a person in charge to signal instructions.

This person will have the responsibility of observing the machine, any part of it and/or the load approaching the electric line from a better standpoint with respect to the Operator’s position. This signalman shall directly communicate with the Operator and the Operator must pay special attention to any signals supplied.

When working in or near pits, in ditches or very high walls, check that the walls are sufficiently propped up to avoid cave-in hazards.

Pay the utmost attention when working near overhang walls or where landslides may take place. Make sure that the support surface is strong enough to prevent landslides.

When digging, there is the risk of cave-ins and landslides.

Always check ground conditions and conditions of the material to be removed. Support everywhere it is required to prevent possible cave-ins or landslides when:

STOP When the machine is to be stopped for whatever reason, always check that all controls are in the neutral position and that the safety lever is on the lock position to guarantee risk-free start-up.

Never leave the machine unattended with the engine running.

Before leaving the driver’s seat and after ensuring noone is near the machine, slowly lower the attachment until it rests safely onto the ground. Move possible additional tools in the safe retracted position. Check that all controls are in the neutral position. Move engine controls to the shut-down position. Switch off the keystart switch. Consult the Operation and Maintenance Instruction Manual.

Park the machine in a non-operating and no-traffic area. Park on firm level ground. If this is not possible, position the machine at a right angle to the slope, making sure there is no danger of uncontrolled sliding.

If parking in traffic lanes cannot be avoided, provide prescribed danger signals such as: flags, barriers, flares and other signals. Moreover arrange further danger signals on traffic lane so as to adequately warn the oncoming drivers.

Always switch off the key-start switch before cleaning, repairing or servicing, or parking the machine to prevent accidental unauthorised start-up.

Never lower the attachment or auxiliary tools other than from sitting in the operator’s seat. Sound horn.

Make sure that nobody is within the machine operating range. Lower the attachment slowly.

Securely block and lock the machine every time you leave it unattended. Return keys to the safe place previously agreed upon.

Perform all necessary operations for stopping as detailed in the Operation and Maintenance Instruction Manual.

Drive the machine far from pits, trenches, rocky hanging walls, areas with overhead electric lines, and slopes before stopping it at the end of the working day.

Align the upperstructure to the tracks in order to allow to easily get on and off the driver’s compartment.

Move all controls to the position specified for machine stopping. Refer the Operation and Maintenance Instruction Manual.

Never park on an incline without accurately blocking the machine to prevent unexpected movement.

Always follow stopping instructions contained in the Operation and Maintenance Instruction Manual.

S4

S SAFETY PRECAUTIONS Do not allow anyone to pass or stay near or below a raised attachment. If you are not absolutely sure about your safety, do not stay or walk under a raised attachment.

Do not place head, body, limbs, hands, feet or fingers near articulated cutting edges deprived of the necessary guards, unless they are suitably and safely locked.

Never lubricate, repair or adjust the machine with the engine running, except when this is specifically required by the Operation and Maintenance Instruction Manual.

Do not wear loose clothing, jewellery near rotating parts.

When service or maintenance require access to areas that cannot be reached from the ground, use a ladder or step platform conforming to local or national regulations to reach the working area. If such means are not available, use machine grab rails and steps.

Always perform all service or maintenance work with the greatest care and attention.

Shop and/or field service platforms or ladders should be manufactured and maintained in accordance with local or national safety regulations in force.

Disconnect batteries and label all controls to warn that service work is in progress, according to local and national safety regulation requirements.

Block the machine and all attachments to be raised according to local and national safety regulation requirements.

Do not check or fill fuel tanks or install batteries near burning or smoking materials and open flames due to the presence of flammable vapours.

The fuel filler pipe nozzle must be constantly kept in contact with the filler neck and this even before fuel starts flowing in. Keep this contact from the beginning to the end of the fuelling operation to avoid possible generation of sparks due to static electricity.

Use a truck or trailer to haul a failed machine. Should it be necessary to tow it, provide for suitable danger signals as required by the local norms and regulations and observe recommendations given in the Operation and Maintenance Instruction Manual. Load/unload the machine on firm level ground providing safe support to the wheels of the truck or trailer.

Use strong access ramps, with adequate height and angle. Keep the trailer flatbed free of mud, oil or slippery materials. Tie the machine securely to the trailer and block carriages and upperstructure.

When aligning the pin bores, never insert your finger or hands into the pin bore. Use a suitable tool.

Remove all sharp edges and burrs from re-worked parts.

Use only approved and grounded auxiliary power sources for heaters, battery chargers, pumps and similar equipment to reduce electrical shock hazard.

Lift and handle heavy components using hoisting devices of appropriate capacity. Ensure the parts are supported by appropriate straps and hooks.

MAINTENANCE GENERAL NOTES Carefully read the Operation and Maintenance Instruction Manual before starting, operating, maintaining, fuelling or servicing the machine in any manner.

Read all safety plates mounted on the machine and observe instructions they contain before starting, operating, repairing, fuelling or servicing the machine.

Do not allow unauthorised personnel to operate or service this machine.

Do not carry out any work on the attachment without prior authorisation.

Observe recommended maintenance and repair procedures.

Do not wear rings, wrist watches, jewellery, loose or hanging garments, such as ties, torn clothing, scarves, unbuttoned or unzipped jackets that can get caught in moving parts. Wear certified safety clothes such as: hard hat, no-slip footwear, heavy gloves, ear protection, safety glasses, reflector vests, respirators when required.

Ask your employer about safety regulations in force and protective equipment.

Do not use controls or hoses as hand holds. Hoses and controls are movable parts and do not provide solid support.

Besides, controls may be inadvertently moved and cause unexpected movement of the machine or its attachments. Do not jump on or off the machine. Always keep both hands and one foot, or both feet and one hand in contact with steps and/or grab rails.

Never service the machine with someone sitting in the driver’s seat, unless this person is an authorised operator assisting in the maintenance being carried out.

Keep the operator’s compartment, step plates, grab rails and handles clear of foreign objects, oil, grease, mud or snow to minimise the danger of slipping or stumbling. Remove mud or grease from your shoes before operating the machine.

Never attempt to operate the machine or its attachments from any position other than sitting in the operator’s seat.

Keep the driver’s seat free from foreign objects, especially if these are not secured.

Should it be necessary to move the attachment for maintenance purposes, do not raise or lower the attachment from any other position than sitting in the operator’s seat. Before starting the machine or moving its attachment, sound the horn and require that nobody remains near the machine.

Raise the attachment slowly.

Always lock all moving components or parts of the machine that must be lifted for maintenance purposes using adequate external means as required by local and national regulations.

S5

S

SAFETY PRECAUTIONS range before starting or operating the machine and/or its attachments. Sound horn.

Rust inhibitors are volatile and flammable. Prepare parts in well ventilated areas. Keep open flames away. Do not smoke. Store containers in a cool well ventilated place where they could not be reached by unauthorised people.

Do not carry loose objects in your pockets that might fall unnoticed into open compartments.

Wear appropriate safety clothing such as hard hat, safety shoes and gloves, safety glasses when splinters or other particles may be ejected.

Wear the appropriate welder’s equipment such as dark safety glasses or mask, hard hat, protective clothing, safety gloves and footwear always while welding or arc-cutting. Wear dark safety glasses when you are near a welding in progress. Do not look the welding arc without proper eye protection.

Become acquainted with all your jacking equipment and their capacity. Ensure that the jacking point on the machine is appropriate for the load applied. Also, be sure the supports under the jack and between the jack and the machine are appropriate and stable. Any equipment supported by a jack represents a possible hazard. Always support the load onto appropriate blocking means as a safety measure before proceeding with service or maintenance work, in compliance with local or national safety regulations.

Metal cables produce steel splinters. Always wear certified protection clothes such as safety gloves and glasses while handling them.

Handle all parts with great care. Keep hands and fingers away from gaps, gears, and similar. Always use and wear certified safety clothes such as safety glasses, gloves and footwear.

The attachment is kept constantly in position by an oil column trapped into the high pressure circuit. Lower the attachment to the ground and relieve pressure from all circuits prior to carrying out any type of maintenance or repair work.

Do not service or repair the machine if it is parked downhill. Consult the Operation and Maintenance Instruction Manual for correct maintenance procedure.

Areas near articulated cutting edges where mechanical parts are in motion are where personal injuries are most likely to occur. Pay attention to prevent possible part movements by means of blocks or by keeping clear of such zones when motion may take place during maintenance or repair.

Move the hydraulic system lock safety lever to the lock position when stopping the machine for whatever reason.

Always install the safety stays for the hood and other hinged covers before performing any maintenance or repair work in the engine compartment.

Use lifting eyes provided to this aim. Pay attention to bystanders near the lifting area.

Never pour gasoline or diesel fuel into an open container.

Never use gasoline, solvents or other flammable fluids to clean parts. Use only proprietary certified solvents, non-flammable and non-toxic.

When using compressed air to clean parts, wear safety glasses with side shields. Limit pressure to max. 2 bars, in accordance with local and national safety regulations in force.

Do not run the engine of this machine in closed buildings without proper forced ventilation capable to remove toxic exhaust gases concentrating in the air.

Do not smoke, nor allow open flames or sparks nearby while refuelling the unit or handling highly flammable materials.

Do not use open flames as light sources to look for leaks or inspect anywhere on the machine.

Make sure that all mechanical tools provided are in good condition at all times. Never use tools with mushroomed or damaged heads. Always wear eye protections with side shields.

Move with extreme care when working under, on or near the machine or its attachments.

In case of attachment tests during which the engine should be kept running, a qualified operator must sit in the driver’s seat at all times while the mechanic is at work. Keep hands and clothes far OFF moving parts.

Stop the engine and move the safey lever to the lock position before starting adjusting or repairing an assembly.

Do not carry out any work on the attachment without prior authorisation. Observe recommended maintenance and repair procedures.

In case of field service, move the machine to level ground and block it. If work on an incline cannot be avoided, securely block the machine and its attachments. Move the machine to level ground as soon as possible.

Do not twist chains and cables. Never use a twisted chain or cable for lifting or pulling. Always wear safety gloves to handle chains or cables.

Be sure chains and cables are firmly fastened and that the anchor point is strong enough to withstand the expected load. Keep all bystanders clear of the anchor point, cables or chains. Do not pull or tow unless the operator’s compartments of the machines involved are fitted with proper guards against cable or chain backlash.

Keep the maintenance area clean and dry at all times.

Clean immediately all water and oil spillage.

Do not pile up oily or greasy rags. They represent a major fire hazard. Always store them in closed metal containers.

Before starting the machine or its attachment, check, adjust and lock the operator’s seat. Also ensure that nobody is within the machine or attachment operating

S6

S SAFETY PRECAUTIONS Keep the exhaust manifold and tube free from combustible matters. Fit the machine with shields and guards when working in the presence of combustible matter free in the air.

Do not refuel with the engine running, especially if hot, as this increases fire hazard in case of fuel spillage.

Never attempt to check or adjust fan belt tensions when the engine is running.

Do not adjust the fuel injection pump when the machine is operating.

Do not lubricate the machine with the engine running.

Do not run the engine with the air intakes open and not protected. If this cannot be avoided for service reasons, place protection meshes on all intakes before servicing the engine.

TRANSFERS AND TRANSPORTATION Before moving or transporting the machine, block upperstructure swing to prevent accidental movement.

Pay particular attention during transfer on inclines, both uphill and downhill. Keep the bucket in a position to provide a possible anchor point into the ground in case of slipping.

During transfers on inclines, both uphill and downhill, keep the upperstructure aligned with the carriages.

Do not travel across the slope.

Never transfer the machine in the working site, in a crowded area, or near people without having at least one person charged with hand-signals who could guide the Operator.

Sound the horn to inform that you are about to move off.

It is necessary to know load limits of bridges and dimensional limits of tunnels. Such limits must never be exceeded. You should also know machine height, width, and weight. Have a signal-man help you when clearances are limited.

Check distance between boom/arm and dimensional limits during transfer or transportation.

Rough terrain may cause the machine to sway and roll to such an extent that boom/arm could get to contact electric lines or other obstacles. Cross obstacles at a right angle at low speed. Pay attention to machine shaking when the centre of gravity overcomes the obstacle.

Keep the bucket down at all times during transfers.

Drive with the lights on and use appropriate signals and flags.

Get to know and respect local and national regulations.

Consider boom/arm and upperstructure dimensions while turning. Use a ramp to load the machine on a trailer. If a ramp is not available, fabricate one using blocks. The ramp should be sufficiently strong to support machine weight. Always load and unload on level surface.

Tow the machine following the instructions contained in the Operation and Maintenance Instruction Manual.

ELECTRIC SYSTEM Pay attention to connect connecting cables to correct poles (+ to +) and (- to -) at both ends. Do not shortcircuit the terminals. Thoroughly follow instructions given in Operation and Maintenance Instruction Manual.

Always move the key-start switch in the lock position before servicing or repairing the machine.

Batteries contain SULFURIC ACID. Protect the eyes when working near the batteries against possible sprays of the acid solution. Should acid contact skin, eyes, or clothes, RINSE IMMEDIATELY IN WATER FOR AT LEAST 15 MINUTES. Seek for immediate medical assistance.

Battery released gas is highly flammable. Leave the battery compartment cover open during recharging to improve ventilation. Never check battery charge by placing metal objects across the posts. Keep sparks or open flames away from batteries. Do not smoke near the battery to prevent explosion hazard.

Before any maintenance or repair, make sure that there are no fuel or electrolyte leaks from the batteries. If any, correct prior to proceeding with further work.

Do not recharge batteries in confined spaces. Ensure proper ventilation is provided to avoid accidental explosions due to build-up of explosive gas released during charging.

Disconnect batteries before working on the electrical system or carrying out any other type of work.

MOTOR Do not run the engine in closed buildings without proper ventilation capable to remove harmful exhaust fumes.

Do not place head, body, limbs, feet, hands or fingers near rotating fans or belts. Be especially careful near blower fans.

Loosen the radiator cap very slowly to relieve system pressure before removing it. Always top-up coolant level with the engine off or idling if hot.

See the Operation and Maintenance Instruction Manual.

S7

S

SAFETY PRECAUTIONS

HYDRAULIC SYSTEM

TYRES AND WHEELS

Pressure fluid escaping from a very small hole can be almost invisible and still have sufficient force to penetrate the skin. Always check any suspected pressure leaks using a piece of cardboard or wood. Do not use hands. If injured by escaping fluid, obtain medical attention immediately. If proper medication is not carried out immediately serious infection or reaction may develop.

Stop the engine and ensure pressure is relieved from all systems before removing side panels, housings, guards and covers. See the Operation and Maintenance Instruction Manual.

Always use gauges of adequate capacity for pressure testing. Refer to the Operation and Maintenance Instruction Manual or Repair Manual.

Always check that inflating pressure of tyres corrresponds to the prescribed value suggested by Manufacturer and check periodically its integrity.

If the inflating pressure of tyres has to be changed, carry out this operation keeping at a safety distance.

The tyres inflating pressure has always to be ckecked with no load and in cold conditions. Never use reconditioned discs wheel many eventual weldings, heat treatments or brazings executed correctly cannot weaken the wheels and being therefore cause of successes to you damagings or damages.

Do not perform torch cutting or welding operations on rims with tyres installed. The spare tyre should be inflated only as far as needed to hold the ring parts together: remember that when not installed on the disc, a tyre inflated to maximum pressure can explode.

When working on tyres, lock previously all wheels front and back ones. After lifting machine with hydraulic jack, prevent its falling down inserting supports according to the safety regulations in force.

Deflate the tyres before removing them.

Before extracting possible foreign bodies jammed in the tread, it is necessary to deflate tyres.

Do not inflate tyres with flammable gas: they may cause explosions and serious personal injuries.

At the end of work shifts check for loose screws and/ or rims mounting brackets, if necessary carry out their tightening according to the instruction given in this issue.

ATTACHMENTS Always keep head, body, limbs, feet, hands, and fingers away from the bucket and attachments, when in the raised position.

Prior to any maintenance or repair work, install all supports necessary to this aim according to local and national safety regulations.

In case the attachment is to be operated for maintenance or repair purposes, do so exclusively while sitting in the driver’s seat. Sound the horn before starting the machine or moving the attachment. Require that nobody remain near the machine. Raise the attachment slowly.

Do not use the machine to transport loose objects, unless proper securing devices are provided.

S8

S SAFETY PRECAUTIONS RECOGNISE SAFETY INFORMATION This is your SAFETY ALERT SYMBOL. When you see this symbol on your machine or in this Manual, be alert of the potential for personal injury.

Follow recommended precautions and safe operating practices.

F3264

UNDERSTAND SIGNAL WORDS In this Manual you will find the following words: DANGER, WARNING, CAUTION.

DANGER

Referring to different hazard risks. These words are always accompanied by the safety alert symbol.

WARNING

DANGER indicates an imminent hazardous situation which, if not avoided, will result in death or serious injury.

CAUTION IMPORTANT

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

NOTICE

CAUTIONindicates a potential hazardous situation which, if not avoided, may result in minor or moderate injury.

IMPORTANT indicates a situation which, if not avoided, may cause damage to the machine.

NOTE indicates an additional explanation for information purposes.

ENVIRONMENTAL PROTECTION This Manual also contains this symbol accompanying instructions for correct behaviour as regards environmental protection.

F5041

S9

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SAFETY PRECAUTIONS

FOLLOW SAFETY INSTRUCTION Carefully read and follow all safety signs on the machine and all safety messages in this manual.

Safety signs should be installed maintained and replaced when necessary.

If a safety sign or this manual is damaged or missing, order a replacement from your dealer in the same way you order other replacement parts (be sure to state machine model and serial number when ordering).

Learn how to operate the machine and its controls correctly and safely.

Allow only trained, qualified, authorized personnel to operate the machine.

F1437

Keep your machine in proper working condition.

Unauthorized modifications to the machine may impair the function and/or safety and affect machine life.

The safety messages in this SAFETY PRECAUTIONS chapter are intended to illustrate basic safety procedures of hydraulic excavators. However it is impossible for these safety messages to cover every hazardous situation you may encounter. If you have any questions, you should first consult your supervisor before operating and servicing the machine.

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.

F1440

S10

S SAFETY PRECAUTIONS WEAR PROTECTIVE CLOTHING Wear tight clothing and safety equipment suitable for the job to carry out.

It is necessary to dispose of: • hard hat, • Safety shoes; • Safety glasses, goggles, or face shield; • Heavy gloves; • Hearing protection; • Reflective clothing; • Water-proof clothing; • Respirator or filter mask; Make sure to wear clothing and safety equipment suitable for the job to carry out.

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

F1438

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 noised.

F1439

INSPECT THE MACHINE Inspect the machine carefully every day or work-shift by an attentive visual inspection of machine outside prior to starting it to prevent damages and personal injuries.

In the walk-around inspection, be sure to cover all points detailed in the Chapter MAINTENANCE, paragraph EXTERNAL VISUAL INSPECTION.

F1441

S11

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SAFETY PRECAUTIONS

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.

F1442

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.

F1443

OPERATE ONLY FROM THE DRIVER’S SEAT To start the motor with an unsuitable procedure may cause sudden movement of the machine with possibility to cause serious injuries or mortal incidents.

• Start the engine only from the driver’s seat.

• Do not start the engine by shorting across starter motor terminals.

• Before starting the engine, ensure that all control levers are in the neutral position.

F24052

S12

S SAFETY PRECAUTIONS DONT 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.

F24154

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 working near electric lines, NEVER MOVE any part of the machine or loads at a distance lower than 3 meters plus twice the length (L)of line insulators.

• Perform all checks and behave in compliance with any applicable local regulation.

• Wet ground will expand the area that could cause any person on it to be affected by electric shock.

• Keep all people and/or assistants away from the working area.

L

F24656

S13

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SAFETY PRECAUTIONS

AVOID INJURY FROM REVERSE GEAR AND SLEW ACCIDENTS If someone stands near the machine when this is carrying out slew or reverse-gear movement, the same can hit or run over this person causing heavy injuries or even death.

To avoid reverse gear and slew accidents: Always look around before REVERSE GEAR OR MACHINE SLEW. BE SURE THAT NOBODY IS WITHIN WORKSITE. Keep travel alarm in working condition (if equipped).

F1447

ALWAYS BE ALERT FOR BYSTANDERS MOVING IN THE WORK AREA. USE HORN OR OTHER SIGNALS TO WARN BYSTANDERS BEFORE STARTING MACHINE..

TAKE ADVANTAGE OF A PERSON THAT WATCHES THE REVERSE GEAR IF VISIBILITY IS PREVENTED. ALWAYS KEEP VISUAL CONTACT WITH BYSTANDERS. 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 signaling.

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

F3625

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

Read and understand all instruction for the operation given in this manual.

S14

S SAFETY PRECAUTIONS DIG WITH CAUTION Accidental severing of underground cables or gas lines may cause an explosion and/or fire, possibly resulting in serious injury or death.

Before digging, check the location of cables, gas lines, and water lines.

Keep the minimum distance required by law from cables, gas lines, or water lines. If a fiber optic cable should be accidentally severed, do not look into the end, to avoid eyes injury.

To solve possible doubts, contact local authorities and/ or the Power companies (Electric Power, Gas, Telephone, Water, Telecommunications, etc.). Ask for information about underground utility lines.

F24954

MOVE AND OPERATE MACHINE SAFELY Bystanders are in danger of being run over. Confirm the location of bystanders before moving, slewing, or operating the machine.

Always keep the travel alarm in good working condition. (if equipped). It warns people when the machine starts to move.

Use a signal person when moving, slewing, or operating the machine in congested areas. Coordinate hand signals before starting the machine.

F24657

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.

F1446

S15

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SAFETY PRECAUTIONS

RULES FOR ROAD TRANSFER The machine is equipped with safety locks to be used for road transfer.

When transfer is necessary: • Position the upper structure toward the front swinging axle and insert the anti-rotation lock.

• Locate cylinders as shown in homologation configuration.

• Lock cylinders (cocks, reference marks).

• Lift stabilizers and blade (if equipped).

• Disengage control levers for attachments by shifting lever of safety equipment in lock position.

On the road follow the rules regulating traffic.

F23960

During road transfers always disconnect front axle lock.

INVESTIGATE JOB SITE BEFORE HAND Clear all persons from area of operation and machine movement.

Make sure worksite footing has sufficient strength to firmly support the machine.

When working close to an excavation, operate the machine with che chassis frame positioned perpendicular to the cliff face, so that the machine can more easily evacuate if the cliff face collapses. Confirm that your machine is equipped with a F.O.P.S. (Falling Object Protective Structure) cab before working in areas where there is the possibility of falling stones or landslides.

When digging deeply, avoid hitting bottom of boom or bucket cylinder hoses against the ground.

Use the bucket only for digging.

To avoid accidents, do not use it as a jack hammer or wrecking ball.

F24672

S16

S SAFETY PRECAUTIONS WRONG

TRAVELLING ON SLOPES Never go down on slopes with gearbox in neutral.

You might loose control and cause serious injuries or death.

When going down on slopes, use a low gear. In this way the engine is used as brake and holds the machine without overloading brakes.

When working on a slope and the fuel warning light lights up refuel immediately.

Because of the machine inclination, the engine can suck air and stop immediately putting in great danger the incolumity of the operator and of the downhill bystanders.

F24955

CORRECT

If the engine stops suddenly, apply brakes and lower immediately the bucket to the ground.

F24956

DRIVE MACHINE SAFELY Before starting the machine, read carefully the “use and instructions manual” to get familiar with pedals and levers.

Before moving the machine, confirm which way to move travel pedals/levers for the corresponding direction you wish to go.

When traveling up or down a grade, keep the bucket in the direction of travel, approximately 30 to 40 cm (A) above the ground. If the machine begins to slip or becomes unstable, lower the bucket immediately.

A F24659

S17

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SAFETY PRECAUTIONS

AVOID TIPPING When operating on a slope, keep bucket low to ground and close to machine.

Point chassis frame uphill to avoid tipping.

To avoid tipping: • Be extra careful before operating on a grade.

• Prepare machine operating area flat by grading.

• Keep the bucket low to the ground and close to the machine.

• Reduce machine operating speed to avoid tipping or slipping.

• Avoid changing direction when travelling on grades.

• Never attempt to travel across a grade steeper than 15 degrees.

• Reduce swing speed as necessary when swinging loads.

Be careful when working on frozen ground.

• Temperature increases will cause the ground to become soft and make ground travel unstable.

F24849

AVOID INJURY FROM UNEXPECTED MACHINE MOVEMENT Death or serious injury may result if you attempt to get on or off a moving machine.

To avoid roll-aways: • Select level ground when possible to park machine.

• Do not park the machine on a grade.

• Lower the bucket and/or other work tools to the ground. Thrust the bucket teeth into the ground if you must park on a grade.

• Disconnect Auto/idle switch.

• Run the engine at slow idle speed without load for 5 minutes to cool down the engine.

• Stop the engine and take off ignition key.

• Pull the safety lever to (LOCK) position.

• Block both tracks.

• Position the machine to prevent overturning.

• Park a reasonable distance from other machines.

F24661

S18

S SAFETY PRECAUTIONS PROTECTION OF DRIVING CAB In case of operation of the excavator under conditions where land slides with falling rocks or any conditions where there is a potential falling of objects of different nature that could endanger the operator, it is necessary to install a F.O.P.S. (Falling Object Protective Structure) to protect the cab.

F24660

OPERATE WITH CAUTION If the front attachment or any other part of the machine hits against an overhead obstacle, such as a bridge, both the machine and the overhead obstacle will be damaged, and personal injury may results as well.

Take care to avoid hitting overhead obstacles with the boom or arm.

F24957

PARK MACHINE SAFELY Before working on the machine: • Park machine on a level surface.

• Lower bucket to the ground.

• Move turret swing lever to lock position.

• Run engine at slow idle speed without load for 5 minutes.

• Turn key switch to Oto stop engine. Remove key from switch.

• Pull the safety lever to (LOCK) position.

• Allow engine to cool.

• Close windows, roof window, and cab door.

• Lock all access doors and compartments.

LOCK

F24662

S19

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SAFETY PRECAUTIONS

NEVER UNDERCUT A HIGH BANK The edges could collapse or a land slide could occur causing serious injury or death.

F24663

PROVIDE SIGNALS FOR JOBS INVOLVING A NUMBER OF MACHINES For jobs involving several machines, provide signals commonly known by all personnel involved.

Also, appoint a signal person to co-ordinate the job site.

Make sure that all personnel obey the signal person’s directions.

F3614

CONFIRM DIRECTION WHERE THE MACHINE IS TO BE DRIVEN Instinctive travel pedal operation may result in serious injury and even death.

Before driving the machine, be aware of the undercarriage position relative to the operator’s seat.

If swinging/steering axle is located behind towards the counterweight, the machine will move reverse when control pedal is moved forwards.

F24664

S20

S SAFETY PRECAUTIONS KEEP PERSONNEL CLEAR FROM WORKING AREA A person may be hit severely by the swinging front attachment or counterweight and/or may be crushed against an other object, resulting in serious injury or death.

Keep all persons clear from the area of operation and machine movement.

Before operating the machine, set up barriers to the sides and rear area of the bucket swing radius to prevent anyone from entering the work area.

F24958

NEVER MOVE THE BUCKET OVER ANY ONE Never lift, move, or swing bucket above anyone or a truck cab.

Serious injury or machine damage may result due to bucket load spill or due to collision with the bucket.

F24665

AVOID UNDERDIGGING Never undercut or the footing might collapse.

Before starting to work, make sure of the excavator control direction.

If the footing starts to collapse and if sufficient retreat is not possible, do not panic.

Often, the machine can be secured by lowering the front attachment.

F24666

S21

S

SAFETY PRECAUTIONS

SAFETY TRANSPORT The danger of tipping is present when loading/unloading the machine onto/from a truck or trailer bed.

• Be sure to observe local regulations when transporting the machine on public roads.

• Provide an appropriate truck or trailer for transporting the machine.

Take the following precautions when loading/unloading the machine: • Select firm level ground.

• Be sure to use a loading dock or ramp.

• Be sure to have a signal person when loading/ unloading the machine.

• Always turn the auto-idle switch off when loading or unloading the machine, to avoid unexpected speed increase due to unintentional operation of a control lever.

• Always select the slow speed mode with the travel speed selector.

F24667

In the high speed mode, travel speed may automatically increase.

• Avoid steering while driving up or down the ramps as it is extremely dangerous.

• If steering is unavoidable, first move back to the ground or flatbed, modify travelling direction, and begin to drive again.

• Operate the safety lever but do not operate any other control except travel control when driving up or down the ramp.

• The top end of the ramp where it meets the trailer flatbed is a sudden bump. Take care when traveling over it.

• Prevent possible injuries caused by the from machine tipping over, while the superstructure is slewing.

• Keep the arm tucked under and rotate the superstructure slowly for better machine stability.

• Securely fasten machine frame using chains or cables.

WEDGES BLOCKS RAMPS F5827

Refer to “Transport” chapter in this manual for details.

F23965

F23967

S22

S SAFETY PRECAUTIONS 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 moving parts.

Before servicing the machine, park the machine on a level surface.

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

F1458

If the machine must be raised, keep a 90 to 110° between boom and arm. Securely support any machine elements that must be raised for service work.

Never work under a machine raised by the boom.

Inspect certain parts periodically and repair or replace as necessary.

Keep all parts in good condition and properly installed.

Fix any damage immediately.

Replace worn or broken parts.

Remove any building of grease, oil, or debris.

Disconnect the ground cable (-) from the batteries before servicing electrical systems or welding on the machine.

F5832

F24668

S23

S

SAFETY PRECAUTIONS

KEEP MACHINE CLEAN Keep engine bay, radiator, batteries, hydraulic lines, fuel tank, and operator’s seat clean. Temperature in the engine bay may go up immediately after engine is stopped.

BE ALERT FOR FIRES IN THAT OCCASION. Open access doors to cool the engine faster, and clean engine bay.

F1460

WARN OTHERS OF SERVICE WORK Unexpected machine movement can cause serious injury.

Before performing any work on the machine, apply the “Maintenance in progress” tag (also see chapter SAFETY PLATES). This tag can be applied to the lefthand control lever, safety lever or cab door.

F2431

WASH THE MACHINE REGULARLY Remove any grease, oil or debris build-up to avoid possible injury or machine damage.

Do not spray water or steam inside the cab.

F1462

S24

S SAFETY PRECAUTIONS STORE ATTACHMENTS SAFELY Stored attachments such as buckets, hydraulic breakers, and blades can fall and cause serious injury or death.

Securely store attachments and implements to prevent them from falling. Keep playing children and bystanders away from storage area.

F1463

SUPPORT MACHINE PROPERLY Never attempt to work on the machine without securing the machine first.

Always lower the attachment or tool to the ground before working on the machine.

If you must work on a lifted machine or attachment, securely support the machine or attachment.

Do not support the machine on cinder blocks, bollow tires, or props that may crumble under continuous load.

Do not work under a machine that is supported solely by a jack.

F3634

PREVENT PARTS FROM FLYING OFF Tyres are charged with pressure.

Tyre and/or rim parts burst may result in serious injury or death.

Only skilled staff can replace tyres.

Always keep the correct tyre pressure.

Never exceed the recommended pressure when inflating tyres.

Slow down or stop and let tyres get cool.

When adjusting tyre pressure, keep at a certain distance and protect yourself. Use an extension equipped with a quick connection for the valve handling.

Always stay behind the tyre when adjusting pressure.

F3635

S25

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SAFETY PRECAUTIONS

STARTING THE ENGINE WITH BOOSTER BATTERIES Battery gas may explode causing serious damages and injuries.

If the engine is to be started using booster batteries, ensure to comply with all procedures detailed in chapter OPERATING INSTRUCTIONS. The operator should be sitting in the driver’s seat to keep the machine under control when the engine starts.

Starting the engine with booster batteries is a two man operation.

Do not recharge batteries that have been stored in the cold for a long time as they might explode. Heat them at 15°C.

F1464

Mistakes in following procedures detailed for starting the engine with booster batteries may cause the batteries to explode or machine to move unexpectedly.

PROTECT YOURSELF AGAINST FLYING CHIPS Guard against injury from flying pieces of metal or chips; wear goggles or safety glasses.

Keep bystanders away from the working area before striking any object, to avoid personal injury.

F1466

STAY CLEAR OF MOVING PARTS Entanglements in moving parts can cause serious injury.

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

F1467

S26

S SAFETY PRECAUTIONS PREVENT BURNS After operation, the engine coolant is hot and is under pressure. Hot water or steam are contained in the engine, radiator and heater lines.

Skin contact with escaping hot water or steam can cause severe burns.

Stop engine and let the same cool together with radiator.

Slowly loosen the cap to release pressure after the system has cooled, then remove it.

Engine oil, gear oil and hydraulic oil also become hot during operation.

The engine, hoses, lines and other parts become hot as well.

Wait for the oil and components to cool before starting any maintenance or inspection work.

The hydraulic oil tank is pressurized.

Again, be sure to release all pressure before removing the cap.

F1477

F1469

REMOVE PAINT BEFORE WELDING OR HEATING Avoid potentially toxic fumes and dust.

Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch.

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

Dispose of paint and solvent properly.

If you sand or grind paint, avoid breathing the dust.

Wear an approved respirator.

F1446

If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.

S27

S

SAFETY PRECAUTIONS

AVOID HEATING NEAR PRESSURIZED LINES Flammable spray can be generated by applying heat near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lined or other flammable materials.

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

F1470

AVOID TO HEAT LINES CONTAINING FLAMMABLE FLUIDS Do not weld or flame cut pipes or tubes that contain flammable fluids.

Clean them thoroughly with nonflammable solvent before welding or flame cutting them.

F5840

BEWARE OF FLUIDS UNDER PRESSURE 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 control levers several times.

Tighten all connections before applying pressure.

Wear a shield or protection glasses to protect your eyes.

F3636

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

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

Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result.

F1471

S28

S SAFETY PRECAUTIONS PREVENT FIRES 1. Check for oil leaks: Fuel, hydraulic oil and lubricant leaks can lead to fires that may result in serious injury.

Check for missing or loose clamps, kinked hoses, lines or hoses that rub against each other, damaged oil-cooler, and loose oil-cooler flange bolts, for oil leaks.

Search for leaks with a piece of cardboard. Pressurized fluid leaks can peneetrate skin and cause serious injuries.

Do not use your bare hand to check for oil leaks.

F3638

Tighten, repair or replace any missing, loose or damaged clamps, lines, hoses, oil-cooler and oil cooler flange bolts.

Do not bend or strike high-pressure lines. Never install bent or damaged lines, pipes or hoses.

2. Check for short circuits: Short circuits can cause fires that may result in serious injury.

Clean and tighten all electrical connections.

Check before each shift or after eight (8) hours of operation for loose, kinked, hardened or frayed electrical cables and wires.

Check before each shift or after eight (8) hours of operation for missing or damaged terminal caps.

DO NOT OPERATE MACHINE if cable or wires are loose, kinked, etc.

Tighten, repair or replace any loose or damaged electrical cables, wires, and terminal caps before operating the machine.

3. Clean flammables: Spilled fuel and oils, and accumulated coal dust and other flammables may cause fires and serious personal injury.

Prevent fires by keeping machine clean every day.

S29

S

SAFETY PRECAUTIONS

4. Check key-start switch: If a fire breaks out, failure to stop the engine will escalate the fire, hampering fire fighting.

Always check key-start switch function before operating the machine every day: • start the engine and run it at slow idle; • turn the start switch key to OFF, to confirm the engine stops.

If any abnormalities are found, be sure to repair them before operating the machine.

5. Check heat shields: F1464

Damaged or missing heat shields may lead to fires.

Damaged or missing heat shields must be repaired or replaced before operating the machine.

HANDLE CHEMICAL PRODUCTS SAFETY Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with your machine include such items as lubricants, coolants, paints, and adhesives.

A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques.

Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely.

F1465

Contact your Dealer for MSDS list of chemical products used on machine.

S30

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

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

Do not pour waste onto the ground, down a drain, or into any water source.

F1473

Air conditioning refrigerants escaping into the air can damage the Earth’s atmosphere. Government regulations may require a certified air conditioning service center 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 center, or from your authorized dealer.

PREVENT ACID BURNS Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes.

Avoid the hazard by: Filling batteries in a well-ventilated area.

Wearing eye protection and rubber gloves.

Avoiding breathing fumes when electrolyte is added.

Avoiding spilling or dripping electrolyte.

Use proper jump start procedure.

If you spill acid on yourself: Flush your skin with water.

Apply baking soda or lime to help neutralize the acid.

Flush your eyes with water for 10-15 minutes.

Get medical attention immediately.

F1474

If acid is swallowed: Drink large amounts of water of milk.

Then drink milk of magnesia, beaten eggs, or vegetable oil.

Get medical attention immediately.

S31

S

SAFETY PRECAUTIONS

HANDLE FLUID UNDER SAFETY CONDITIONS - AVOID FIRE SPREAD Handle fuel with great care : it is highly flammable.

Do not refuel the machine while smoking or near open flame or sparks.

Always stop engine before refuelling machine.

Fill fuel tank outdoors.

Store flammable fluids away from fire hazards.

Do not incinerate or puncture pressurized containers.

F1475

Make sure machine is clean of trash, grease, and debris.

Do not store oily rags; they can ignite and burn spontaneously.

F1457

SERVICE MACHINE SAFELY Tie long hair behing you head.

Do not wear a necktie, scarf, loose clothing, or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result.

Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.

F1476

SERVICE COOLING SYSTEM SAFELY Explosive release of fluids from pressurized cooling system can cause serious burns.

Shut off engine.

Only remove filler cap when cool enough to touch with bare hands.

F1477

S32

S SAFETY PRECAUTIONS WORK IN A CLEAN AREA Before starting a job, clean the work area.

Remove objects that may be a safety hazard to the mechanic or bystanders.

F5835

SAFELY ILLUMINATE WORK AREA Illuminate your work area adequately and safely.

Use a portable safety light for working inside or under the machine.

Make sure the bulb is enclosed by a wire cage.

The hot filament of an accidentally broken bulb can ignite spilled fuel or oil.

F1480

USE PROPER TOOLS Use tools appropriate to the work. Makeshift tools and procedures can create safety hazards.

Use power tools only to loosen threaded tools and fasteners.

For loosening and tighening hardware, use the correct size tools. Do not use U.S. measurement tools on metric fasteners. Avoid bodily injury caused by slipping wrenches.

Use genuine spare parts only.

F1479

S33

S

SAFETY PRECAUTIONS

EVACUATING IN CASE OF FIRE If a fire breaks out, evacuate the machine in the following way:

If time is available, stop the engine by turning the start switch key to O. Use a fire extinguisher if there is time.

Exit the machine.

F3638

S34

S SAFETY LABELS SAFETY LABELS 1. Decal, equipment safe area of operation.

2. Decal, counterweight safe area of operation.

2

1

F23969

8. Decal, hooking points.

71433093 I-D

8

F23970

S35

S SAFETY LABELS 3. Decal, no walking.

4. Decal, window lock.

5. Decal, reference to manuals.

6. Decal hydraulic biodegradable oil level check 7. Card, maintenance in progress.

8. Decal, hooking points.

9. Decal controls lock/unlock (safety lever) 10.Decal for engine hood warning.

11.Decal for system bleeding warning 12.Decal for twin tyres warning.

4 BIODEGRADABLE HYDRAULIC OIL

6 5

F24080

Cab inside right

LOCK

9

F24131

Card, maintenance in progress

10

F24132

S36

S SAFETY LABELS 1 - Decal, equipment safe area of operation Make sure that exposed personnel in the area of operation are clear of the machine before moving the machine or its attachments. Sound horn.

Background: yellow Stripe and graphics: black

F2455

2 - Decal, counterweight safe area of operation Make sure that exposed personnel in the area of operation are clear of the machine before moving the machine or its attachments. Sound horn.

Background: yellow Stripe and graphics: black

F24079

3 - Decal, no walking Prohibition of walking on this area.

Ignoring this prohibition could cause damages to the engine cowling, as well as endangering the safety of persons not obeying this rule.

Background: transparent Stripe and graphics: black F2436

S37

S SAFETY LABELS 4 - Decal, window lock It indicates the danger of injury deriving from incorrect block of front windshield in open position.

Background: yellow Edge and graphics: black

F2437

5 - Decal, reference to manuals It is positioned inside the cab to recommend the careful reading of the Operation and Maintenance Instruction Manual prior to proceeding with the starting, operation, maintenance, refuelling or other interventions on the machine.

Background: yellow Stripe and graphics: black

F2456

6 - Decal hydraulic biodegradable oil level check Position indication of biodegradable hydraulic oil level on machine.

Background: yellow Edge and graphics: black

BIODEGRADABLE HYDRAULIC OIL

F25449

S38

S SAFETY LABELS 7 - Maintenance in progress plate It is compulsory, for maintenance operators, to apply a card warning about incomplete efficiency of the machine and the presence of personnel performing maintenance in unseen positions. This card must be located on the left pilot control or the cab door.

Background: yellow Edging and lettering: black Edges: red

F2431

8 - Decal, hooking point 71433093 I-D

Indication of the four hooking points (two on counterweight, two on the lower frame) to be used for towing or lifting the machine.

Background: white Edging and lettering: black

F20305

9 - Decal controls lock/unlock (safety lever) It indicates the position that the safety lever can have when the engine is running.

It is imperative that should the operator abandon the cab with engine running, even for a very short time, the safety lever must be moved to LOCK position. Controls are thereby disconnected and any accidental equipment movement is impossible.

Background: white Stripe and graphics: black

LOCK

F2440

S39

S SAFETY LABELS 10 - Decal for engine hood warning.

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

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

Background: transparent Stripe and graphics: black

F2435

11 - Decal of air bleeding from hydraulic oil pump It indicates that the pumps air bleeding is compulsory at each hydraulic oil change.

Danger of pump seizure.

Background: yellow Stripe and graphics: black

F3536

12 - Decal for twin tyres warning It indicates that tyres have to be deflated before their possible disassembly.

Background: yellow Stripe and graphics: black

S40

1 - SPECIFICATIONS

FEATURES

FOREWORD tions on this matter address to the Sales Dealer or to the Manufacturer’s Headquarters, which are at disposal for any useful information.

This manual has been prepared to assist you in the correct safe procedures for driving, operating and servicing the machine.

Only continuous compliance with the norms herein detailed guarantees best performance, economic operation, and durability of your machine and prevents the commonest causes for accidents which might occur during operation or maintenance.

Particularly, as regards safety, we recommend to carefully read the general safety precautions detailed from the chapter SAFETY PRECAUTIONS. Repair procedures for this machine are contained in specific Service Booklets, which you may obtain from your Dealer upon request.

YY

S

DANGER

YY

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

YY

Each machine is supplied complete with a copy of this Manual. Descriptions and illustrations herein are not binding. The Manufacturer, provided that the basic characteristics of machine types described and shown in this Manual remain the same, reserves the right to change components, parts and accessories supplied without any commitment to timely update this publication; and this any time it deems it convenient for improvement purposes or due to commercial or manufacturing requirements. In order to obtain clarifica-

S

DANGER

YY

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

F23971

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

1-1

FEATURES

IDENTIFICATION DATA

WHEELED EXCAVATOR MARKING TAGS 1.

2.

3.

4.

5.

6.

7.

8.

Machine technical type Homologation number Identification number Machine total mass allowable Max. load on front axle Max. load on rear axle Not applicable Not applicable

9.

10.

11.

12.

13.

Not applicable Not applicable Machine manufacturing year Engine power in kW Absorption coefficient

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

1-2

FEATURES

NOISE LEVELS (2000/14/EC)) SOUND POWER LEVEL WX95 - Lwa = 102 dB (A) 3

WX125 - Lwa = 101 dB (A) Plate (3) shows the guaranteed sound power level, determined in compliance with 2000/14/EC European Standard.

SOUND PRESSURE LEVEL AT THE OPERATOR’S SEAT WX95 - Lpa = 73 dB (A) WX125 - Lpa = 74 dB (A) Sound pressure level continuous, equivalent and average (A) measured in compliance with ISO 6396:1992 on an identical machine with conditioning fan at the maximum operating speed.

The operating speeds (from the 1st to the 4th included) are the speeds suggested for manual selection during a long conditioning operation. They are a compromise for the performances of the system concerning air circulation and sound comfort.

Higher speeds (from the 5th to the 8th included) must be selected (manually) for short periods only and until reaching an acceptable temperature inside the cab.

F23973

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

1-3

FEATURES LEVEL OF VIBRATIONS TRANSMITTED TO THE OPERATOR The level of vibrations transferred to the operator depend mainly on the ground conditions the work is performed, on the machine’s use modes 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; • regularly carry out the maintenance of the operator’s seat: tyre pressure, brakes, steering and levers; • operate the equipment evenly, avoiding sudden motion or excessive shocks, if possible; • adjust the speed and the transfer path, to avoid as far as possible rough terrains or the collision with possible obstacles, so as to reduce the vibration level.

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

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

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

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

1-4

FEATURES

SUMMARY PLATE FOR MAINTENANCE OPERATIONS A summary decal (1) indicating the main lubrication, cleaning and replacement operations to be performed periodically, is located inside the tool compartment.

1 F23976

F23975

Replacement of fuel pre-filter

Replace alternator/fan belt

Lubrication Replace brake system/power control system oil filter Replace reduction gear oil, axle oil and transmission oil Replace engine oil filters Replace hydraulic oil Replace engine coolant Replace oil filter

hydraulic

system

return Replace engine oil

Replace fuel filters Replace air cleaner

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

1-5

FEATURES

WHEELED EXCAVATOR MAIN COMPONENTS

15

10

8

19

12

7

23

9

11

6

24 22 18

14 5

25

4 16

3 17

2 13

1 20

21 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

F23977

Bucket Link rod Linkage Bucket cylinder Arm Arm cylinder Triple articulation arm Fuel tank Boom cylinder Positioner cylinder Counterweight Hydraulic oil tank Wheel assy

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

Rear axle Cab and operator’s compartment Carriage Front axle Blade Boom (lifting) Swinging assy Swing cylinder Hoods Exhaust gases silencer Engine and radiator Main control valve

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

1-6

FEATURES

WX95 TECHNICAL SPECIFICATIONS

DIESEL ENGINE Manufacturer Model Type

CNH / IVECO F4BE0454B* D602 Diesel, 4-stroke, direct injection, turbocharged (turbo) 74 kW 4 in line 3.9 l 102 x 120 mm

Net power at flywheel at 2100 rpm(ISO 14396) Cylinders number Displacement Bore per stroke

ELECTRICAL SYSTEM Operating voltage Batteries (Capacity/Voltage) Alternator (Current/Voltage) Starter motor (Power)

24 V 2 x 100 Ah / 12 V 70 A / 24 V 4 kW

HYDRAULIC SYSTEM Travel/attachment control pump Maximum delivery Maximum power

151 l/min 35 MPa

Upper structure slew control circuit Maximum delivery Maximum power

70 l/min 19 MPa

Hydraulic cylinders (Ø x stroke) Swing Boom Digging Bucket Positioner

95 x 600 mm 110 x 700 mm 95 x 875 mm 70 x 800 mm 105 x 600 mm

TRANSMISSION Type

with variable displacement hydraulic motor and twospeed synchronized gearbox

Travel speed Working I II III Travel I II III

0 ÷ 2 km/h 0 ÷ 5 km/h 0 ÷ 11 km/h 0 ÷ 6 km/h 0 ÷ 15 km/h 0 ÷ 33 km/h

Maximum allowable gradient Working Travel

84 % 19 %

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

1-7

FEATURES

UPPER STRUCTURE SLEW Slew motor Slew brake Final reduction gear Slew bearing Slew speed

at axial pistons automatic operation, disc-type oil-immersed planet reduction in grease bath 8.0 min-1

AXLES Rear axle Front axle Engine Brakes Final reduction gear

steering swinging ± 7° at axial pistons oil bath brake discs oil-immersed planet reduction

BRAKING SYSTEM Service brakes

disc-type, in oil bath, operating on four wheels

Working brake

operating on service brakes and on front axle swing lock

Parking brake

multiple oil bath brake discs, mechanically activated by springs, hydraulic-control disconnection split braking circuit and automatic parking brake connection with engine off

Emergency brake

STEERING SYSTEM Steering mode Steering angle Minimum steering diameter with twin tyre 8.25-20: with steered front axle with both axles steered

2 steering wheels, 4 steering wheels, crab steering 29°

12600 mm 7700 mm

TYRES Twin wheels Individual wheels

8.25 - 20 EM NB-38 14PR 500/45-20

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

1-8

FEATURES

WX125 TECHNICAL SPECIFICATIONS

DIESEL ENGINE Manufacturer Model Type

CNH / IVECO F4BE0484B* D605 Diesel, 4-stroke, direct injection, turbocharged with aftercooler (turbo) 87 kW 4 in line 3.9 l 102 x 120 mm

Net power at flywheel at 2000 rpm(ISO 14396) Cylinders number Displacement Bore per stroke

ELECTRICAL SYSTEM Operating voltage Batteries (Capacity/Voltage) Alternator (Current/Voltage) Starter motor (Power)

24 V 2 x 100 Ah / 12 V 70 A / 24 V 4 kW

HYDRAULIC SYSTEM Travel/attachment control pump Maximum delivery Maximum power

182 l/min 35 MPa

Upper structure slew control circuit Maximum delivery Maximum power

80 l/min 20 MPa

Hydraulic cylinders (Ø x stroke) Swing Boom Digging Bucket Positioner

95 x 600 mm 145 x 740 mm 110 x 1060 mm 95 x 875 mm 120 x 680 mm

TRANSMISSION Type

with variable displacement hydraulic motor and twospeed synchronized gearbox

Travel speed Working I II III Travel I II III

0 ÷ 2.5 km/h 0 ÷ 6 km/h 0 ÷ 11 km/h 0 ÷ 8 km/h 0 ÷ 18 km/h 0 ÷ 33 km/h

Maximum allowable gradient Working Travel

80 % 18 %

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

1-9

FEATURES

UPPER STRUCTURE SLEW Slew motor Slew brake Final reduction gear Slew bearing Slew speed

at axial pistons automatic operation, disc-type oil-immersed planet reduction in grease bath 8.3 min-1

AXLES Rear axle Front axle Engine Brakes Final reduction gear

steering swinging ± 7° at axial pistons oil bath brake discs oil-immersed planet reduction

BRAKING SYSTEM Service brakes

disc-type, in oil bath, operating on four wheels

Working brake

operating on service brakes and on front axle swing lock

Parking brake

multiple oil bath brake discs, mechanically activated by springs, hydraulic-control disconnection split braking circuit and automatic parking brake connection with engine off

Emergency brake

STEERING SYSTEM Steering mode Steering angle Minimum steering diameter with twin tyre 10.00-20: with steered front axle with both axles steered

2 steering wheels, 4 steering wheels, crab steering 31°

12500 mm 8400 mm

TYRES Twin wheels Individual wheels

10.00 - 20 EM NB-38 16PR 600/40-22.5

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

1-10

FEATURES

WX95 OPERATING WEIGHTS Equipment with twin tyres of the type: 8.25 - 20 EM NB-38 14PR Arm (mm) Rear stabilizers

(kg) Front and rear stabilizers

(kg) Blade (kg) Blade and

stabilizers (kg)

1850

9400

9800

9550

9950

2200

9450

9850

9600

10000

WX125 OPERATING WEIGHTS Equipment with twin tyres of the type: 10.00 - 20 EM NB-38 16PR Arm (mm) Rear

stabilizers (kg) Front and

rear stabilizers (kg) Blade (kg)

Blade and stabilizers

(kg)

2000

11850

12350

12050

12550

2350

11900

12400

12100

12600

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

1-11

FEATURES

WX95 DIGGING PERFORMANCE E G

9000

8000

7000

6000

5000

D

C

4000

3000

H

2000

1000

2000

B

1000

B'

F

0

3000

4000

2440

5000

0

1000

2000

3000

4000

5000

6000

7000

8000

9000

6000

A' A

F23978

(Dimensions in mm)

ARM

1850

2200

A

7941

8282

A'

7743

8095

B

3951

4298

B'

3793

4151

C

8066

8397

D

6147

6490

E

2959

3189

F

2138

2403

G

1627

1726

H

3404

3126

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

1-12

FEATURES

WX125 DIGGING PERFORMANCE E G

9000

8000

7000

6000

C

5000

D

4000

3000

H

2000

1000

0

F

1000

B

B'

2000

3000

4000

5000

2440 1000

2000

3000

4000

5000

6000

7000

8000

9000

0

6000

A' A

F23980

(Dimensions in mm)

ARM

2000

2350

A

8668

9008

A'

8474

8824

B

4491

4838

B'

4352

4708

C

8759

9080

D

6201

6510

E

3174

3378

F

2570

2841

G

2027

2190

H

3471

3208

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

1-13

FEATURES

WX95 TRANSPORT DIMENSIONS Version with twin tyres: 8.25 - 20 14PR

(Dimensions in mm) ∆

A

B

C

D

E

F

*G

H

I

L

M

N

O

P

Q

R

1850

2200

535

1115

1485

410

2640

1690

3025

2200

290

3790

980

2200

950

6970

6940

2200

2200

535

1115

1485

410

2315

1690

3025

2200

290

4160

980

2200

950

7340

7310

∆ Arm * With single tyres 500/45 - 20 PR20 Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

1-14

FEATURES

WX95 TRANSPORT DIMENSIONS WITH CLAMSHELL BUCKET Version with twin tyres: 8.25 - 20 14PR

D

H

F L

C

B A

M

G*

N

Q

O

F23990

D

H

F L E G*

A

M

I

C

P

R

F23991

(Dimensions in mm) ∆

A

B

C

D

E

F

*G

H

I

L

M

N

O

P

Q

R

1850

2200

535

1115

1485

410

2940

1690

3025

2200

290

4090

980

2200

950

7270

7240

2200

2200

535

1115

1485

410

2920

1690

3025

2200

290

4210

980

2200

950

7390

7360

∆ Arm * With single tyres 500/45 - 20 PR20 Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

1-15

FEATURES

WX125 TRANSPORT DIMENSIONS Version with twin tyres: 10.00 - 20 14PR

D

H

F L E M

G*

A

I

C

P

R

F23995

(Dimensions in mm) ∆

A

B

C

D

E

F

*G

H

I

L

M

N

O

P

Q

R

2000

2400

500

1155

1670

380

2540

1920

3085

2480

360

4235

1095

2480

1030

7730

7665

2350

2400

500

1155

1670

380

2500

1920

3085

2480

360

4600

1095

2480

1030

8095

8030

∆ Arm * With single tyres 600/40 -22.5 PR16 Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

1-16

FEATURES

WX125 TRANSPORT DIMENSIONS WITH CLAMSHELL BUCKET Version with twin tyres: 10.00 - 20 14PR

(Dimensions in mm) ∆

A

B

C

D

E

F

*G

H

I

L

M

N

O

P

Q

R

2000

2400

500

1155

1670

380

2960

1920

3085

2480

360

4465

1095

2480

1030

7960

7895

2350

2400

500

1155

1670

380

2960

1920

3085

2480

360

4575

1095

2480

1030

8070

8005

∆ Arm * With single tyres 600/40 -22.5 PR16 Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

1-17

FEATURES

WX95 BUCKET USEFULNESS DEPENDING ON ARM ARM (mm)

BUCKET Width

Capacity (dm3) ISO 7451

Mass (kg)

350

96

95

450

135

108

600

193

127

700

237

141

800

280

1850

2200

12345678901234567 12345678901234567 12345678901234567 12345678901234567 12345678901234567

145

General digging work (specific weight of material < 1.8 t/m3) 12345 12345 12345 12345

Slightly heavy digging work (specific weight of material < 1.5 t/m3)

NOTE: The data refer to a machine in transversal-digging position with rear blade in raised position.

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

1-18

FEATURES

WX125 BUCKET USEFULNESS DEPENDING ON ARM ARM (mm)

BUCKET Width

Capacity (dm3) ISO 7451

Mass (kg)

500

232

194

600

297

208

700

364

230

800

433

244

900

503

271

1000

574

285

2000

2350

12345678901234567 12345678901234567 12345678901234567 12345678901234567 12345678901234567 12345678901234567

1234567890123456 1234567890123456 1234567890123456 1234567890123456 1234567890123456 1234567890123456

General digging work (specific weight of material < 1.8 t/m3) 12345 12345 12345 12345

Slightly heavy digging work (specific weight of material < 1.5 t/m3) Loading work (specific weight of material < 1.2 t/m3)

NOTE: The data refer to a machine in transversal-digging position with rear blade in raised position.

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

1-19

FEATURES NOTE:

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

1-20

2 - OPERATING INSTRUCTIONS

OPERATING INSTRUCTIONS

YY

S SAFETY PRECAUTIONS FOR THE MACHINE USE YY

Read carefully this chapter before proceeding with the start, use, maintenance, refuelling operations or other interventions.

Before getting inside the cabin, walk all around the machine to inspect it.

Sound the horn.

S This symbol draws your attention on the items

Keep persons away from the lifted tools to avoid possible damages.

relevant to safety.

It means: WARNING! BE ALERT! INVOLVED.

YOUR

Never attempt to operate the machine or its attachments from any position other than from the driver’s seat.

Under all circumstances keep your head, body, limbs, hands, and feet within the driving area to minimise the risk of exposure to external dangers.

SAFETY IS

Read and observe all safety precautions headed by the key words DANGER, WARNING AND CAUTION.

Check the engine exhaust system for leaks.

Climb on the machine without excessive rush; use the fastening points (handles and steps) which has to be kept clean.

Clean the platform ensuring that it is free from hindrances; possible tools and/or personal objects, not necessary on the machine, must be taken off or firmly fastened.

When working in the darkness, make use of all available lights.

Check also during the day for burnt lamps, if there are some, replace them immediately.

Never leave the machine unattended with the engine running.

This machine and its attachments should be operated exclusively by qualified operators sitting in the driver’s seat.

Before leaving the driver’s seat and after ensuring that nobody is near the machine, slowly lower the attachment to the ground and rest it safely.

The attachment can be lowered by means of the control lever and with the engine running.

Your safety and the safety of those working with you, depends on your care and wisdom in operating the machine.

It is necessary to be thoroughly acquainted with the location and function of all controls and with stability features of the unit before operating it.

Move possible additional tools in the safe retracted position.

Move all controls to the neutral position. Move engine controls in the shutdown position.

Lift the safety control lever to the (LOCK ) position and switch off the switch start-key.

Before starting the machine, adjust and lock the seat to obtain maximum riding comfort and control accessibility.

Never park downhill without securely locking the machine beforehand to prevent any possible movement.

Before moving off or operating the attachments, ensure that nobody is within the machine operating range.

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-1

OPERATING INSTRUCTIONS

CONTROLS AND INSTRUMENTS

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

Safety lever Upper structure slew lock control Start-key switch Travel control pedal L.h. control lever • arm cylinder control • upper structure slew control • control for clamshell bucket left slew • horn control R.h. control lever • boom cylinder control • bucket cylinder control • control for clamshell bucket right slew • stabilizers control • blade control Selection control of steering mode Steering wheel Brake Control Pedal Hydraulik breaker pedal (opt.)

Pedal for articulated arm positioner and swing control Steering column panel Monitor panel Lateral r.h. instruments console R.h. control lever console

19

F24134

16.

17.

18.

19.

Heater/Air condittioner (opt.)

L.h. control lever console Radio (optional) Hour meter

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-2

OPERATING INSTRUCTIONS

SAFETY LEVER The safety lever (1) allows to signal the slew controls locking, the attachment motion and the blade/stabilizers motion.

It may assume two positions: • when in closed position (LOCK), with the machine stationary and the engine running or stopped, it prevents the possibility of machine unexpected movements if the control levers/pedals are accidentally moved.

• in unlocked position open, the safety lever allows the operation of all controls. Therefore, to control and operate the machine, the lever should be moved to this position.

1

2

F24137

To lock the safety device, lift the l.h. console (2) which automatically sets to lock position.

Unlock position W

Unlock by pushing grip (2) of the l.h. console downwards until hooking to the fastening device.

YY

S

YY

2

Before starting the engine, make sure the safety lever is locked (LOCK).

1

YY

S

WARNING

WARNING

YY

When the machine is not operating or whenever you need to leave it, always make sure the safety lever is in the correct position (LOCK).

F24138

Lock position v

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-3

OPERATING INSTRUCTIONS

UPPER STRUCTURE SLEW LOCKING CONTROL The control lever for the slew mechanical locking (1) allows the safe location of the lower structure orientation according to the upper structure.

This is obtained by means of the pin which comes down from upper structure and fits into the corresponding lower structure cavity.

The located orientation is to meet road circulation rules, upper structure front part oriented with lower structure (front part), swinging axle side.

1

The control lever (1) can have two positions: • when in forward position, the pin has come down from the upper structure and is fitted into the corresponding seat of the lower structure; the upper structure cannot slew; • when in back position, the pin remains in the upper structure, and this can slew.

YY

S

WARNING

F19081

Lock position v

YY

For road circulation, slew mechanical locking is compulsory.

2

SLEW LOCK CONNECTION • Locate the upper structure parallel to the lower structure for hole alignment.

• Lower slew lock lever (2).

• Slowly activate the slew control as much as to confirm the locking.

F19082

Unlock position W

START SWITCH KEY-START SWITCH POSITIONS: OFF

- Engine stopped (the key can be removed).

ON

- Engine started and powering of all electrical circuits (even when the engine is stopped).

START - Engine start-up (momentary position: after being rotated to START position, the key returns automatically to position ON).

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-4

OPERATING INSTRUCTIONS

NOTE: after the start-key has been moved to ON, all lamps on the monitor panel illuminate (bulb test) for approximately 3 seconds, with exception of the warning lamps: • low batteries charge • low engine oil pressure which will remain on until engine is started up. If any light does not come on during the CHECK operation, address to Customer Service for monitor replacement.

km/h

15:25

OK

E

F

L

H

C

H

F24093

TRAVEL CONTROL PEDAL

YY

S

WARNING

YY

When the upper structure is turned of 180°, steering control will be opposite.

NOTE: the r.h., l.h., forward, backward, clockwise, counter clockwise indications, refer to the machine travel operation in road transport configuration.

A

MACHINE MOVEMENTS N - Neutral A - Forward motion B - Backward motion

N

B F24112

LEFT CONTROL LEVER ARM CYLINDER CONTROL

A

N - Neutral A - Arm extended B - Arm retracted

N

B

F24001

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-5

OPERATING INSTRUCTIONS UPPER STRUCTURE SLEW CONTROL N - Neutral D - Anticlockwise rotation C - Clockwise rotation

D

N

C

360°

F24002

CONTROL FOR CLAMSHELL BUCKET LEFT SLEW • By pressing button (A) the clamshell bucket will rotate anticlockwise.

HORN CONTROL G

The horn control button (G) is located on the top front of the l.h. control lever and allows use during working steps. (digging and loading).

Press to activate it.

A second horn control is located under the flywheel, r.h. on the gearbox selector.

F24140

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-6

OPERATING INSTRUCTIONS

RIGHT-HAND CONTROL LEVER

YY

S

WARNING

YY

Prevent possible injury to things and persons caused by unexpected machine movements. Make sure to know thoroughly the location and function of each control before operating the machine.

LIFTING/LOWERING CYLINDERS CONTROL N - Neutral E - Boom and arm lowering F - Boom and arm lifting BUCKET CYLINDER CONTROL N - Neutral G - Bucked heaped H - Bucked dumped

CONTROL FOR CLAMSHELL BUCKET RIGHT SLEW • While pressing key (K) the clamshell bucket will rotate clockwise.

STABILIZERS CONTROL Stabilizers control: • Button (C) enables the use of the l.h. stabilizers.

• Button (B) enables the use of the r.h. stabilizers.

• When holding the selected button pressed and when activating the control lever forward (A) the activated stabilizers lower down, when activating the control lever backward (D) the stabilizers lift.

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-7

OPERATING INSTRUCTIONS A switch (3) allows to activate the movement of the front stabilizers.

YY

S

WARNING

YY

The description r.h.or l.h. button refers to machine in digging position.

BLADE CONTROL • With front button (K) you enable blade use.

Keeping button (K) pressed and activating control lever (B) forwards dozer blade lowers, activating the control lever (C) backwards dozer blade raises.

Button (4) allows to activate continuously the dozer blade control by only shifting the control lever. The activation of button (4) stops the control function for boom and arm lifting.

CONTROLS PLATES Control levers plates (1) Indication of the various possible controls when using the (r.h and l.h.) control levers.

Background: transparent Stripe and graphics: black

1 D

B

C

E D

G

K

B

Control pedals plates (2) Indication of the various pedals controls.

Background: yellow Stripe and graphics: black

E

K

RIGHT

+

E

E

C A

A

LEFT

+

+

+

F

+

K

+

F

F

A

G

F D

G

K

LEFT

RIGHT

72116242 I-D

2

F24082

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-8

OPERATING INSTRUCTIONS

STEERING MODE SELECTION CONTROL (OPTIONAL) When on machine are installed two steering axles, three steering modes can be selected by switch (1).

NORMAL STEERING: with this kind of steering, only the front wheels are turned (according to the running direction). When selecting central switch (1) P, warning light (2) comes on. It flashes while selected and is fixed whenever the steering is actuated.

Flashing warning light (2) indicates switching from double or crab steering to standard steering.

1

2

6

5

1

3

6

5

1

4

6

5

F24118

ROUND STEERING MODE: with this steering mode, both the front wheels and the rear wheels turn in the opposite direction (a smaller steering radius is achieved). When selecting switch (1) in R position, warning light (3) comes on. It flashes while selected and is fixed whenever the steering is actuated.

CRAB STEERING: with this steering mode both the front wheels and the rear wheels turn in the same direction (in this way a crosswise transfer is achieved).

When selecting switch (1) in Q position, warning light (4) comes on. It flashes while selected and is fixed whenever the steering is actuated.

YY

S

WARNING

F24119

YY

Do not turn the steering selector before turning ON the start key.

YY

S

WARNING

YY

After selecting the normal steering mode, lower the mechanical protection of the selector.

YY

S

WARNING

YY

F24120

Before starting road transport phase, after the engine start-up, carry out the steering test; • turn the round steering mode switch and the flywheel until the axles are misaligned, • set the steering switch to normal mode and turn the flywheel until the steering is obtained and the rear axle is locked.

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-9

OPERATING INSTRUCTIONS In order to select the required steering proceed as follows: Normal steering mode • select steering by selector (1); • if warning light (5) is not lit (rear axle misaligned), by keeping the steering in round or crab mode, turn the flywheel clockwise or counter clockwise, so as to align the rear axle; • at the same time, until the normal steering mode is engaged, warning light (2) will carry on flashing and simultaneously you will hear the buzzer sound, before warning light (2) sets in fixed mode (steering engaged); • lower protection on selector.

Round steering It is achievable both with normal steering and with crab steering.

• lift the mechanical protection and select the round steering mode; warning light (3) will flash and simultaneously you will hear the buzzer sound searching the steering mode. Turn the flywheel clockwise or counter clockwise until obtaining the alignment of the front axle (warning light (6) on). As soon as the ideal conditions will be verified (front and rear axle aligned) warning light (3) will become steady and the buzzer will stop sounding; • select the round steering mode: warning light (3) will keep on flashing and simultaneously the buzzer sounds, indicating the steering mode search. Turn the flywheel clockwise or counter clockwise until obtaining the alignment of the two axles (warning lights (5) and (6) on). As soon as the ideal conditions will be verified (front or rear axle aligned) warning light (3) will become steady and the buzzer will stop sounding.

Crab steering mode It is achievable both with normal steering and with round steering.

• lift the mechanical protection and select the crab steering mode; warning light (4) will flash and simultaneously you will hear the buzzer sound searching the steering mode. Turn the flywheel clockwise or counter clockwise until obtaining the alignment of the front axle (warning light (6) on). As soon as the ideal conditions will be verified (front and rear axle aligned) warning light (4) will become steady and the buzzer will stop sounding; • select the crab steering mode: warning light (4) will start flashing and simultaneously the buzzer sounds, indicating the steering mode search. Turn the flywheel clockwise or counter clockwise until obtaining the alignment of the two axles (warning lights (5) and (6) on). As soon as the ideal conditions will be verified (front or rear axle aligned) warning light (4) will become steady and the buzzer will stop sounding.

1

2

6

5

1

3

6

5

1

4

6

5

F24118

F24119

F24120

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-10

OPERATING INSTRUCTIONS

COMPATIBILITY BETWEEN TRAVEL SPEED SELECTION AND STEERING MODE

Travel mode

Tortoise

Speed change lever

T

U

Hare

I

II

III

I

II

III

Steering normal

P

Engageable

Engageable

Engageable

Engageable

Engageable

Engageable

Steering round

R

Engageable

Engageable

Engageable

Engageable

Engageable

Not engageable

Steering crab

Q

Engageable

Engageable

Engageable

Engageable

Engageable

Not engageable

NOTE: the third speed is selectable only with NORMAL STEERING (front wheels).

STEERING WHEEL

YY

S

WARNING

YY

When the upper structure is turned 180°, steering control will be opposite.

Knob (2) is fitted on the steering wheel (1). Use this knob for quick turns.

When travelling on rough terrain, be sure to grip the steering wheel firmly with both hands.

If the diesel engine stops during travel, the pump stops feeding the steering control. Steering is always possible but hard. Set the machine as far as possible off the road, remove the start-up key and search for aid.

The horn control button is located under the flywheel, on the right side, on top of the gearbox selector.

For horn activation, press button (3).

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-11

OPERATING INSTRUCTIONS

BRAKE CONTROL PEDAL This machine uses a full-hydraulic brake, supplying large braking force in response to light pressing of the brake pedal (1).

For smooth braking, follow these procedures: • Gradually lift the travel pedal 25-30 meters before the stopping point.

• Lightly depress brake pedal 5-6 m before stop point.

The machine includes two types of braking.

SERVICE, for the use of a car-type braking. It is used to slow down or stop and acts on the four wheels.

WORKING, it is operated when locking the pedal by means of a suitable hook located under the pedal itself, pressing the pedal (1)deeply, to make the machine more stable during digging operations. The same brake automatically ensures the locking of the front steering axle.

F19093

Press lever (2) to release the pedal and to restore braking in SERVICE mode.

F19120

HYDRAULIK BREAKER CONTROL PEDAL OPTIONAL When pressing pedal (3) the activation of hydraulic breaker is obtained.

It is possible to disconnect the pedal by means of a block (4) located in the pedal front part.

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-12

OPERATING INSTRUCTIONS

SWING /POSITIONER OF ARTICULATED ARM CONTROL PEDAL When activating switch (1), pedal (2) is enabled for two different functions: ON: In this position the hydraulic function of swing cylinder control is activated.

ON: In this position the hydraulic function of positioner cylinder control is activated.

It is possible to disconnect the pedal by means of a lock (3) located in the pedal front part.

SWING CONTROL The hydraulic operation for the swing cylinder control is obtained by pressing pedal (2).

N - Neutral F - Attachment anticlockwise slew G - Attachment clockwise slew

POSITIONER CONTROL

YY

S

WARNING

YY

With triple articulation option, the bucket might hit the cab.

• By pressing pedal (B)articulated arm extends.

• By pressing pedal (C), the articulated arm retracts.

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-13

OPERATING INSTRUCTIONS

STEERING COLUMN PANEL

3 1 12

2 7

6

5

8

10

4

9 11

F24142

1.

Horn

2.

Switch • Turning lights • upper beams, traffic beams and parking lights • windscreen wiper, windscreen washer switch

3.

Lever for steering column adjustment

4.

Switch for parking brake, axle lock/unlock

5.

Warning light for axle lock engagement

6.

Warning light for slow speed engagement

7.

Warning light for upper beams switch on

8.

Warning light for parking brake engagement

9.

Warning light for direction indicator switch on

10. Available warning light 11. Available warning light 12. Lever for selection of travel mode

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-14

OPERATING INSTRUCTIONS HORN Horn control button (1) is located on top of the r.h. switch, under the flywheel.

Press to activate it.

A second horn control is located on the l.h. control lever.

1

F19111

SWITCH Turning lights Turn signal switch (2) is used to engage the r.h. or l.h. turning signals.

YY

S

WARNING

2

YY

always use the turning light to advise for direction change, to avoid accidents.

Push lever switch (2) forward to activate r.h.turning signal.

The right turn lights will come on.

Pull lever switch (2) backwards, to activate l.h. turning signal.

The left turn lights will come on.

F19113

2

F19112

Upper beams, traffic beams and parking lights To switch on the lights, press the button located on the lateral r.h. instruments console.

1st click = parking lights.

2nd click = traffic beams.

Pull lever switch (2) down to turn upper beams on.

Lift lever switch (2) up to obtain blinking, the lever switch returns automatically to neutral position when released.

The warning light on the steering column panel indicates that the upper beams are on.

YY

S

WARNING

2

YY

Always use lower beams when following or meeting other vehicles.

F19114

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-15

OPERATING INSTRUCTIONS Windscreen wiper switch, windscreen washer To power the windscreen wiper, turn grip (1); the controls are following: O - Windscreen wiper disconnected I - Intermittent operation II - Continuous operation 1 NOTE: in case of faulty jet, it is necessary to clean the cleaning liquid spraying holes of the nozzle by means of a needle.

IMPORTANT: do not press down the windscreen washer control button longer than 20 seconds. Do not press down the button if the tank is running out of cleaning liquid.

Damage to the windscreen washer motor may ensue.

F25422

Windscreen wiper Blade replacement.

For the replacement of the windscreen wiper blade: • lift the arm outwards; • untighten the fastening nut and replace the blade.

F19147

Windscreen washer Press the button located on the upper part of the l.h. lever under the flywheel.

Spraying nozzles cleaning. in case of faulty jet, it is necessary to clean the cleaning liquid output holes of the nozzle by means of a needle.

IMPORTANT: do not hold down the windscreen washer control button longer than 20 seconds. Do not press down the button if the tank is running out of cleaning liquid.

Damage to the windscreen washer motor may ensue.

Check the detergent level in the relevant tank and fill if necessary.

F19116

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-16

OPERATING INSTRUCTIONS STEERING COLUMN ADJUSTMENT LEVER In order to adjust the position of the steering wheel according to the operator’s needs, pull down lever (3) and change the steering column inclination.

3

PARKING BRAKE SWITCH, AXLE LOCK AND UNLOCK

F19118

Switch (4) has three different positions indicated by a position warning light: • parking brake K (rear axle) • axle lock x • axle unlock X

8

5

4

The warning lights on the steering column panel, indicate the operation of the parking brake, the axle lock and the axle unlock.

Warning lights (8) and (5) light up when the parking brake is engaged.

Warning light (8) lights off when the axle lock is engaged.

Warning lights (5) and (8) light off when the axle unlock is engaged.

NOTE: Axle unlocks after 2 seconds. The engagement is combined with a sound signal. If the slew of the upper structure is performed with axle unlocked, an acoustic alarm sounds, concurrently with the appearance of a symbol on the monitor after 4 seconds, to indicate the danger.

F19119

The hereunder reported table resumes the machine operations according to the switch position during the various operations.

OPERATION POSITION

MACHINE

Brake parking

Locked axle

Attachment

Travel

Connected

Connected

Disconnected

Disconnected

Work with axle locked

Disconnected

Connected

Connected

Connected

Work with axle unlocked

Disconnected

Disconnected

Connected

Connected

SWITCH Parking

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-17

OPERATING INSTRUCTIONS TRAVEL MODE SELECTION LEVER The travel mode selection lever (12) is located on the upper right side of the steering column.

The translation mode selection lever allows to select three speeds for two travelling modes (hare, tortoise), making up six travel ratios.

By activating lever (12) with motion up-down we select: position up tortoise mode (low) position down hare mode (fast).

Warning lamp (6), lights up when low speed is engaged.

YY

S

WARNING

YY

F24092

The speed mode exchange (hare, tortoise) occurs only after positioning the selector (4) brakes switch in the parking position.

YY

S

WARNING

YY

1

During the exchange operation the travel pedal has not to be pressed.

When activating lever (12) in the three positions it is possible to select: forward position - 1st speed central position - 2nd speed rear position -3rd speed

YY

S

WARNING

2

12

6

YY

3

If slopes with a gradient higher than 18% have to be overtaken, position the control lever in the tortoise position (slow).

YY

S

WARNING

YY

In case downhills with a gradient higher than 12% have to overtaken, do not select the 3rd speed hare position.

4

F24141

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-18

OPERATING INSTRUCTIONS TRAVEL MODE WHILE WORKING It is achieved by positioning the lever onT (tortoise), at the same time the warning light (6) lights up.

Speed in Km/h WX95

WX125

I: 0 ÷ 2 II: 0 ÷ 5 III: 0 ÷ 11

I: 0 ÷ 2.5 II: 0 ÷ 6 III: 0 ÷ 11

TRAVEL MODE ON THE ROAD is achieved by positioning the lever on U (hare) at the same time warning light (6) lights off.

Speed in Km/h WX95

WX125

I: 0 ÷ 6 II: 0 ÷ 15 III: 0 ÷ 33

I: 0 ÷ 8 II: 0 ÷ 18 III: 0 ÷ 33

MONITOR PANEL 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

Monitor Monitor functional keys.

Fuel level gauge Braking pressure indicator Diesel engine coolant temperature gauge Diesel engine coolant warning light Alternator warning light Engine oil level warning light Air filter clogging warning light Fuel prefilter warning light Front axle aligned warning light Low diesel engine oil pressure warning light Glow plug preheating warning light Normal steering mode warning light Round steering mode warning light Crab steering mode warning light Front axle aligned warning light

NOTE: for cleaning use a soft cloth dampened with water. Do not use vapour, detergents or alcohol-based products.

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-19

OPERATING INSTRUCTIONS MONITOR It gives the operator the information displayed in the menus: clock, maintenance, Diesel engine speed or revs, language.

MONITOR FUNCTIONAL KEYS They allow to navigate in the control panel menus.

The buttons L and l allow to scroll the menu upwards/ downwards.

OK button, confirms the selection.

E

F

OK

Menu screens Correct operation display which appears after the initial check.

The screen is displayed under following conditions: start-up key in ONposition.

With the diesel engine started and the machine working or travelling, the travel speed (configuration 1), or the engine revs (configuration 2) are displayed.

km/h

rpm

15:25

15:25 F19107

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-20

OPERATING INSTRUCTIONS Press OK to enter the menu, selecting the scrolling keys L, l set the display to configuration (1) with Km/ h, or (2) with revolutions number.

Confirm with OK key to return to the start screen.

Esci

Km/h * rpm

Lingua OK

Set ora * Km/h o rpm

OK

* Km/h rpm OK

F19108

Scrolling the menu by keys L, l select: clock.

The hours start running, set them with keys L, l, confirm with OK, the minutes start running, set them with OK and exit.

Uscita * Orologio

OK

Manutenz.

Km/h o rpm

OK

F19121

Scrolling the menu by keys L, l select: maintenance.

A submenu with frequency is activated, confirm with OK and enter the submenu with specific operations, confirm with OKto exit.

Uscita

Esci * Quotidiano

Orologio * Manutenz.

Km/h o rpm

OK

OK

250 h 500 h

1000 h * 2000 h

OK

2500 h 3000 h

NOTE: The menu display follows exactly the intervals and operations mentioned in the MAINTENANCE chapter.

2000 h * 2500 h 3000 h 3500 h

F19122

Scrolling the menu with keys L, l the following information are selected: language.

A submenu with the menu languages is activated.

Confirm with OK to enter the selected language in the menu.

Orologio Manutenz.

Km/h o rpm * Lingua

Italiano OK

* Francese Inglese

OK

Spagnolo

Francese Inglese * Spagnolo Tedesco

OK

F19123

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-21

OPERATING INSTRUCTIONS Servocontrols switched off.

km/h

15:25

F19125

Locked axle indication during the upper structure slew, it is coupled with a acoustic signal.

km/h

15:25

F19126

Signal of working brake engaged (hooked or pressed) when pressing the travel control pedal. A sound signal warns that the working brake is engaged. km/h

15:25

W

F19127

Signal of parking brake engaged during travel. A sound signal warns that the parking brake is engaged.

km/h

15:25

P

F19128

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-22

OPERATING INSTRUCTIONS Indication of danger: the diesel engine stops within 6 seconds from the signal appearance. An acoustic signal warns about the diesel engine fault.

STOP

F19129

Error signal when reading the engine oil pressure. An acoustic signal warns about the diesel engine fault. A submenu with the error indications is activated. Confirm with OK to enter the display.

Error indicated by the hydraulic pump control unit. An acoustic sound warns about the fault. A submenu with the error indications is activated. Confirm with OK to enter the display.

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-23

OPERATING INSTRUCTIONS FUEL LEVEL GAUGE When the red fuel level warning light (A),comes on with the machine on level ground, this indicates that approximately 30 litres of fuel still remain in the fuel tank.

When the fuel level gauge needle (B) reaches the reference E, the fuel tank is almost empty.

It is therefore necessary to refuel immediately.

BRAKING PRESSURE INDICATOR Pressure gauge (A) allows to read the braking system pressure which must be included between 90 and 150 bar.

If pressure drops below 90 bar, warning light (B) operates, combined with an acoustic sound.

YY

S

WARNING

YY

Check that the brake system operating pressure is correct.

YY

S

WARNING

YY

If the pressure is not correct, have it checked by an after-sale centre.

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-24

OPERATING INSTRUCTIONS DIESEL ENGINE COOLANT TEMPERATURE INDICATOR When starting the engine indicator needle (A) sets at the temperature range bottom.

Let the engine idle for at least 5 minutes. Wait until coolant temperature indicator (A) sets on the green range.

If indicator needle (A) is in the red zone, the working temperature is higher than 105°C. If the temperature rises, warning light (B) comes on. This indicates that the engine coolant temperature is too high.

DIESEL ENGINE COOLANT LEVEL WARNING LIGHT Warning light (6) lights up to indicate that the engine cooling system is running out of coolant.

IMPORTANT: do not shut off the engine immediately if the gauge needle enters the red range and/or the red warning light indicating high coolant temperature and associated buzzer activate. Stop working momentarily and decrease engine speed until the warning light and the buzzer go off and the gauge needle comes back into the green zone. Then, stop the engine, wait a couple of minutes, check for possible clogging in the cooling system, check the coolant level and the tension of the fan control belt.

F24102

ALTERNATOR WARNING LIGHT When the key-start switch is moved to the ON position, the red warning light (7) comes on, but it should go off as soon as the engine is started.

NOTE: a possible delayed extinction of the warning light (7) is allowed only with the engine at low speed.

During machine operation the light switches on to indicate an insufficient load of the batteries.

F24103

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-25

OPERATING INSTRUCTIONS ENGINE OIL LEVEL WARNING LIGHT When fed (start-up key switch on ON) the control panel runs its CHECK, warning light (8) comes on to indicate that operation is correct. It remains lit to indicate that engine oil is missing. Fill if necessary.

If it is blinking, the sensor connection is faulty.

NOTE: the engine oil level check, carried out during the startup CHECK, should not replace the daily inspection.

F24104

AIR FILTER CLOGGING WARNING LIGHT When fed (start-up key ON), the control panel runs its CHECK. Warning light (9) comes on to indicate that operation is correct. During diesel engine operation, warning light (9) comes on to indicate that the air filter is clogged.

Clean or replace the filtering elements.

F24105

FUEL PREFILTER WARNING LIGHT When fed (start-up key ON), the control panel runs its CHECK. Warning light (10) comes on to indicate that operation is correct. During diesel engine operation, warning light (10) comes on to indicate that some water is in the filter.

Clean or replace the filtering elements.

F24106

FRONT AXLE ALIGNED WARNING LIGHT When fed (start-up key ON), the control panel runs its CHECK. Warning light (11) comes on to indicate that operation is correct.

During machine operation, warning light (11) comes on when the front wheels are parallel to the lengthwise axle of the machine.

F24085

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-26

OPERATING INSTRUCTIONS WARNING LIGHT FOR ENGINE INSUFFICIENT OIL PRESSURE When the key-start switch is moved to the ON position, the red warning light (12) comes on, but it should go off as soon as the engine is started.

During machine operation, the warning light (12) comes on, if the engine oil pressure is too low. After 2 seconds, the engine stop symbol is displayed on the monitor for 6 seconds. Then the engine stops. An acoustic signal warns on the fault.

12

F24086

GLOW PLUG PRE-HEATING WARNING LIGHT (OPTIONAL) When fed (start-up key ON), the control panel runs its CHECK. Warning light (13) comes on to indicate that operation is correct, then it switches off; it will remain lit only if the pre-heating system activates.

The system starts operating when temperature is included between +7.5 °C ± 2.5 °C and -33.5± 2.5 °C. Preheating time varies from 10 to a max. of 15 seconds.

Start diesel engine when the light turns off (start-up key on START).

13

F24087

NORMAL STEERING MODE WARNING LIGHT (OPTIONAL) When fed (start-up key ON), the control panel runs its CHECK. Warning light (14) comes on to indicate that operation is correct.

During machine operation, light (14) flashes when the switch is selected in steering mode, the normal steering mode, with not aligned rear axle; remains lit when the switch steering mode is engaged and the rear axle is aligned.

14

F24088

ROUND STEERING MODE WARNING LIGHT (OPTIONAL) When fed (start-up key switch on ON) the control panel runs its CHECK, warning light (15) comes on to indicate that operation is correct.

During machine operation, warning light (15) flashes when the switch round steering mode is selected with front axle not aligned (wait for ideal condition of engagement); it remains lit when the steering mode is engaged.

15

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-27

F24089

OPERATING INSTRUCTIONS CRAB STEERING MODE WARNING LIGHT (OPTIONAL) When fed (start-up key ON), the control panel runs its CHECK. Warning light (16) comes on to indicate that operation is correct.

During machine operation, warning light (16) flashes when the switch crab steering mode is selected with front axle not aligned (wait for ideal condition of engagement); it remains lit when the steering mode is engaged.

16

F24090

REAR AXLE ALIGNED WARNING LIGHT (OPTIONAL) When fed (start-up key ON), the control panel runs its CHECK. Warning light (17) comes on to indicate that operation is correct.

During machine operation, warning light (17) comes on when the rear wheels are parallel to the lengthwise axle of the machine.

17

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-28

F24091

OPERATING INSTRUCTIONS

RIGHT HAND INSTRUMENTS PANEL 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

Emergency light switch Swing/positioner switch Rotating light switch (opt) Load limiter alarm switch Working light switch Road light switch (parking lights/traffic beams) Switch for memory function.

Manual accelerator control Auto-idle switch Switch for power steering control lock/unlock Switch for blade even motion.

Contemporary stabilizer switch (opt) Switch (available) Switch (available)

NOTE: use a moistened rag to clean the control panels and the switches, to avoid damaging the surfaces.

EMERGENCY LIGHT SWITCH IMPORTANT: when the engine is stopped and the emergency lights switch (1) remains connected for a long time, the battery can discharge.

1

Press the switch (1) to turn on emergency lights on.

Use the emergency lights to indicate a fault or emergency and when the machine temporarily stops on the road.

F19144

SWING/POSITIONER SWITCH When activating switch (2) the swing operation is switched with the hydraulic breaker operation.

When the road lights switch activates, the relevant warning light on the control, lights up.

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-29

OPERATING INSTRUCTIONS ROTATING LIGHT SWITCH (OPTIONAL) Activating switch (3) the rotating light comes on.

The control engagement is indicated by a warning light.

When the road lights switch activates, the relevant warning light on the control, lights up.

IMPORTANT: it is compulsory to operate the flashing light devices during the transfer on the road.

LOAD LIMITER ALARM SWITCH When activating switch (4) the alarm system for max. load liftable is engaged/disengaged.

The control engagement is indicated by a warning light.

When the road lights switch activates, the relevant warning light on the control, lights up.

If the maximum liftable limit of the machine is exceeded, an acoustic signal activates.

WORKING LIGHT SWITCH Switch (5) can have the following positions: • OFF position: both lights switch off.

• position 1: the equipment working light (A) switches on; The control engagement is indicated by a warning light.

When the road lights switch activates, the relevant warning light on the control, lights up.

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-30

OPERATING INSTRUCTIONS ROAD LIGHT SWITCH Switch (6) can have the following positions: • OFF position: all the road lights switch off.

• position 1: the general lights switch on (front and rear parking lights); • position 2: the front traffic beams switch on (upper beams only if the control on the steering column has been activated); The control connection is signalled by a warning light.

SWITCH FOR MEMORY OPERATION Operate switch (7) to store the engine revolution number set with the potentiometer. Store by pressing switch (7) for 5 seconds. Once the control has been memorized, the warning light comes on.

Once the memorization has been performed, at each button activation the operation activates/deactivates.

When the road lights switch activates, the relevant warning light on the control, lights up.

7

F19171

MANUAL ACCELERATOR CONTROL The engine speed control knob (8) is used to increase or decrease engine rpm: • turn it completely clockwise: max. engine rpm; • turn it completely counterclockwise: min. engine rpm.

8

F19153

AUTO/IDLE BUTTON (auto/idle) With the start-key switch on position ON, press A/I (9) button to bring the engine rpm to the set auto/idle. This rpm is achieved in about 4 seconds provided that the servo controls are in the neutral position.

Press the control button (9) and the indicator light on the monitor panel lights up. Press the button again to disengage the auto-idle mode. The indicator light will go off at the same time.

When the road lights switch activates, the relevant warning light on the control, lights up.

9

F19154

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-31

OPERATING INSTRUCTIONS POWER STEERING CONTROLS LOCK UNLOCK SWITCH The activation of switch (10) is indicated on the monitor and the operation of both control levers is inhibited.

The control connection (UNLOCK) is indicated by a warning light.

The control connection (LOCK) is indicated by the symbol of a padlock on the monitor.

When the road lights switch activates, the relevant warning light on the control, lights up.

10

F19155

CONTINUOUS BLADE BUTTON (OPTIONAL) When operating switch (11) the stabilizer blade can be evenly lowered/raised whether it is positioned on the machine front or on the rear.

The control engagement is indicated by a warning light.

When the road lights switch activates, the relevant warning light on the control, lights up.

11

F19156

FRONT STABILIZERS SWITCH (OPTIONAL) When activating button (12) the lowering/raising of the front stabilizers is enabled.

The control engagement is indicated by a warning light.

When the road lights switch activates, the relevant warning light on the control, lights up.

SWITCH (Available switch)

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-32

OPERATING INSTRUCTIONS

HEATER AND AIR CONDITIONER (OPTIONAL) CONTROLS 1.

Monitor It displays the adjustments typed in with the controls and the operating conditions of the system 2. Ventilation It increases the air flow fan speed 3. Ventilation It decreases the air flow fan speed 4. Adjustment button + It increases the set temperature 5. Adjustment button It decreases the set temperature 6. Air distribution button Direct flow and rear flow setting 7. Air distribution button Direct flow, rear flow and under the seat flow setting 8. Air distribution button Setting of defrost flow and flow under the seat 9. Air distribution button Defrost flow setting 10. Outside temperature button (for 2 seconds) It displays the outside temperature 11. Automatic run It runs automatically the ventilation intensity adjustment, thus saving on consumption. It also allows the disconnection of the compressor (press the control twice) 12. Air recirculation It closes the flow of the outside air intake, thus avoiding cab pollution

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-33

OPERATING INSTRUCTIONS AIR CONDITIONING SENSORS 1.

2.

3.

Sun sensor Outside temperature sensor (near horn) Inside temperature sensor

HEATING / COOLING AUTOMATIC AIR CONDITIONING • Press buttons (4) and (5) to set the desired temperature. Press button (11) for automatic air conditioning setting.

• The system will set on the wished position by adjusting the distribution and ventilation automatically.

(If air conditioner is not installed the min. temperature achievable is the outside one).

4

5

11 F19164

DEFROST • Press button (9) for more than 2 seconds. Afterwards the ventilation will set at maximum speed for 2 minutes, thus enabling the operation.

F19165

ADVICES FOR THE BEST USE To obtain a quick cooling: If the machine has been exposed to the sun rays for a long time, the cabin temperature can reach very high values.

For fast cooling, open the side windows and door while ventilating cab inside.

After starting the engine, set the automatic procedure described above. Close the windows and the door.

F24146

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-34

OPERATING INSTRUCTIONS If windows become misted: If inner cab windows become cloudy during rainy days or in very humid conditions, activate the air conditioner to reduce humidity level in the cab.

When atmosphere is very damp and the air conditioner has run excessively, outer windows may become misted. If this happens, switch off the air conditioner to balance outside and inside temperature.

Error signals on the display: F19167

ERROR CODE OPEN CIRCUIT

SHORT CIRCUIT

Cab inside temperature sensor First sensor for treated air temperature Second sensor for treated air temperature Outside air temperature sensor Sun sensor Mixer jammed Wrong connection on mixer wires Error on PWR (over temperature)

F25452

Check: Periodically check the inner and outer filters of the air conditioning system.

In order to protect each compressor part from lubrication lack during a period of scarce use (e.g.: in winter), it is necessary to let the air conditioner run at least once a month for several minutes with engine at low rpm.

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-35

OPERATING INSTRUCTIONS

L.H. CONTROL LEVER CONSOLE 1.

2.

Cigarettes lighter Ashtray

CIGARETTES LIGHTER Press the control button (1); after approximately 20 seconds the button returns automatically to the original position and the lighter is ready to be pulled out and used.

YY

S

WARNING

YY

The cigarette lighter attains very high temperatures.

Always handle it with care: fire and burn hazards.

F19169

NOTE: The cigarette lighter seat can be used as a power socket for 24V-operated equipment, max. 180W.

ASHTRAY

2

Pull the opening tongue (2) until hearing a locking click: the ashtray is ready for use.

NOTE: the ashtray can be removed (to be emptied) after releasing the inner spring.

F19170

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-36

OPERATING INSTRUCTIONS

RADIO (OPTIONAL)

CONTROLS 1.

2.

3.

4.

5.

6.

7.

8.

9: 10.

11.

12.

13.

Preselection button Preselection button Preselection button Preselection button Preselection button TA: short press, activation/deactivation AF: long press, activation/deactivation Modes selection sound/audio Short press: Switching on and activation or cancellation of audio deactivation Long press: switching off Volume knob: press upwards or downwards to set the volume, setting of audio mode selected Tuner mode short press: automatic upwards/downwards search Long press: upwards/downwards manual search RDS: long press, activation/deactivation AST: automatic memorization Short press: to select the band Display

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-37

OPERATING INSTRUCTIONS PROTECTION CODE

set, keep the key pressed until display shows CODE and you hear a beep. The code protection is now active.

If the protection code is active, each time the set is switched on, on the display shows for some seconds CODE.

If the set has to be sent for repair: • Deactivate Code Protection (as described above), or write protection code on a label and attach it to the set. After repair, remove the label from the set.

If the protection code has been activated and the supply is cut-off, the set deactivates the audio and the display shows CODE (anti-theft device).

NOTE: Code protection is deactivated ex-works.

Code input: (indicated on the Safety card, e.g. 4359): Operation Display • Open the set CODE • Press preselection key (1) 0--- Enter the first code digit 4--With key (10) o • Press again preselection key (1) 4--- Enter the second code digit 43-With key (10) o • Press again preselection key (1) 430- Enter the third code digit 435With key (10) o • Press again preselection key (1) 4350 - Enter the fourth code digit 4359 With key (10) o • Press again preselection key (1) • If the correct code was entered, the set gives a beep and the will function normally.

• If a wrong code is entered, the set sends an error beep. The display shows WAIT.

AUDIO ON /OFF Press key (8) to switch on the set, press for more than 2 seconds to switch off the set.

Volume • Press volume button up/down to adjust the volume.

Always make sure you can still hear traffic (horns, sirens...)

Mute (silence) Short press key to mute or cancel the mute (silence).

NOTE: the silence period may be interrupted by alarm or traffic messages (if TA is switched on).

Sound Whether you listen to Jazz, Pop, Classic or Rock music, or to Vocal programmes key (7) is the best solution.

• Press key (7) and then the sound button to select the bass / trebles for your own sound style, or adjust the settings with volume up / down buttons to select the preferred audio styles: - BASS-TRE: Your own personalized settings of bass and treble.

- FLAT: Original - JAZZ: Jazz music - VOCAL: Speech - POP: Pop music - CLASSIC: Classic music - ROCK: Rock music

This means that a waiting period has started: 1. Do not switch-off the set while the display shows WAIT (The waiting period will start all over again when the set is switched on.)

2. Wait until the display shows CODE. This indicates that waiting period has finished.

3. Enter correct code as described in Entering the code.

The waiting period doubled each time an incor rect code is entered (1 minute, 2 minutes, 4 minutes, etc...).

Deactivation of Code Protection: 1. While keeping key (10) pressed, switch on the set, keep key pressed until an beep is heard.

2. Enter correct code as described in Entering the code. Two beeps are sent to indicate that code protection has been deactivated.

If a wrong code is entered, you have to follow the same procedure as described in Entering the code.

Activation of Code Protection: • While keeping the key pressed (10) , switch on the

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-38

OPERATING INSTRUCTIONS Audio setting • Press key (7) to select the desired audio mode.

• Adjust the settings with the volume up/down buttons: - Sound style: (BASS-TRE, FLAT, JAZZ, VOCAL, POP, CLASSIC, ROCK) - BASS: (Low notes) - TREBLE: (High notes) - BALANCE: (Left-right) - FADER: (Rear-front) - LOUD: (OFF, LOW, MID, HIGH) • Press the volume key to adjust the selected audio mode. After 5 seconds the display goes back to the last operating mode. Adjustment of Bass and Treble setting is only possible when BASS-TRE is selected as the sound style.

Automatically storing stations (AUTO-STORE): You can automatically store 5 strongest FM stations on the FM AST band or 5 strongest MW (AM) stations on the MW(AM) AST band. When you use Auto Store, the new stations replace any stations previously stored in the FM AST band or the MW(AM) AST band.

• Press key (11) AST to activate autostore - The set gives a beep and then mutes - When it has finished, you hear a beep followed by the station stored on preset 1 - Sometimes it may not be possible to find 5 stations

RADIO DATA SYSTEM (RDS) More and more stations broadcasts RDS informations in order to offer you many advantages including: • Program Service Name (PS) Allows the radio to display the name of the station instead of its frequency.

• Automatic Retuning (AF) The set remains tuned to the current station by continually searching the best alternative frequency for best reception.

WAVEBAND SELECTION Press key (12) to select the desired band: FMI, FM II, FM AST, LW, MWAST (AMAST), MW I

STATIONS SEARCH AND MEMORIZATION Automatic search Use this function to automatically search for a station.

• Press key (10) to tune to a lower frequency station or to an higher frequency.

- To search for another station, press the key again.

NOTE: You can switch AF off.

Activate/Deactivate AF: This set continuously search for other alternative frequencies for the tuned radio station and automatically selects the best frequency for reception. Long press for more than 2 seconds to activate/deactivate AF. Long press (6) for more than 2 seconds to activate/ deactivate AF.

Manual tuning (only if you know the frequency of the requested station).

• To switch to manual tuning: Long press the search button or for more than 2 seconde will switch the tuning to manual tuning.

• Then press to tune to a station of a lower frequency or to a higher frequency.

• When keys are released, a time-out start to count.

After 5 seconds, display shows Auto for one second and return to automatic search.

Alarm messages (PTY alarm): This set automatically receives emergency messages made by the broadcaster.

• During the messages the display shows ALARM and the station name alternately.

Preselected stations Manually storing stations in a preset: Five stations per band can be stored and recalled using the preset keys (from 1 to 5).

• Tune in to the desired station.

• Press the desired preset key (1-5) for more than 2 seconds to store the current tuned station.

When storing an FM station, the current Program Station Name and the AF mode are stored on the preset (Some stations use alternating Program Service Name).

Traffic announcements (TA): You can activate the TA modes to give priority so as to hear traffic announcements (even if you play a cassette*/CD* or mute the set).

Activate/Deactivate TA: • Short press key (12) to select an FM band.

• Press key (6) to activate/deactivate TA. If you active TA mode: • You will hear the Traffic Announcements when broadcast by station (even if you play a cassette*/ CD* or mute the set).

• If the tuned station does not enable the reception of Traffic Announcements, the display shows NO TA. The radio automatically searches an appropriate station.

Stored station recalled: • Press the desired preset key (da 1 a 5) to recall the stored station

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-39

OPERATING INSTRUCTIONS Interrupting Traffic Announcement mode qif you do not wish to continue listening to a particular Traffic Announcement about traffic condition: • Short press key (6) to interrupt Traffic Announcement without switching off the mode.TA. - The set will return to the previous operating mode.

Radio Cannot tune to desired station.

• Check that the aerial is fully extended and properly connected.

• Check that the negative terminal (brown lead) is connected to earth (vehicle chassis).

• Desired station is too weak, try Manual Tuning.

NOTE: You can switch off RDS feature if not required.

Poor tuner reception.

• In some vehicles there is an active aerial on the roof that needs a 12 Volt supply. Please ask your dealer to check whether a 12 volt is supplied to the antenna.

Please ask your dealer to check whether a 12 volt is supplied to the antenna.

• Long press key (11) to switch off RDS. - All RDS related features e.g.,TA, etc. will be deactivated when RDS is switch off.

Display shows frequency (not station name).

TROUBLE SHOOTING • Set is tuned to non-RDS station.

• RDS function is switched off.

There may be times when you suspect that your car radio is not functioning as you would expect. Before calling for service, please read the operating/installation instructions and review the following checklists.

You may find that an apparent malfunction can easily be rectified.

If you still have to send your set for service, always send the complete set (with detachable panel).

Do not try to open the set to service it yourself.

Radio mutes momentarily while display shows SEARCH and station name/frequency alternately.

• Set is checking a list of Alternative Frequencies (AF) for the tuned radio station as reception is weak. In case no AF is transmitted for the tuned station, switch off AF. Display shows NO TA, and set beeps at intervals.

• The tuned station becomes too weak to enable the reception of Traffic Announcements. Use search tuning to find another station.

• If the TA mode is switched on, search tuning only selects stations which enable the reception of Traffic Announcements.

Sound Set does not function. No display.

• Check fuse (set and vehicle) and connections.

• Check the operating voltage.

Set functions but no sound.

• Adjust the volume of the set.

• Check fader and balance settings.

• Check aerial and its connection.

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-40

OPERATING INSTRUCTIONS AUXILIARY SOCKET 12 V This socket is used for 12V electrical accessories absorbing up to 180 W. With the engine stopped, batteries run down. The electromagnetic compatibility of the additional electrical users, for example fridges, fans, etc., should comply with DIN WDE40839 standard, otherwise the operation of the excavator may be compromised.

NOTE: this socket operates only if car radio is installed.

F20098

HOUR COUNTER The hour counter (1), located near the floor in the l.h. side console, records the machine working hours.

1 NOTE: the first digit (black digit on white field) shows hour tenths (6 minutes).

F24147

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-41

OPERATING INSTRUCTIONS

OPERATOR’S SEAT ADJUSTING THE OPERATOR’S SEAT MECHANICAL SEAT Prior to setting the machine in motion, adjust and lock the seat in the correct position, to guarantee maximum driving comfort and maximum control accessibility.

Seat adjustment to operator’s weight Seat suspension is adjusted by turning the knurled knob (1).

Set the scale according to the Operator’s weight for optimum ride comfort.

Seat fore-aft adjustment Two types of fore-aft adjustment are available for the Operator’s seat (forwards-backwards), as follows: • move lever (2) to adjust seat distance from side levers; • move the lever (3) to adjust the distance of both seat and side levers from the control pedals.

Seat angle and height adjustment Move the lever (4) and adjust seat angle and height by moving your body back and forth. Release the lever to lock the seat.

F19172

Backrest adjustment The backrest inclination relative to seat cushion is adjusted by moving the lever (5).

Armrest adjustment The armrest angle relative to the backrest is adjusted by turning the armrest controls (6) (one per armrest).

5

6

4

6

NOTE: in case the previous adjustments are insufficient to obtain driving comfort and easy control access, a further three-point adjustment (7) varies control lever angle with respect to the seat.

2

1

3

7

F20192

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-42

OPERATING INSTRUCTIONS

CAB DOOR NOTE: in addition to starting up, the start-up key is also available for following functions: • open/close door; • open/close tool box door; • open/close l.h. side door; • open/close the fuel tank plug; • open/close r.h. back door; • open/close the oil tank plug; • open/close l.h. back door;

1

F20088

OPENING THE DOOR FROM THE OUTSIDE When the door is unlocked, press button to open the door and pull the handle outwards (1).

CLOSING THE DOOR FROM THE OUTSIDE 2

Close the door and turn the key in the lock.

OPENING THE DOOR FROM THE INSIDE Pull the opening lever (2).

F20089

UNLOCKING THE DOOR FROM INSIDE NOTE: in order to keep the door open during the machine operation, it is necessary to open it until you hear one click, signalling the door automatic hooking with the cabin.

3

Release the door using the lever (3).

F24149

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-43

OPERATING INSTRUCTIONS

FRONT WINDSCREENS AND WINDOWS OPENING/CLOSING THE SLIDING FRONT WINDSCREEN To close the windscreen, untighten pins (1) of the rear fastening devices.

The windscreen wiper will automatically locate into the bracket on the cab outer post when the right-hand lock pin is released.

By means of handle (2), let the windscreen slide in the relevant guides of the cabin frame, until automatic hooking of the rear lock devices is obtained.

YY

S

WARNING

1

2

1

YY

F20091

Always ensure that the windscreen is safely locked into the rear retainers.

To close the windscreen, untighten pins (1) of the rear retainers.

By means of handle (2), let the windscreen slide in the relevant guides of the cabin frame, until the automatic hooking of the locking pins (1) of the front retainers is obtained.

YY

S

CAUTION

YY

Always make sure that the lock pins are securely engaged into the front retainers.

1

2

1 F20092

REMOVING/INSTALLING THE FRONT LOWER WINDSCREEN To remove the front lower windscreen (3) (after opening the sliding windscreen as described above), lift it and remove it. Place it on the suitable bay behind the operator’s seat.

Reposition the front lower windscreen and reinsert it correctly, so that it leans against the lower retainers.

YY

S

CAUTION

3

YY

Always make sure it engages with the lower retainers.

F20093

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-44

OPERATING INSTRUCTIONS OPENING/CLOSING THE DOOR WINDOW Release the locks (1) to open the sliding window pane.

Close the window pane by moving it back to its previous position until the locks (1) automatically engage in their seats.

1 4

F20094

CAB ACCESSORIES FRONT SUN CURTAIN 3

By pulling the guide (3) the curtain extends, and then it locks automatically in the required position; close it by disengaging the red retaining lever (2); use guide (3) to facilitate closing.

2

F20095

UPPER SUN CURTAIN When pulling hooks (4) the curtain extends. It can then be hooked with the window pane front pillar; unhook the curtain to facilitate closing.

4

F20096

UPPER CEILING LIGHT The upper ceiling light is always lit when the cab door is open; to light it up with cab door closed, press on the ceiling light frame (5).

The ceiling light has three different positions: • always lit; • on with the door open; • always off.

5

F20097

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-45

OPERATING INSTRUCTIONS LOCATION OF FIRE EXTINGUISHER In order to avoid accidental fire spread on the machine, we recommend always keeping on board a portable fire extinguisher, preferably inside the cabin.

The location suggested for the fitting of the fire extinguisher holder is located on the right rear cabin pillar.

1

F20099

ESCAPE ROUTES If the cab door cannot be opened (due to an accident occurred while working), recommended escape routes are the following: • opening of the front sliding windscreen.

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

YY

S

WARNING

YY

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

MIRRORS The machine is equipped with mirrors to guarantee the operator’s comfortable and wide view.

YY

S

WARNING

YY

Before operating with the machine, adjust mirrors for a better visibility.

NOTE: before the machine transport, remove the rearview mirrors or position them within overall dimensions.

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-46

OPERATING INSTRUCTIONS

FASTENING POINTS In order to climb, or to dismount from the cabin, or in order to move outside the machine during standard checking operations, always make use of fasteners (handles and steps), as shown in the pictures.

YY

S

WARNING

YY

Always use the grab rails and steps provided on the machine: danger of accidental fall.

F20103

F24014

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-47

OPERATING INSTRUCTIONS

MACHINE USE Prior to starting the machine carefully read all procedures and precautions contained in this Operation and Maintenance Instruction Manual.

YY

S

DANGER

YY

Do not run the engine in closed spaces without proper ventilation and when no adequate systems allowing lethal exhaust gases discharge are provided.

YY

S

WARNING

YY

Before starting the machine or operating its attachments, ensure that all bystanders are clear of the machine operating range. Before mounting on the machine, carry out an inspection all around it. Sound the horn.

Before starting the machine, adjust and lock the driver’s seat in the most suitable position, to allow maximum riding comfort and control accessibility.

Never park downhill without securely locking the machine beforehand, to prevent any possible movement.

Before leaving the driver’s seat and after ensuring noone is near the machine, slowly lower the attachment until it rests safely onto the ground. Move possible additional tools in the safe retracted position.

Always stop the engine before leaving the driver’s seat.

Each time you stop working with the machine for whatever reason, ensure that all controls are in the neutral position and that the safety lever is set at stroke end, in vertical locked position (LOCK).

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-48

OPERATING INSTRUCTIONS

REFUELLING

YY

S

WARNING

3

YY

The fuel is flammable. Do not puncture or burn fuel containers.

Follow instructions given on the containers as regards storage and distribution.

Following the presence of highly flammable vapours, extinguish all smoking materials and open flames before checking the fuel level, refuelling, replacing the filters or opening the drain plug.

Do not refuel the machine while the engine is running.

Do not use matches, cigar lighters or torches as a light source on the machine.

NOTE: refuelling should be performed by means of decanted fuel. Transfer fuel from the storage container to the machine tank by using the electrical pump (upon request).

We advise to fill the tank at the end of the working day, to prevent condensation formation overnight.

Check that the tank does not run out of fuel, because this would cause air seepage in the fuel system and air should then be bled from the fuel tank.

3

2

1

4

F24155

• Open door (3).

• Verify the fuel level by means of indicator (1) located on the tank (4) side.

• Open the filler neck (2) by using the key supplied and refuel.

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-49

OPERATING INSTRUCTIONS

CHECKS BEFORE ENGINE START-UP 1

CONTROLS CHECK Ensure that the safety lever (1) is locked (see paragraph “INSTRUMENTS AND CONTROLS” in this Chapter).

Ensure that all controls (control levers and pedal/lever assemblies) are in neutral position.

Ensure that the engine speed hand control (2) is turned fully anticlockwise (minimum engine speed).

2

F24156

INSTRUMENT CHECKS After the start-key has been moved to ON, all lamps on the monitor panel illuminate (bulb test) for approximately 3 seconds, except the following warning lamps: • low charge battery warning light (1) • low engine oil pressure warning light (2) which will remain on until engine is started up.

F24107

START SWITCH Start switch positions: OFF

- Engine stopped (the key can be removed).

ON

- Engine started and powering of all electrical circuits (even when the engine is stopped).

START - Engine start-up (momentary position: after being rotated to START position, the key returns automatically to the previous position ON).

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-50

OPERATING INSTRUCTIONS

STARTING THE ENGINE

YY

S

WARNING

YY

The engine must be started exclusively from the driver’s seat.

Before starting the engine, make sure that the safety lever is in vertical (LOCK) position.

When the checking phase is over, before start-up, the following should be performed. (See the instructions detailed in the previous paragraph.)

• Turn the start key to position ON. • Move the start key to position START. After releasing, the key will automatically return to position ON. IMPORTANT: avoid insisting on starting-up for a long time. When the machine does not start-up, return key to position OFF and wait for at least 30 seconds before repeating the start-up procedure.

CHECKS AFTER ENGINE START-UP Check that: • Let the engine run at low speed for at least 5 minutes and wait until coolant temperature indicator (1) reaches the green zone.

• warning light (3) for insufficient battery load is switched off. A possible delayed extinction of the warning light is allowed only while the engine is running at low speed.

• all warning lights which were on during the check phase must now be off.

• the noise and the engine exhaust gases are to be considered a normal condition.

IMPORTANT: If the warning lights do not go off after start-up, immediately stop the engine and investigate the causes.

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-51

OPERATING INSTRUCTIONS

STARTING THE ENGINE AFTER PROLONGED STORAGE If the machine has been stopped for a long time, it is necessary to bleed air from the fuel system, as follows: • untighten bleed screw (1) on the rear side of the fuel filter to let air bleed; • repeatedly press the button (2) located on the priming pump to let the fuel circulate into the system.

• continue priming until a minimum amount of fuel, free of bubbles, comes out of the loosened bleed screw (1). Close the screw; • then perform the engine start-up.

WARM-UP IN COLD WEATHER CONDITIONS IMPORTANT: when hydraulic oil is cold, hydraulic functions move slowly.

Do not attempt normal machine operation until hydraulic functions move at close-to normal cycle times.

After completing warm-up operation, extend the bucket cylinder and keep the control operated for several seconds (no more than 30 seconds) at stroke end.

F24020

Retract the bucket cylinder and keep the control operated for several seconds (no more than 30 seconds) at stroke end.

Slowly operate the arm and boom cylinder a few times.

Operate travel and swing functions slowly. Cover short distances at the beginning.

Repeat the above procedures until the bucket cycle time is normal. In extremely cold conditions, extend the warming-up period by running the engine at medium speed.

Also after an accurate heating, the travel function can have a slow reaction for a certain period, due to the low temperature of the axles and transmission lubricants, and not because of possible inconvenients.

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-52

OPERATING INSTRUCTIONS

STARTING THE ENGINE USING BOOSTER BATTERIES

YY

S

WARNING

YY

Explosive gas is produced while batteries are in use or being charged. Keep open flames and/or sparks away from the battery charging area. Charge the batteries in a properly ventilated area. Park the machine on a dry firm, surface. Do not park the machine on metal surfaces. Avoid incorrect connections: never connect a positive terminal (+) to a negative terminal (-).

F1464

IMPORTANT: The machine electrical system is 24V with negative (-) ground. For the emergency start, use only booster batteries having the same tension.

CONNECTING BOOSTER BATTERIES

1

Carry out connection in the following order: • Connect one terminal of the red cable (1) to the positive (+) pole of machine batteries and the other terminal of same cable to the positive (+) pole of booster batteries.

• connect one terminal of the black cable (2) to the negative (-) pole of booster batteries and the other terminal (of same cable) to ground (machine frame).

• then carry out start-up.

Booster batteries

2

Service batteries

Machine frame ground F5625

REMOVAL DISCONNECTING BOOSTER BATTERIES Proceed in the following order: • Disconnect the black cable (2) terminal from ground (machine frame), then disconnect the other terminal of same cable from the negative (-) pole of booster batteries.

• Disconnect the red cable (1) terminal from the positive (+) pole of booster batteries, then disconnect the other terminal (of same cable) from the positive (+) pole of machine batteries.

2

1

F6036

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-53

OPERATING INSTRUCTIONS

STOPPING THE ENGINE

YY

S

WARNING

YY

8

Park the machine on a firm and possibly level ground.

Always rest the bucket safely onto the ground before stopping the engine.

YY

S

WARNING

YY

Never leave the machine unattended while the engine running. Attachment may be lowered to the ground by the control lever motion, with engine operated or stopped.

F19153

• Park the machine on a firm and possibly level ground.

• Rest the bucket to the ground.

• Disengage the auto-idle and turn the engine speed hand control (8) fully anticlockwise (minimum engine rpm).

• Let the engine run at minimum speed for some minutes to guarantee turbocharger progressive slowdown and cooling.

IMPORTANT: Do not accelerate during engine shut-down as it may cause the turbocharger turbine shaft to rotate without proper lubrication, due to inertia, with consequent severe damage to the turbocharger.

3

• Move the start key (2) to the OFF position.

• Remove the ignition key from the start switch.

• Move the safety lever (3) to the vertical (LOCK) position.

F24161

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-54

OPERATING INSTRUCTIONS

TRAVEL CONTROL PEDAL

YY

S

WARNING

YY

When the upper structure is turned of 180°, steering control will be opposite.

A

N

B

NOTE: the r.h., l.h., forward, backward, clockwise, counter clockwise indications, refer to the machine travel operation in road transport configuration.

3

2

1

Press travel control pedal (3) to move the machine N - Neutral A - Forward travel B - Backward travel

F20117

Knob (2) is fitted on the steering wheel (1).

Use this knob for one-hand drive or for quick steering.

SWITCH FOR TRAVEL SPEED AND TRAVEL MODE

YY

S

WARNING

YY

Should downhill with a gradient equal to or higher than 12% have to be overtaken, do not select the 3rd speed on the hare position.

Six travel speeds can be selected with switch lever (4).

A diagram aside helps to get more familiar with them: • slow travel: bring the switch on T (high) for transfers inside the yard.

• fast travel : bring the switch on U (low) for road transfers.

F24092

Travel mode switch (4) is located on the upper right side of the steering column console.

The travel mode lever has three operating positions: high speed III, normal speed II low speed I. 6

1

2

4 3 F24133

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-55

OPERATING INSTRUCTIONS

TRAVELLING INSTRUCTIONS TRAVELLING ON THE ROAD Road circulation (on public roads) is ruled by special provisions varying from country to country. Previously check for circulation provisions with local authorities.

YY

S

WARNING

YY

Road circulation (on public roads) is ruled by special provisions varying from country to country. Previously check for circulation provisions with local authorities.

YY

S

WARNING

YY

During road circulation, the equipment and control levers should be locked with the suitable devices. The safety lever must be locked.

YY

S

WARNING

YY

Do not turn the steering mode selector with key one OFF.

YY

S

WARNING

YY

Always check the pressure of the tyres.

YY

S

WARNING

YY

The road circulation is allowed only with normal steering mode (only front axle wheels).

PRECAUTIONS 1

2

• Verify the integrity of the tyres, since they should not show damages.

• Previously check for circulation provisions with local authorities.

• Make sure that the lights system works properly.

• Check the steering operation before starting travelling on the road: - with motor on, check that the steering selector (1) is set on “normal” mode; F25255

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-56

OPERATING INSTRUCTIONS - check the alignment of the rear axle wheels with the lower structure, ensuring that light (17) is lit; - carry out complete steering of the front wheels (from right to left and/or opposite) and verify that at the same time the back wheels have not moved, ensuring that light (17) is lit; - make sure that selector (1) is positioned by means of lock (2).

• Raise stabilizers and blade.

• Apply the red reflex reflectors on back stabilizers, if present.

• Make sure that stabilizers feet are vertical by means of suitable brackets.

17

F24091

CIRCULATION PRESCRIPTIONS • The machine should circulate only load less (i.e. with bucket unloaded).

• Transfer on public roads (each time you leave a yard) is allowed only with an approved configuration, complying with dimensions (A), (B) as shown on the table.

A

WX95 B Arm

mm

1850

2200

A Max. height

mm

3900

3900

B Frontal off-set

mm

2560

2490

F24021

WX125 Arm

mm

2000

2350

A Max. height

mm

3970

3970

B Frontal off-set

mm

2700

2680

F24528

• Fully raised boom (lifting) (the lifting cylinders are at the end-of-stroke, in fully open position). Cylinder is equipped with safety valves.

• Fully lowered articulated arm (positioning cylinders at the end-of-stroke and in fully open position).

Cylinders equipped with safety valves.

• The digging arm is positioned as shown by the reference mark on the articulated arm. Check dimensions (A) and (B).

• Bucket retracted with bucket cylinder fully extended.

F24529

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-57

OPERATING INSTRUCTIONS

F24530

• The controls of the working system should be locked by means of switch (10) for servo control lock/ unlock.

• Lock superstructure swing by means of special pin (1).

• Machine road towing is not allowed.

10

F19155

1

F19081

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-58

OPERATING INSTRUCTIONS • This machine is slow-moving vehicle. Always drive to the side of the road and yield to faster vehicles.

• Front attachment reduces visibility to the right and right front of the machine.

Before curves, reduce speed and drive with extra care.

Also, take special care for right side and right front side clearance while driving through curves.

• Periodically check instruments (especially brake pressure indicator).

If any abnormality is indicated, stop the machine immediately, and check for causes.

START Visually check that nobody is standing inside the machine working area. Remove also possible hindrances.

Turn the starting switch to perform the machine running.

Move the switch for parking brake, axle lock/unlock from parking position to another (axle lock/unlock).

NOTE: if the parking brake switch is operated before starting the engine, the display shows the engine stop symbol; start is no longer possible.

YY

S

WARNING

YY

S

WARNING

YY

If during travel the engine stop symbol appears on the monitor display: immediately drive alongside because the engine stops after 6 seconds. The possible causes are: low engine oil pressure or low hydraulic oil level.

YY

Should you have a flat tyre while driving, hold the steering wheel tightly, and stop the machine gradually. Do not apply the brake suddenly. This procedure could cause the machine tipping over or accidents involving your machine and/or following vehicles. Do not try to get on or off the machine while travelling.

Only the operator should stay on the machine. Keep riders off.

• Ask for the assistance of a signalman when driving on the shoulder of a road or in congested areas.

• Before restarting at an intersection or turning right, be sure to check the right and right front of the machine for any obstructions. Do not restart when conditions are not safe.

Stopping and restarting while travelling on a public road.

• Lock the power steering by means of the special button or lifting the l.h. console.

• Slowly press the travel control pedal to start the machine moving again.

• Gradually remove your foot from the travel control pedal, and gently step on the brake pedal to stop the machine.

INSTRUCTIONS FOR TRAVELLING ON A SLOPE

DRIVING INSTRUCTIONS

In case of descending a long slope, hydraulic oil temperature in the travel circuit may rise.

Occasionally, try to depress the travel control pedal.

If hydraulic oil temperature in the travel circuit becomes very high, hydraulic components may be damaged.

• In case the engine stalls on a slope, depress the brake pedal and restart the engine.

• Before down a slope, apply the brake to confirm that the brake functions normally.

• When hydraulic and lubrication oils are not sufficiently warmed up, large enough gradeability to ascend a steep slope may not be obtained.

Be sure to warm up the machine fully before ascending a steep slope.

YY

S

WARNING

WARNING

YY

when descending a slope, use a low speed and depress the brake pedal only if necessary.

It is dangerous to rely only on the brake pedal, since brakes may overheat thus decreasing performance.

For your safety and the safety of other people, keep to the following instructions and obey all traffic regulations while driving.

YY

S

YY

Stopimmediately the machine if you hear the sound alarm for low brake pressure.

• Avoid, if not necessary, to turn the engine at high speed.

• If you notice any abnormal sounds or smells, immediately stop the machine, turn off the engine, and check for causes.

• Do not turn the steering wheel or brake suddenly.

This condition may cause accidents involving your machine and/or following vehicles.

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-59

OPERATING INSTRUCTIONS PARKING Follow these procedures when parking: • Carefully release the travel pedal.

• Gently depress the brake pedal (1) to stop the machine.

• While the machine is stopped, set the parking brake switch, axle lock/unlock (2) in position K. • Make sure that the rotation locking lever (3) is set on position x. Then, lower the bucket onto the ground.

• Turn the start switch (4) to position O to stop the engine.

• Set the left console (5) on position x.

• Close windows and cab door.

• Lock all access doors and compartments.

• Block both tyres.

EMERGENCY PARKING • Turn emergency lights on.

• Look out for following vehicles. Slow down gradually.

• Move the machine to the side of the road. Stop and apply the parking brake K. • If trouble should occur inside a short tunnel, try to get out if possible and stop the machine outside the tunnel.

• Use one or more of the methods below to indicate that your machine is damaged. Failure to do so may cause accidents, such as passing vehicles colliding into your machine.

- Place a hazard mark, indicating emergency parking, behind your machine and keep the safety distances.

- Use luminous signalling devices such as windproof torches.

- Place a red flag or a luminous signal on the machine.

- Tie a handkerchief on the most visible, rear part of your machine.

• Troubleshooting.

Whenever possible, try to repair failures on site.

Before and while repairing, always keep to the recommended safe conditions.

YY

S

WARNING

YY

Avoid spilling oil on the road to avoid pollution and accidents.

• When hydraulic oil is leaking, stop the leak as soon as possible. Should a large amount of oil be spilled on the road, warn following vehicles first, then remove the oil from the road.

• When repairing operations are difficult, contact the company seat or a nearby authorized dealer.

• If the machine is parked in a tunnel, do not try making even easy repairs outside of the machine.

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-60

OPERATING INSTRUCTIONS

EMERGENCY BOOM LOWERING PROCEDURE

YY

S

WARNING

YY

Ensure that no one is under or near the front attachment before starting the boom lowering procedure.

If the engine stops and cannot be run again, lower lifting arm to lay the bucket onto the ground as follows: • Turn the start-up switch to ON. • While the brake switch is in position K, select x.

• While the brake switch is in position x, select K, then select x.

• Make sure the servocontrols are enabled (button (2) or l.h. console).

• The equipment starts lowering when shifting the right control lever (3) forward, as the system is equipped with an accumulator (1).

YY

S

WARNING

YY

The accumulator is equipped with energy reserve. Do not service the hydraulic system without draining the remaining accumulator pressure.

1

F24531

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-61

OPERATING INSTRUCTIONS

EXCAVATOR REMOVAL

YY

S

CAUTION

YY

Towing the machine on the road is forbidden.

The machine can be removed by hooking to front hooks (1) and on hooking points of front or rear axle.

For removal with diesel engine running, follow general safety rules and operate only with skilled personnel and a signal person for operation coordination.

1 F24024

IMPORTANT: the machine is braked when diesel engine is off. Do not remove the machine WITH BRAKE CONNECTED.

• Start-up switch ON and power supply enabled.

• While the brake switch is in position K, select x.

• While the brake switch is in position x, select K, then select x.

NOTE: the excavator is equipped with tyre lock wedges.

YY

S

DANGER

YY

Lock the machine travel by means of tyre wedges each time you release the negative brake. The machine cannot be controlled without brakes; follow general safety rules.

F24026

F24121

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-62

OPERATING INSTRUCTIONS To remove a damaged machine (discharged battery and diesel engine not running) the following should be observed: • release the negative parking brake • manually set the gearbox in neutral position.

2

3

Release of parking brake (negative brake) On the front axle (swinging) the brake body is fitted. The retaining unit (2) is located on the right side.

Release the retaining unit (2) by beating the outside ring with a mallet. Blow again pressure and check that the retaining unit is hooked at the cylinder stroke end (2) on rod (3).

Check that cylinder (5) is retracted until a 4 ÷ 5 mm projection is obtained from the cylinder head (4).

YY

S

CAUTION

F24128

4 5 mm

YY

4

5

Have parking brake checked at an authorized workshop.

5

Gearbox in neutral position - manual control

F24624

On the left side of the rear axle you can find the gearbox.

Keep to the following instructions to set the gearbox on neutral position: • a 5 mm-diameter pin (e.g. a screwdriver) should be fit inside the gearbox control lever (6).

• pull or push the lever until the stroke half has been found.

After excavator removal phase, bring gearbox back to the original conditions. Follow the reverse order with respect to the operations described above.

YY

S

WARNING

6

YY

During removal, do not allow anybody to get close to the machine.

Ask for the assistance of a second operator on the ground as a signalman for operation coordination.

YY

S

WARNING

F5859

YY

Reset parking negative brake and bring gearbox lever back to normal conditions when excavator removal is no longer necessary.

6

F5859B

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-63

OPERATING INSTRUCTIONS

SPEED SENSOR The rear axle is equipped with the gearbox, while on the right side the speed sensor (1) has been fitted.

Keep to the following instructions whenenever the speed sensor should be replaced: • Disconnect the electric cable from sensor (1).

• Loosen nut (2) and gradually untighten sensor (1).

Keep to the following instructions to assemble the speed sensor: • Tighten sensor (1) until the end of stroke and step back by 2 turns, then lock through nut (2).

• Connect sensor (1) to the electric cable.

1 2 F25251

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-64

OPERATING INSTRUCTIONS

SAFETY LEVER The safety lever (1) allows to signal the slew controls locking, the attachment motion and the blade/stabilizers motion.

It may assume two positions: • When it is in stopped (LOCK) position with machine stopped and engine running or stopped, it prevents the control levers to move and cause possible unintentional manoeuvres. The travel pedal is still actuated; • when set on unlock position, the safety lever enables the operation of all controls. Therefore, to control and operate the machine, the lever should be moved to this position.

1

2

F24137

To lock the safety device, lift the l.h. console (2) which automatically sets to locking position.

Unlock position v

Unlock by pushing grip (2) of the l.h. console downwards until hooking to the fastening device.

YY

S

WARNING

YY

2

When the machine is parked or upon leaving it for whatever reason, always ensure that the safety lever is in the correct LOCK position (vertical).

1

BEFORE START-UP Before starting the engine, ensure that the safety lever (1) is at the end of stroke, in stopped(LOCK) position.

AFTER START-UP F24138

After starting the engine, ensure that the travel controls and control levers are in the neutral position.

Lower the safety lever (1) to the unlock position to enable operation of cab controls.

YY

S

WARNING

Lock positionV.

YY

Whenever safety lever is lowered and released, and any attachment movement is detected, the following should be observed even if control levers are still in neutral position: • lift the l.h. console to the end of stroke to set it in locking position; • stop the engine; • contact the nearest Dealer.

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-65

OPERATING INSTRUCTIONS

CONTROL LEVERS NOTE: the following descriptions concerning use of the controls are to be intended with the travel motor on rear position with respect to the travel direction.

Indications stating right, left, front, back, clockwise, and anticlockwise are to be referred to an Operator properly sitting in the driver’s seat.

YY

S

CAUTION

YY

Prior to any digging operation, get acquainted with location and function of each control lever, as detailed below.

YY

S

DANGER

YY

It is forbidden to expose limbs or any part of the body outside the cab windows during working phase: danger of severe injuries and even death.

4

NOTE: the machine is fitted with a plate showing all functions of control levers and pedals.

3

1

2

MAIN CONTROLS 1.

2.

3.

4.

5.

6.

7.

8.

Arm extension (forward) Arm retraction (reverse) Upper structure left slew Upper structure right slew Boom lowering Boom raising Bucket heaped Bucket dumped

F24123

When a control lever is released, it returns automatically to the neutral position and the associated work function stops.

YY

S

CAUTION

6

YY

5

If the machine is fitted with the following options: triple articulation, clamshell bucket or hydraulic breaker, refer to descriptions of controls shown in paragraph “CONTROLS AND INSTRUMENTSof this chapter”.

7

8 F24124

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-66

OPERATING INSTRUCTIONS

MACHINE WARM-UP Engine correct warm-up should be performed as follows: • Start the engine by turning the speed hand control (1) fully anti-clockwise to slow idle, as shown.

• Let the engine run at low speed for at least 5 minutes and wait until coolant temperature indicator (2) reaches the green range.

Perform correct warm-up of the hydraulic system components as follows: • After correct engine preheating as previously explained, move the engine speed hand control (1) to the intermediate position.

F24625

IMPORTANT: hydraulic system components can be seriously damaged if the machine is operated with hydraulic oil temperature below 30°C. Do not keep drive cylinders fully extended for more than 15 seconds (by holding the control lever). This is to avoid overheating of hydraulic oil inside the operating section only. After each operating cycle, wait 5 to 10 seconds at least.

• Move control levers slowly to operate lifting cylinders, digging cylinders and bucket respectively to stroke end. Repeat this operation several times.

• Slowly move the upper structure swing control towards one direction and then towards to the other.

Repeat this operation several times.

• Operate travel control pedals and, at first, travel short distances only.

ENGINE SPEED HAND CONTROL The engine speed hand control knob (1) is used to increase or decrease engine rpm. To increase engine rpm: turn control knob clockwise. To decrease engine rpm: turn control knob counterclockwise.

NOTE: the maximum position of the accelerator control knob (1) does not correspond to the diesel engine maximum speed. This condition is reached only during travel phase. Before stopping the engine, fully turn the accelerator hand control knob anticlockwise (minimum engine rpm).

F20237

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-67

OPERATING INSTRUCTIONS

AUTO/IDLE SWITCH (auto/idle) With the start-key switch on position ON, press A/I (2) button to bring the engine rpm to the set auto/idle.

This speed is attained in approximately 4 seconds, provided that all controls are in the neutral position, with consequent fuel savings.

NOTE: engine speed will immediately increase, according to the rpm set through the engine speed hand control (1), as soon as any control lever is operated.

When the A/I control button (2) is pressed, the indicator light will light up.

Press the button again to disable this function. The indicator light will go off at the same time.

F20238

NOTE: The auto idle function can be activated/deactivated only when the key-start switch is set the ON position.

MEMORY BUTTON Use the function M to store the desired revolution number.

The machine will always reach the set revolution number, apart from the position of the engine speed hand control position.

When operated, button M (3) remains connected and the green warning light lights on.

Press button M (3) again to return to the original position and deactivate the function.

F20239

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-68

OPERATING INSTRUCTIONS

MACHINE OPERATION

YYYYYYy S WARNING yYYYYYY Keep the attachment down or in any case in a suitable position to guarantee maximum visibility and control of the machine. Do not slew the upper structure, raise the load or brake abruptly if not necessary. This may cause accidents. Should the machine be suddenly powered (e.g.: after pulling out an electric line), never touch machine metal structure while getting off. Spot an even, not rough adjacent area and jump directly over it from the cab.

Working near electric lines can be very dangerous, therefore some special precautions should be observed. By “working near electric lines” we mean that the attachment or load raised by the machine (in any position) may reach the minimum safety distance according to local or international Safety Regulations.

For a riskless operating cycle, keep maximum distance from electric lines and always keep to the minimum safety distance recommended.

The Electric Power Company, if previously advised and involved in the work, as well as machine Operator, Owner and/or any natural person or legal entity being responsible at the time by contract or law, are liable for the adoption of all necessary precautions.

Contact the Electric Power Company owner of the line or its nearest branch before starting the work.

Look up address and number in the telephone directory.

Define which precautions should be taken to guarantee work safety together with the Electric Power Company representative.

Decrease work speed. Reaction time could be too slow and distance evaluation wrong.

Warn all ground personnel to keep clear of the machine and its load at all times.

If the load has to be guided down for laying, ask the Power Company which precautions should be taken.

Appoint a person in charge to signal instructions. This person will have the responsibility of observing the machine, any part of it and/or the load approaching the electric line from a better standpoint with respect to the Operator’s position. This signal-man shall directly communicate with the Operator and the Operator must pay special attention to any signals supplied.

Ensure that local and/or national Safety Regulations

concerning work near electric lines are duly observed.

Working near overhead or underground electric lines involves the danger of severe injuries and even death.

All electric lines should be considered as operating live lines even though it might be well known that a line is out of work and visibly connected to the ground.

Working on slopes is dangerous.

Do not travel with a loaded bucket or with a load being set downstream to upstream. Do not work while the bucket points uphill. We recommend to work on slopes with bucket pointed downhill. Check first machine stability with unloaded bucket and retracted attachment, by slowly swinging the upper structure by 360°. Keep the machine sufficiently far from the digging border.

Never dig under the machine.

Never use the bucket or attachment to lift persons or carry riders on the machine.

Before beginning the work near gas distribution mains or other public utilities (water ducts, sewers, telephone and/or telematic lines, etc.), always contact the nearest branch of the Power Company.

When working in or near pits, in ditches or near gullies, very high rocky or supporting walls, check that the walls are sufficiently propped up according to safety regulations in force, in order to avoid collapsing hazards. Pay the utmost attention when working near overhanging walls. When digging, pay attention to risks of collapsing and landslides.

Always check ground conditions and the conditions of the material to be removed. Support any exposed area to prevent possible collapsing or landslides when: • digging near recently formed trenches filled with materials; • bad ground conditions; • digging trenches subject to vibrations from railroads, working machines, city or highway traffic.

Always appoint a person in charge of signalling when Operator visibility in the working area is limited.

Keep all people clear of the attachment (or any auxiliary equipment) when raised, to prevent possible injuries.

Only highly experienced personnel should be allowed to work on difficult virgin soils.

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-69

OPERATING INSTRUCTIONS

MAIN OPERATING RULES KEEP THE BUCKET LOWERED Always move with lowered bucket, especially on slopes or during transfers. The bucket, however, should be sufficiently raised from the ground to overcome possible obstacles. Do not use the bucket to lift or carry riders.

F24669

F24670

AVOID ELECTRIC LINES

YY

S

WARNING

L

YY

Contact with electric lines may cause severe injuries and even death.

When working near electric lines, NEVER MOVE any part of the machine or loads at a distance lower than 3 meters plus twice the length of line insulators.

Perform all checks and behave in compliance with any applicable local regulation. Wet ground will expand the area that could cause any person on it to be affected by electric shock. Keep all people and/or assistants away from the working area.

F24656

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-70

OPERATING INSTRUCTIONS AVOID TIPPING OVER When working on slopes, do not swing the upper structure and boom towards the downhill side. When moving heavy loads at the sides of the tyres pay attention that the machine does not overturn. With a loaded bucket, pay the utmost attention and care while swinging or lifting the attachment.

F24962

WORK WITH CAUTION While working, when the machine is moving or being transported, avoid any contact of the boom and/or arm with possible overhanging obstacles. Prior to digging, check location of electrical lines, gas ducts, water pipes or other public utilities installations. To solve possible doubts, contact local authorities and/or the Power companies (Electric Power, Gas, Telephone, Water, Telecommunications, etc.).

YY

S

WARNING

YY

If optical fibre cables are accidentally damaged, do not look into their ends to avoid eye injuries.

F24957

Never dig under the machine. In case of emergency, should the engine stall and not be possibly restarted, lower the boom and rest the bucket safely onto the ground following the EMERGENCY BOOM LOWERING PROCEDURE detailed in this chapter.

F24954

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-71

OPERATING INSTRUCTIONS CHECK THE WORKING AREA Always make sure that the ground supporting the work has sufficient strength to firmly sustain machine weight.

F24672

AUTOMATIC LIFTING While lifting the machine by the front thrust of the attachment, the angle between both arms should always be kept between 90° and 110°. The external part of the bucket should be used as a strength point on the ground. Refer to the shown configuration.

F24668

AVOID EXCESSIVE DIGGING EFFORTS Never travel with the bucket teeth deep into the ground, nor try to dig using the excavator weight as additional digging force: both operations may cause excessive machine stresses.

F24675

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-72

OPERATING INSTRUCTIONS WORKING IN WATER OR ON SOFT TERRAINS • Do not operate the machine with the axles, transmission, or prop-shafts submerged in water.

Avoid travelling in water, if possible.

• When travelling in water is unavoidable, the machine may be submerged up to a depth of 30 cm, as long as the stream bed is even and the water flows slowly.

If the bed is uneven and the water flow is rapid, leave safety margins in order to guarantee the machine will not be submerged deeper than 30 cm.

• When operating the machine on muddy grounds, mud will easily accumulate on the chassis frame, even when the chassis is not directly submerged.

Periodically check and clean, if necessary.

IMPORTANT: once the axles, transmission, etc. are submerged, they should be reconditioned immediately. Otherwise, operated parts and brakes could be exposed to sever wear and become inoperable. Consult the nearest dealer.

HAMMERING OR PILING Never use the bucket as a hammer. Improper use would damage the bucket and other parts of the front attachment.

F24731

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-73

OPERATING INSTRUCTIONS DIGGING INSTRUCTIONS • Mainly use arm force to excavate.

• Move the arm and bucket control levers back and forth a few times to remove soil stuck to the bucket.

• Position the bucket as parallel as possible to the digging direction, and use full-stroke bucket wrist action to effectively fill the bucket.

• When digging trenches, position the chassis frame parallel to the trench and move in reverse to dig the trench.

• Avoid extending cylinders to stroke ends. Try to operate cylinders by leaving a proper distance before stroke end.

F24673

IMPORTANT: take care not to hit the tyres with the bucket teeth when digging in diagonal configuration with respect to the undercarriage.

Machine will receive a large impact load when boom lowering operation is suddenly stopped. Lower the boom as smoothly as possible. Prevent the boom bottom or the bucket cylinder hoses from touching the ground while performing deep excavations.

F24674

GRADING OPERATION IMPORTANT: do not pull or push soil with the bucket when travelling.

Select grading mode when finishing work is required.

Position the arm in a slightly forward position with respect to the vertical line with rolled-back bucket, as shown.

Operate arm-in function while slowly raising the boom.

Once the arm moves past the vertical position slowly lower the boom to allow the bucket keeping grading operations.

F24677

Grading operations can be more accurate by operating the boom, arm and bucket simultaneously.

F24960

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-74

OPERATING INSTRUCTIONS Swing Do not use the swing force (rotation) to move huge stones, pull down walls, etc. This condition may damage the front attachment and swing device.

Avoid improper use Performance which can be obtained from the machine is clearly defined by the Manufacturer’s specifications: never exceed allowed operation.

Improper travel Never travel with the machine bucket firmly fitted into ground.

F24733

F24676

PRECAUTIONS DURING OPERATION

YY

S

WARNING

YY

Carefully inspect the work site before digging. If there is the possibility of falling objects, install overhead cab safety guards against accidental fall of objects.

If the ground in which you are going to work is not compact or firm, adequately reinforce (prop up) the work area to operate safely.

• Wear clothing and safety equipment suitable for the job, such as hard hat, etc..

• Clear all persons and obstacles, if any, from the area of machine operation and movement.

• Always beware of the surroundings while operating the machine.

• When working in a small area, congested or surrounded by obstacles, take care not to hit the upper structure or counter weight against such obstacles while slewing.

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-75

OPERATING INSTRUCTIONS

PARKING THE MACHINE Drive the machine to a firm and possibly level ground.

Lower the bucket to the ground Stop the engine following the procedure detailed in paragraph “USING THE MACHINE” of this Chapter.

Move the key-start switch to OFF and remove the ignition key.

Pull the l.h. console (upwards) make sure to bring it at stroke end, in locked position.

Close all windows.

Lock the cab door and the following doors: • side door (engine compartment, pump and filters); • r.h. rear door (radiator compartment); • l.h. rear door (fuel tank compartment and electric components)

YY

S

CAUTION

F24671

YY

Whenever possible, avoid parking the machine on slopes.

Should parking the machine on a slope be unavoidable, carry out what detailed before and observe the following: • thrust the bucket teeth into the ground; • adequately lock both tracks (using wedges), as shown in the figure.

IMPORTANT: Always protect cab electrical components from bad weather taking care to close all windows, roof window, and access door.

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-76

OPERATING INSTRUCTIONS

PRECAUTIONS FOR TRAVELLING ON SLOPES

YY

S

WARNING

YY

If it is necessary to operate the machine on slopes, carefully observe following precautions.

This is to prevent injuries due to accidental machine overturn.

YY

S

WARNING

YY

Carefully shift gears while travelling with the machine. Especially avoid shifting to quick travelling mode while travelling on a slope: it may be dangerous.

F24849

• Never attempt go up or to come down from the machine on 30° (~ 58%) slopes or steeper grounds.

• Avoid travelling across the slope as much as possible.

• Never attempt to travel across 15° slopes or steeper grounds.

• Keep the bucket towards the travel direction at approximately 20 - 30 cm from the ground.

• If the machine starts slipping or becomes unstable, immediately lower the bucket to the ground.

• Always travel at slow speed.

F24669

• Never attempt to steer the machine while travelling on slopes.

Steering is allowed only on very gentle slopes where the ground is firm.

• Do not slew the upper structure on slopes.

F24670

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-77

OPERATING INSTRUCTIONS • Never attempt to swing the upperstructure downhill: the machine could tip over.

If slew uphill is unavoidable, carefully operate by moving very slowly the upper structure slew and lift control.

CORRECT

• Never turn loads downhill. Keep the bucket uphill and reduce slew speed at minimum.

• If the engine stalls on a slope, immediately lower the bucket to the ground and move control levers back to neutral position. Then restart the engine.

• Be sure the machine has completely warmed up before travelling on a steep slope.

If hydraulic oil has not warmed up correctly, the machine performance may not be satisfactory.

F24956

WRONG

F24962

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-78

OPERATING INSTRUCTIONS

MANOEUVRING OF HANGING LOADS

YY

S

WARNING

YY

The machine has been specially designed for digging/ loading operations. The moving of hanging loads to complete the working cycle digging and/or loading, is always allowed.

When moving hanging loads, strictly follow national regulations concerning safety rules, the rules listed herebelow and those described on chapter SAFETY RULES.

YY

S

WARNING

YY

• If available, lower stabilizers or blade to the ground to increase machine stability.

• Pre-arrange the engine rpm according to the hydraulic effort required.

• Evaluate (If unknown) the weight of the object to be handled and compare it with the data of the table located in the cab and shown in this chapter. Do not lift loads exceeding the maximum values shown on the table.

• Before any lifting operation, press switch (4) to connect anti-tipping sensor. This sensor activates the acoustic alarm when reaching safety limit load.

Boom antidrop valves, located on cylinders, the acoustic alarm, the loads table hanging in the cabin and the bucket hook ARE SAFETY DEVICES, belonging to the hanging loads handling option.

When one of said safety devices is missing or damaged, the machine cannot be used to handle hanging loads.

For the handling of hanging loads, observe following:

YY

S

WARNING

YY

Before starting to work check the valves for any remarkable damage or abnormal noise. If troubles are noticed, refer to your Dealer and, in the meantime, do not use the machine for handling hanging loads.

Check for lifting devices (hooks, chains, etc.) integrity and make sure they are not too much worn out.

Keep to the rules in force concerning checking procedures of said devices (not supplied with the machine).

YY

S

WARNING

YY

To avoid injuries, do not exceed the machine load rated capacity. If the machine is not set on a level ground, load capacities are reduced. Anyway, always operate with care.

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-79

OPERATING INSTRUCTIONS A lifting hook(2), located on the link rod, is paired with the antidrop valve.

YY

S

WARNING

YY

Check for lifting devices (hooks, chains, etc.) integrity and make sure they are not too much worn out.

Keep to the rules in force concerning checking procedures of said devices (not supplied with the machine). The device can only be used for lifting objects that are not anchored to the ground. It cannot be used for towing, uprooting and breakout.

3

2 • In order to avoid the load swing, do not sling a load with too long ropes and/or chains.

• Check the working area and make sure the load run is free from obstacles.

• Lift the load slowly avoiding sudden motion that can cause load swing. As a rule, keep the load close to the machine in order to increase stability and operate lengthwise rather than crosswise.

• Lift the load from the ground at the minimum distance from ground.

YY

S

WARNING

F24534

YY

Loads can turn and swing in all directions. Therefore they might hit persons or machine cab. In order to limit this danger, keep people within machine safe area of operation and shift the load slowly. In case the load turns or swings during transport, slow down until you stop and slowly lower it to the ground. Then correct the hooking system.

YY

S

WARNING

YY

in case sound alarm is active during load handling, lower the load to the ground and check for load conditions with the help of the special table in the cab.

• Lay the load onto the desired position and make sure it is firmly and safely rested on a solid surface.

• Remove chains.

YY

S

WARNING

YY

Check for screws (3) fastening every 50 hours or less • Wrench: 24 mm •Torque: 26.5 ± 2 daNm

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-80

OPERATING INSTRUCTIONS

READING KEY FOR THE LIFTABLE LOAD TABLE LOCATED IN THE CAB

Ld

2 XXX

7

2

XXX

1

1 m

4

5

6

XX XX

m

XXX

XXX

XXX

8

360°

F25252

1.

2.

3.

4.

5.

6.

7.

8.

Boom length Length LD of optional second arm Load distance from slew centre Maximum liftable load in tons to tip-off limit as per ISO 10567 Standards Maximum liftable load in tons at maximum distance from slew centre Maximum working distance from slew centre Counterweight weight Hydraulic system main pressure overload relief valve/pressure relief valves Value limited to the machine hydraulic capacity

NOTE: lifting loads as per ISO 10567 Standards (75% stability, 87% hydraulic system).

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-81

OPERATING INSTRUCTIONS

BUCKET INSTALLATION Install the bucket as follows: • using a suitable hoist, place bucket on the same level of tyres; • use arm cylinder and boom cylinder controls to carry out short vertical and horizontal movements, in order to fit the pivot pin (B) connecting bucket to arm, in the bore (A).

• use the bucket cylinder control, to align the connecting rod (C) with hole (D), and then insert pivot pin (E).

• lock the pins by means of relevant screws (F) and nuts (G).

YY

S

WARNING

F

C A

B

D

YY

Always use suitable tools to align holes. NEVER USE FINGERS OR HANDS.

G

E

F24535

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-82

OPERATING INSTRUCTIONS

BUCKET TOOTH TIP DISASSEMBLY

YY

S

CAUTION

YY

2

3

Keep people not involved in maintenance operations outside the working area.

Wear adequate personal clothes and glasses with side shields as a protection against flying debris.

• Verify that the machine is parked on a level surface.

• Rest the bucket to the ground.

• Switch off the auto/idle, fully turn the engine speed manual knob anticlockwise, stop the engine, remove the ignition key and set the l.h. console in locked position (LOCK).

• Use a hammer (3) and a punch(2), as shown, and drive the lock pin (1) out of its seat, then remove the tooth.

F6048

NOTE: to drive out the lock pin (1) from its seat, hit it with punch (2) on the tapered portion.

1

F6142

ASSEMBLY • Clean tooth surface (5) and set a new tip (4) onto the tooth.

• Install the lock pin (1) into its seat and drive it in using a punch(2) and a hammer (3), until it is properly fixed.

5 4

1 F6143

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-83

OPERATING INSTRUCTIONS

ROAD TRANSPORT TRANSPORT RULES • When transporting the machine on a trailer on public roads, you must know and observe all the Rules of the road as well as all provisions released by the different Companies owning the roads (Municipality, Province, Region, Country).

• Prior to transporting the machine on a flatbed, check width, height, length and weight of the trailer with the machine loaded.

NOTE: dimensions and weight may differ according to the type of tyres and/or front attachment installed.

F24678

• Investigate beforehand the conditions of the road you are going to travel, weight and size limits, and special local traffic regulations.

NOTE: In some cases, it may be necessary to disassemble the machine to bring it within dimensional and/or weight limits provided for by local regulations.

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-84

OPERATING INSTRUCTIONS

RULES FOR LOADING/UNLOADING THE MACHINE ON A TRAILER Always load/unload the machine on a firm level surface. Thoroughly clean the flatbed of the trailer and ramp before loading.

Block the truck and trailer by adequately wedging the wheels. The loading/unloading ramp should be of sufficient width, length, and strength. Also ensure that ramp angle is lower than 15°.

YY

S

WARNING

YY

1

Make sure that the A/I(auto-idle) mode is turned off to prevent unexpected engine rpm increase, due to unintentional operation of any control lever.

Always select the slow travel speed mode T, proceed with extreme care and attention. Avoid steering while driving the machine onto the ramp: danger of machine overturn. Should corrective steering be necessary, move back to ground or flatbed, change travel direction, and resume driving. The ramp end, where the flatbed is met, (area linking the trailer) shows a sudden bump. Travel over the bump with extreme care and increase machine stability using the front attachment.

YY

S

WARNING

F20495

YY

When loading the machine, position it with the cab directed toward the opposite side with respect to the travelling direction of the transport vehicle, otherwise remove the rain protection (1) and store it properly in the cab. This precaution prevents the risk of rain protection (1) sudden detachment, caused by the “sail effect” of the air during the transport on road.

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-85

OPERATING INSTRUCTIONS

LOADING THE MACHINE ON A TRAILER Observe the following when loading the machine on a trailer: NOTE: with cold weather, the machine should be properly warmed up, before loading operations are performed.

• Loading procedures may differ according to the front attachment, which could be installed or not.

With the front attachment installed: • travel slowly along the ramp forward, keep the attachment positioned frontally; • once the ramp top has been reached, and before the machine starts falling forward onto the flatbed (shifting its centre of gravity), rest the bucket flat onto the trailer flatbed (boom to arm angle should be 90° to 110°).

• drive slowly forward until the wheels are correctly positioned on the trailer flatbed; • slightly raise the bucket from the flatbed, retract the arm and keeping it tucked under, slowly slew the upper structure by 180°; • retract the bucket and rest it on proper blocks (e.g.: wooden blocks).

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-86

OPERATING INSTRUCTIONS Without attachment: • Travel in reverse along the ramp, as shown.

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

• Stop the engine and remove the ignition key from the start switch.

• Cycle the control levers to relieve any residual hydraulic pressure from the boom and arm drive cylinders.

• Shift the safety lever to stroke end, in vertical lock position.

• Close all windows, front windscreens, and cab door.

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

• Adequately secure the machine to the trailer to prevent dangerous movements. Proceed as follows: - lock machine frame to the trailer flatbed by means of chains or metal cables of suitable size. Do not place metal cables or chains over or against hydraulic tubing and hoods; - block track ends using wedges; - lock the front attachment (if installed) to the flatbed using chains or metal cables of suitable size.

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-87

OPERATING INSTRUCTIONS

UNLOADING THE MACHINE FROM THE TRAILER The following precautions should be observed while unloading the machine from a trailer: • Unloading procedures may differ according to the front attachment, which could be installed or not.

With the front attachment installed: • travel slowly in reverse along the trailer flatbed; • once at the flatbed end and before the machine starts falling forward onto the ramp (shifting the position of its centre of gravity), rest the bucket flat side onto the ground (boom to arm angle should be 90° to 110°); • drive slowly forward while retracting the boom, extending the arm and repositioning the bucket resting to the ground until the entire machine is unloaded.

Without attachment: • travel forward down the ramp.

YY

S

WARNING

YY

Always stop the machine before selecting the other travel speed mode.

Never shift gears while travelling with the machine.

Avoid especially shifting to quick travelling mode while travelling on a slope: it may be dangerous.

IMPORTANT: To avoid damaging the front attachment, observe the following while unloading the machine: minimum angle between boom and arm should never be lower than 90° and the bucket should never suddenly hit the ground.

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-88

OPERATING INSTRUCTIONS

SEA TRANSPORT CRANING THE MACHINE FOR SEA TRANSPORT

YY

S

DANGER

YY

Metal cables or chains may break and cause severe injuries.

Carefully inspect metal cables and/or chains prior to use and check for damages or wear. Always wear suitable protection gloves when handling metal cables or chains.

Use metal cables or chains of appropriate size according to the load to be raised.

Arrange the lifting sling with the utmost care to avoid any possible movement of the machine while it is being raised.

Crane the machine very slowly.

Ensure no one is under or near the machine while this is being raised: danger of death.

F24063

Observe the following to raise the machine: • Fully extend the arm and bucket drive cylinders and tuck in the front attachment.

• Lower the boom and gently rest the bucket onto the ground.

• Move the l.h. console upwards, to end of stroke, in (LOCK) position.

• Stop the engine and remove the ignition key from the start switch.

• Prepare a hoist and properly fit safety elements such as rubber, parts of used tyres, wooden blocks, so to avoid possible damages during the lifting phase. See the figure.

• Check that the sling is correctly attached to the crane hook prior to start lifting.

• Ensure that nobody is standing near the working area. Slowly raise the machine and check that it is correctly balanced when it is taken off the ground.

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-89

OPERATING INSTRUCTIONS

PRECAUTIONS IN COLD WEATHER CONDITIONS The antifreeze fluid is recommended under any weather condition: it widens the operating temperature range, lowers the freezing point and raises the boiling point. When temperature is next to 0°C, to avoid freezing hazard, it is necessary to check that the cooling system is filled with an antifreeze mixture: otherwise replace the radiator coolant with this mixture.

Flush the cooling system prior to filling with the antifreeze mixture (refer to Chapter MAINTENANCE).

YY

S

CAUTION

YY

Fluid under pressure. Turn cap or cover slowly before removing to relieve pressure.

We recommend to use Premium Anti-freeze fluid.

Refer to the table below for mixing percentage according to outer temperature.

F6057

Outer temperature (up to...)

Premium Anti-freeze

Water

- 8°C

20%

80%

-15°C

30%

70%

- 25°C

40%

60%

- 35°C

50%

50%

We recommend to use lubricants of adequate viscosity, as detailed in the FILLING CHART on chapter MAINTENANCE. NOTE: do not use the machine immediately after first startup or after prolonged stops.

Always warm up hydraulic, engine and cylinder oil as detailed in the previous paragraphs.

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-90

OPERATING INSTRUCTIONS • If the machine is to be stored for a prolonged period of time, operate 2-3 times the travel, slew and digging hydraulic systems at least once per month to guarantee proper lubrication.

• Before operating the machine, check coolant level (or refill the system if drained) and lubrication conditions.

• Check battery charge each month and recharge, if necessary.

PROLONGED MACHINE INACTIVITY

YY

S

DANGER

YY

Do not run the engine in closed spaces without proper ventilation and/or an adequate system capable to remove noxious exhaust gases.

YY

S

WARNING

YY

Explosive gases are produced while batteries are being charged. Keep open flames and/or sparks away from the battery charging area.

Avoid incorrect connections: never connect a positive terminal (+) to a negative terminal (-). Remove cell plugs during recharging.

• Inspect the machine. Repair damaged or worn parts.

Install new parts, if necessary.

• Clean the air cleaner.

• Fully retract all cylinders, if possible. Otherwise coat the exposed cylinder rods with grease.

• Lubricate all greasing points.

• Park the machine on a level ground.

• Wash the machine.

• Remove the batteries and store them in a dry protected place after full charging.

If not removed, disconnect battery negative cable from the terminal (-).

• Drain coolant. If the system is filled with antifreeze mixture, draining is not necessary.

• Release alternator and fan belts.

• Remove injectors and inject a small amount of engine oil into the cylinders through injector holes. This operation should be carried out using a syringe after bringing each piston to the bottom dead centre.

• After injecting oil, crank the engine several turns (using the starter motor) to spread a protective coat of oil over cylinder walls.

• Reinstall injectors.

• Paint any exposed part to prevent rust formation.

• Store the machine in a dry protected place.

If the machine is parked outside, cover it with a tarpaulin arranged so to allow ventilation.

Otherwise humidity harmful to the machine may result.

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-91

OPERATING INSTRUCTIONS

USING THE MACHINE AFTER PROLONGED STORAGE

YY

S

DANGER

MACHINE DEMOLITION

YY

YY

S

WARNING

YY

• The decommissioning of the machine must be carried out exclusively by trained, qualified and authorised personnel.

• Start the removal of hydraulic components only after the same, the hydraulic oil and lubricants are completely cooled-off and after releasing the residual pressure, as described by the Workshop Manuals.

• Before proceeding with removal/disassembly operations, comply with the GENERAL SAFETY RULES and drain all components of the machine filled with fluids both in reservoirs and the relevant systems.

Do not run the engine in closed spaces without proper ventilation and/or an adequate system capable to remove noxious exhaust gases.

• Remove grease from cylinder rods.

• Adjust alternator and fan belt tensions.

• Fill the tank with fuel.

Bleed air from the fuel system.

Check levels of all fluids.

• Start the engine.

Run the engine at medium speed for several minutes prior to operating it at full load.

• Cycle all hydraulic functions several times.

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

To dismantle the machine, it is necessary to have access to specific equipment (hoist, hydraulic presses, containers for liquids, etc.) and special tools described in the Workshop Manual, available from Dealers.

This is in order to avoid that during disassembly operations dangerous situations arise both for the personnel involved and the environment.

NOTE: after prolonged machine storage, perform all the operations detailed above and the following checks: • Check condition of all hoses and connections.

• Warm up the engine.

• Stop the engine.

• Install new fuel filters.

• Replace engine oil filters and top up engine oil.

The machine contains: • Fluids under pressure (hydraulic system, cooling system, etc.).

• Gases (air conditioning system and accumulator, as applicable).

• Acid (batteries).

• Heavy components (booms, buckets, etc.).

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.

Handle and dispose of fluids according to current regulations.

Use only authorised disposal procedures. For any doubt, apply to authorities concerned.

F5041

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

2-92

3 - OPTIONAL VERSIONS

OPTIONAL VERSIONS

HYDRAULIC BREAKER HYDRAULIC BREAKER SELECTION AND INSTALLATION If it is required to install an hydraulic breaker on the excavator, select a breaker model that meets the requirements of stability, pressure and oil quantity of the excavator hydraulic system.

YY

S

WARNING

YY

Ask your Dealer for the choice of the most suitable breaker for your machine and also for the possible regulations necessary to supply the electric power and the working pressures needed by the tool chosen.

F6159

PRECAUTIONS WHEN USING THE HYDRAULIC BREAKER

YY

S

WARNING

YY

The hydraulic breaker is much heavier than the bucket, therefore it reduces excavator stability and increases overturn hazard. During operation, splinters or flying debris may hit the cab or other parts of the excavator.

Observe all following precautions and take all necessary measures to prevent accidents that may damage the excavator and cause personal injuries to the Operator.

F24658

Avoid hitting objects with breaker. The breaker is heavier than the bucket and lowers faster. This may cause damages to the breaker, attachment, and upperstructure.

Always lower the breaker slowly until the chisel point touches the object to be broken before starting breaker operation.

Do not use the hydraulic breaker and/or slew function to push objects so to avoid damages to the attachment.

F5954

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

3-1

OPTIONAL VERSIONS Do not operate the breaker with the excavator cylinders fully extended or retracted to avoid attachment and/or cylinder damage.

F24679

Stop working if hydraulic hoses look abnormally bent.

Contact your authorised Dealer.

F24680

Do not operate the hydraulic breaker in water. This condition will cause rust and seal damage, resulting in damage to the hydraulic system components.

F6103

Do not use the hydraulic breaker to move objects. The excavator might overturn and/or the hydraulic breaker may be damaged.

F24681

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

3-2

OPTIONAL VERSIONS Do not operate the breaker to the side of the machine.

The machine may become unstable and undercarriage component efficiency may be compromised.

F6552

Operate the excavator carefully to avoid hitting the boom with the hydraulic breaker.

F24682

Do not operate the breaker while the arm is vertically positioned. Excessive vibration to the arm cylinder may cause oil leakage.

F24683

Press the breaker so that the chisel point thrust is square (perpendicular) to the object to be broken.

CORRECT

WRONG F6555

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

3-3

OPTIONAL VERSIONS Never operate the hydraulic breaker for more than one minute since the chisel could be damaged.

If an object could not be broken within one minute, apply chisel in other areas for less than one minute for each location.

F6556

Never lift the undercarriage front part by pushing the hydraulic breaker downwards: in this way the front attachment could be damaged. Although raising the front edge of the undercarriage up to 150 mm is a permitted condition, do not follow this procedure if not strictly necessary.

Never exceed the admissible 150 mm tolerance.

150 MAX

F24684

HYDRAULIC BREAKER CONTROL To operate the hydraulic breaker, proceed as follows: • Set the machine in parking position; on the left side, under the engine protection panels, a valve has been fitted.

• Check if the position of cock (1) connects the return of the breaker with the radiator (open cock; see the positions of the reference mark indicated on the selector).

In case the cock position is wrong, proceed as follows: - turn cock head (1) with a 19 mm wrench.

• Start the engine.

• Release hydraulic control pedal (3) shifting pedal lock device (2) outwards (illustration with pedal (3) in released position).

• Operate pedal (3) to start the hydraulic breaker.

• Release pedal (3) to stop the operation of the hydraulic breaker.

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

3-4

OPTIONAL VERSIONS

NIBBLER CHOICHE AND ASSEMBLY OF NIBBLER Considering that the nibbler is heavier than the bucket, select a nibbler model whose characteristics meet the excavator requirements to prevent problems, namely as regards stability.

NOTE: for any operation with the nibbler, refer to the relevant Instruction Manual provided by the Manufacturer.

YY

S

CAUTION

YY

Ask your Dealer for the choice of nibbler most suitable for your machine and also for the possible regulations of the feed capacity and of the working pressures needed by the chosen tool.

PRECAUTIONS TO BE OBSERVED WHEN USING THE NIBBLER

YY

S

WARNING

WRONG

YY

The nibbler is much heavier than the bucket, therefore it reduces excavator stability and increases overturn hazard. During operation, splinters or flying debris may hit the cab or other parts of the excavator.

Observe all following precautions and take all necessary measures to prevent accidents that may damage the excavator and cause personal injuries to the Operator.

F24685

1.

2.

Never support machine weight by means of nibbler and cylinders set in end-of-stroke configuration (extended or retracted) to avoid damaging the front attachment. While the nibbler cylinder is completely extended the front attachment is subject to greater wear.

While using the nibbler, the front attachment should be directed towards the excavator in longitudinal direction. Any use including different configurations could compromise stability and cause machine tipping over.

WRONG

F24963

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

3-5

OPTIONAL VERSIONS

YY

S

WARNING

YY

WRONG

Works for the demolition of buildings and general structures present a high level of intrinsic risks.

Should a building be demolished by means of any excavator equipped with standard arm and bucket configuration, consider that the maximum working height should not exceed the values approved on local and national regulations.

3.

4.

5.

6.

7.

When operating the nibbler up high with the boom fully extended, pay attention to falling objects.

When operating the nibbler on a floor of a building, first make sure that the floor has sufficient strength to support the load caused by crushing in addition to machine weight.

Operate the excavator on a level and firm ground.

Never operate on demolished materials or on slopes.

Do not use the nibbler to haul or move crushed scraps.

Always remove the nibbler from the excavator before transporting the machine.

Do not travel the excavator with the bucket cylinder fully extended. This may damage the attachment due to high travel vibrations.

F24964

WRONG

F24965

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

3-6

OPTIONAL VERSIONS

NIBBLER CONTROL To operate the nibbler, proceed as follows: • Set the machine in parking position; on the left side, under the engine protection panels, a valve has been fitted.

• Check if the position of cock (1) connects the return of the breaker with the radiator (closed cock; see the positions of the reference mark indicated on the selector).

In case the cock position is wrong, proceed as follows: - turn cock head (1) with a 19 mm wrench.

• Start the engine.

• Release (if locked) hydraulic control pedal (3) moving pedal lock device (2) outwards (illustration with pedal (3) in released position).

• Act on pedal (3) to operate the nibbler.

• Release pedal (3) to stop the operation of the nibbler.

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

3-7

OPTIONAL VERSIONS

HYDRAULIC OIL AND FILTER ELEMENT SERVICE INTERVAL

(*) IMPORTANT: intervals shown should be applied if the machine is used 100% of the time and equipped with the hydraulic breaker or nibbler.

In case of lower time percentage of breaker or nibbler use, hydraulic oil and filter element change intervals may vary accordingly to the following diagram.

When the hydraulic breaker or nibbler is used, the excavator is subject to working conditions more critical than usual, that speed up hydraulic oil deterioration and contamination.

To prevent damages to the excavator hydraulic system, breaker or nibbler, carefully respect service intervals detailed in this Manual. In particular, replace hydraulic oil and filter element according to the instructions below:

(**) IMPORTANT: if the machine has been refilled with biodegradable hydraulic oil HYDRAULIC EXCAVATOR FLUID BIO (on demand), be informed this oil cannot be mixed with mineral hydraulic oil. Refer to the service intervals shown in the table hereunder for filter element replacement. If in doubt, do not hesitate to contact your Dealer.

Change intervals (hrs)

Hydraulic breaker or nibbler using time (%)

Component to be replaced

Machine equipped with hydraulic breaker or nibbler

Machine equipped with bucket

Hydraulic oil (**)

600 (*)

2500

Filter element

100 (*)

500

Change interval hydraulic oil

Change interval filter element

Change intervals (hrs) Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

3-8

F21428

OPTIONAL VERSIONS

ATTACHMENT SLEW SYSTEM This system is especially suitable while using attachments requiring rotation. They are: nibbler, clamshell bucket, etc.

The choice of a rotating equipment, must be made in agreement with the Dealer. This is because the equipment one intends to use must ensure, in any case, the stability of the excavator and the compatibility with its hydraulic and electrical systems. The evaluation of the factors mentioned above can make the engineers decide to equip the excavator with further devices to prevent the tipping over the machine.

Also, the system requires adjustments, which must be performed exclusively by engineers.

F10592

ATTACHMENT SLEW CONTROL • By pressing button (A) the clamshell bucket will rotate anticlockwise.

• While pressing key (K) the clamshell bucket will rotate clockwise.

YY

S

WARNING

YY

• When a rotating attachment is installed, operate and slew the excavator slowly.

• Rotate the attachment when the excavator is stopped.

This is in order to avoid dangerous slew which could endanger the stability.

• When lowering the boom, make sure that the rotating attachment is in vertical position.

• Never use a rotating attachment for piling jobs or removing poles.

• Before leaving the operator’s compartment, lower the boom until the rotating attachment rests on the ground. This is to avoid that the attachment loads the excavator, representing a danger of personal injuries, being suspended in the air.

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

3-9

OPTIONAL VERSIONS

CLAMSHELL BUCKET SYSTEM For the use of the clamshell bucket, the following should be observed: Check that cocks (1) and (2) located on the bucket and arm cylinders are closed (see the position of the notch on the cock).

1

F25253

2 F25254

CLAMSHELL BUCKET CONTROL When operating the r.h. control lever, the following controls are activated: N - Neutral G - Bucket closure H - Bucket opening

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

3-10

OPTIONAL VERSIONS

CAB PROTECTION (F.O.P.S.) The use of protection (1) is essential when working in areas where stones or wreckage can fall.

In case the machine has not been originally equipped with this protection, it is possible to refer to the Dealer and have it installed.

1

F25421

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

3-11

OPTIONAL VERSIONS

FUEL TRANSFER PUMP

YY

S

WARNING

YY

The fuel is flammable. Do not puncture or burn fuel containers. Follow the instructions given on containers as far as storage and distribution is concerned.

Following the presence of highly flammable vapours, extinguish all smoking materials and open flames before checking the fuel level, refuelling, replacing the filters or opening the drain plug. Do not refuel with the engine running. Do not use matches, cigar lighters or torches as light source on the machine.

4

5

YY

S

WARNING

YY

F24151

Never use gasoline, solvents or other flammable fluids to clean parts. Use only proprietary certified solvents, non-flammable and non-toxic.

3

NOTE: use decanted fuel for refuelling.

We advise to fill the tank at the end of the working day, to prevent condensation formation overnight. Do not run-out of fuel in the reservoir. This would cause the entry of air in the fuel system, making its bleeding necessary.

1

9

• Fuel transfer pump (5) has been installed on the fuel tank, on the rear side. Reach the pump by raising cover (4).

• The filling of the fuel tank using the electric fuel transfer pump is made in the following manner: - remove cap (1) from the fuel tank; - unroll hose until its end with filter can be immersed in the fuel container. Fit it to quick connection installed on the machine; - move switch (8) located on pump (5) from position (OFF) to position (ON); - check on level visual indicator (3) the filling of the tank; - once the desired fuel level is reached in tank (9), move switch (8) from position (ON) to position (OFF); - install cap (1) on the fuel filler neck;

5

F24152

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

3-12

OPTIONAL VERSIONS - drain completely the residual fuel from hose, then wind it up and store it in its place, inside the tool storing compartment; - close the fuel tank bay access panel.

YY

S

WARNING

YY

Check that there are no traces of fuel inside the tool storing compartment. Otherwise wipe it up with a rag and let it evaporate. This is to prevent the danger of fires.

IMPORTANT: when rewinding the hose, pay attention to avoid kinking it, to prevent damages and leakages.

MAINTENANCE • The fuel transfer pump is fitted with an electrical circuit being protected through a special 10A-fuse(7).

Should the fuse be blown, thus preventing the pump from operating, then replace it.

• Fuse (7) is located inside the fuel pump. Remove the two screws on cover (10) to reach the fuse.

• The end of hose is fitted with a mesh filter which should be cleaned in case of clogging, otherwise the fuel intake process could be compromised. Replace the filter, if cleaning may not be possible.

10

7

IMPORTANT: the use of non genuine components can involve the risk of malfunctions of the machine and a reduction of the safety limits during its operation.

F20028

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

3-13

OPTIONAL VERSIONS NOTE:

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

3-14

4 - MAINTENANCE

MAINTENANCE

YYYY

S MAINTENANCE PRECAUTIONS YYYY

The following chapter MAINTENANCE is directed to specialised personnel of the service network. Users/ operators of the machine are authorised to perform the following operations, in compliance with the general precautions as indicated: • Greasing (attachment, slewing ring, front axle pivot bush and drive shaft).

• Check liquid levels and top up when required (engine oil, hydraulic system oil, engine coolant).

• Air filter cleaning.

• Checking tyre pressure and possible inflation.

Do not allow unauthorised personnel to operate or service this machine. Carefully read the Operation and Maintenance Instruction Manual before starting, operating, maintaining, fuelling or repairing the machine.

Never lubricate, repair or adjust the machine with the engine running, except when this is specifically required by the Operation and Maintenance Instruction Manual to avoid being caught in or crushed by machine moving parts.

Stop the machine according to the procedure detailed in the Operation and Maintenance Instruction Manual prior to lubricating or servicing.

Each time it is necessary to disassemble or assemble machine components which should be supported by jacking means, ensure that the supports under the jack and between jack and machine are adequate to the load they should hold. Immediately transfer load onto appropriate means of support or jacks. Do not loosen hydraulic connections located on the front attachment if the attachment is not lowered and fully resting on to the ground, and all residual pressure has not been relieved with stopped engine.

In case of sudden engine stall, lower the attachment

YYYYYY

S

to the ground as possible and contact your authorised Dealer before carrying out any work on the hydraulic system. Never work on or under the machine or on its components if supported solely by jacks or other lifting means according to local or national safety regulations. Never work under or near an attachment or parts of the machine which are not adequately supported or locked. Always move the safety lever to the lock position prior to cleaning, repairing or servicing the machine and after parking it to prevent injuries.

Never use gasoline, solvents or other flammable fluids for cleaning operations. Use only proprietary certified solvents, non-flammable and non-toxic.

NEVER USE YOUR BARE HANDS to check for pressure leaks. Escaping fluid under pressure can penetrate the skin.

When service or maintenance require access to areas that cannot be reached from the ground, use a ladder or step platform conforming to local or national regulations to reach the working area. Always perform all service or maintenance work with the greatest care and attention. Use only approved and grounded auxiliary power sources for heaters, battery chargers, pumps and similar equipment to reduce electrical shock hazard. Before starting the engine, warn all people who are carrying out repairs or other works around the machine. Keep your hands and face away from loose hose connections while carrying out leak and performance tests on injectors and/or systems. Always wear safety glasses with side shields. Do not work under or near moving parts of the attachment or other machine parts if not adequately supported and locked. Always move the safety lever to the lock position.

WARNING

Always lock engine hood before servicing any component inside the engine compartment.

Keep all people clear of equipment and/or attachments when in the raised position to prevent injury hazards.

Following the presence of flammable fluids, do not use matches, cigar lighters or torches as lighting means when servicing the machine.

Deflate tyres before removing any foreign objects from treads. In any case, you should deflate them before disassembly.

YYYYYY

Always use suitable tools to align holes. DO NOT USE FINGERS OR HANDS. Do not park, service, repair the machine nor carry out any work without prior moving the hydraulic system lock safety lever in the locked position.

Always lower the attachment to the ground and relieve pressure from all circuits before carrying out any type of maintenance work.

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-1

MAINTENANCE

GENERAL NOTES To operate the machine correctly means to prolong its working life.

Follow instruction for inspection and correct service the machine supplied in this Manual.

Check the machine every day before commencing the work: • Check controls and instruments.

• Check oil, fuel, and coolant levels (with the machine parked on level ground).

• Check pipes and hoses for possible leaks, fluid, kinking, fraying or damages.

• Visually inspect the machine outside considering its condition, noises if any or excess heat release.

• Check for loose or detached parts.

F1441

If the machine exhibits any fault, repair before starting the machine or contact your Dealer.

IMPORTANT: • Use only recommended fluids and lubricants (refer to the FILLING CHART in this chapter).

• Use only genuine spare parts.

• Using fuel, lubricants, fluids or spare parts other than the recommended ones will immediately invalidate the warranty.

• Never change the fuel injection pump governor setting or the hydraulic system safety valve setting.

• Lead seals can be removed solely by authorised personnel, otherwise the Manufacturer rejects any responsibility as regards the guarantee.

• Always keep protected electrical parts away from water and dampness.

• Never remove electrical components such as the main electronic central unit, sensors, etc. as they may be irreversibly damaged.

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-2

MAINTENANCE

CHECK HOUR METER REGULARLY • Read machine worked hours on the hour-counter (1) and determine, on the basis of the GENERAL MAINTENANCE AND LUBRICATION CHART in this chapter, when and which type of servicing is required.

• Service intervals indicated in the table refer to a machine working under normal operating conditions.

• During the first period of use of the machine and under particularly heavy operating conditions shorter service intervals may be required than shown in the table.

1

F24147

SERVICE REMINDER PLATE A plate (1) is located inside the toolbox, showing main lubrication and cleaning operations and replacements to be carried out periodically.

1 F23976

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-3

MAINTENANCE

PREPARE THE MACHINE FOR MAINTENANCE Before performing the maintenance procedures detailed in the following chapters, park the machine as described below if not otherwise specified.

• Park the machine on a level surface.

• Lower the bucket to the ground • Turn the auto-idle switch off.

• Turn the hand engine speed control fully counterclockwise.

• Turn the key-start switch (OFF) and remove the ignition key. (If maintenance is to be performed with the engine running, do not leave the machine unattended).

• Pull the l.h. console (1) and move it to the (LOCK) position.

• Before performing any maintenance work on the machine, maintenance engineers must apply the sign “maintenance in progress” (2) signalling that the machine is not completely efficient and that such maintenance staff is located in not visible positions.

This warning can be placed on the l.h. control lever, on the safety lever or on the cab door.

• Prior to and after any lubrication work, thoroughly clean grease fittings, covers and plugs to avoid penetration of foreign matters inside the mechanisms.

• We recommend to replace oil in the different components, immediately after stopping the machine. In this way, oil being hot is drained more easily together with possible loose particles.

YY

S

CAUTION

F24729

1

YY

If it is advised to carry out maintenance work with the components still hot, that is immediately after stopping the machine, the body must be protected with suitable clothing and protections to avoid burns and personal injuries.

F24536

2

F6069

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-4

MAINTENANCE

HOOD AND ACCESS COVERS

YY

S

CAUTION

YY

Do not keep the hood and access covers open when the machine is parked on a slope or if the wind is blowing. The hood and access covers may accidentally close resulting in serious personal injury.

Engine hood (r.h. side of machine) Lift the hood (1) by using the special handle on the hood itself. The hood is kept in the open position by means of two gas springs (2).

1 2

F24031

Tank compartment door (machine rear l.h. side) 3

Open the access cover (3) with the special handle. The door is locked in opening position through a gas spring (4).

4 F24032

Radiator compartment door (machine rear r.h. side)

5

Open the access cover (5) with the special handle. The door is locked in opening position through a gas spring (6).

6

F24033

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-5

MAINTENANCE

EXTERNAL VISUAL INSPECTION If proper corrective action is taken as soon as the problem is first suspected, machine maintenance costs and down-times may be consistently reduced.

Therefore, we recommend to visually inspect from the outside the components indicated in the figure each day, before starting the work or at the end of the working day, to assess their condition.

Dirt found in the outer air prefilter

Loose bolts, nuts, and/or straps; worn or damaged parts Oil leaks from the hydraulic system; dirt found on the hydraulic cylinders and leaks

Failed or inoperative gauges Dirt found in the radiator grid

Tyre pressure and wear Attachment conditions Oil or water leaks from the engine

Axles and differential: oil leaks

Transmission: oil leaks

Wheels side reduction gears: oil leaks F24034

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-6

MAINTENANCE

CHECKS BEFORE STARTING DAILY WORK Replace

ITEMS TO BE CHECKED Engine oil Hydraulic system oil Fuel tank Windscreen washer tank

Lubrication

Cleaning

Check

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Fuel pre-filter

12345678901234 12345678901234 12345678901234

Engine cooling system

ENGINE OIL (Visual inspection and topping up)

YY

S

DANGER

YY

Do not run the engine in closed spaces without proper ventilation and/or an adequate system capable to remove noxious exhaust gases.

YY

S

WARNING

YY

Always ensure that engine hood is correctly locked in the open position: danger of personal injuries.

YY

S

WARNING

YY

F24729

Remember that engine and oil can reach high working temperatures. Therefore, while carrying out this operation when the engine is still hot, protect your body with suitable clothing and means so to avoid burns and personal injuries.

IMPORTANT: check oil level with the engine cold and stopped.

• Park the machine on a level surface.

• Rest the bucket to the ground.

• Switch off the auto-idle, fully turn the engine speed manual control anticlockwise, stop the engine, remove the ignition key and move the l.h. console in the locked position (LOCK) • Wait for 15-20 minutes until oil flows inside the sump.

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-7

MAINTENANCE

• Open the engine hood as described in chapter “ HOOD AND ACCESS COVERS”.

• Pull out the dipstick (2), wipe it clean using a clean

2

cloth and insert it again into its seat. Remove again and check level. The level should be between the MIN and MAX marks indicated on the dipstick.

NOTE: insert the dipstick slowly into its seat, so as to avoid that the pressure alters the level check.

MAX

MIN.

If a low engine oil level is indicated, remove the plug (1) and restore correct level by adding oil through the filler neck.

• Close the engine hood.

F20466

IMPORTANT: Do not top up using oil with different specifications from the oil already in the hydraulic oil reservoir (see FILLING CHART in this chapter).

1

2

F24622

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-8

MAINTENANCE

HYDRAULIC SYSTEM OIL (Visual inspection and topping up)

YY

S

CAUTION

YY

Hydraulic system components and hoses can reach very high temperatures during operation. Stop the machine and let engine cool down before starting any inspection or maintenance: danger of burns.

If a check is performed at the end of the working period, follow the indications herebelow: • Park the machine on a level surface; • Fully retract the arm cylinder and fully extend bucket cylinder.

• Rest the bucket onto the ground; • Switch off the auto/idle, fully turn the engine speed manual control anticlockwise, stop the engine, remove the ignition key and move the l.h. console to the locked position (LOCK).

• If hydraulic oil level is low, (1) top up as detailed in MAINTENANCE AFTER 2500 HOURS OF OPERATION in paragraph “HYDRAULIC SYSTEM OIL”.

F24729

IMPORTANT: do not top up using oil with different specifications from the oil already in the hydraulic oil reservoir (see FILLING CHART in this chapter).

1

F24036

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-9

MAINTENANCE

FUEL TANK (Visual inspection and refuelling)

YY

S

WARNING

2

YY

The fuel is flammable. Do not puncture or burn fuel containers. Follow instructions given on the containers as regards storage and distribution.

Following the presence of highly flammable vapours, extinguish all smoking materials and open flames before checking the fuel level, refuelling, replacing the filters or opening the drain plug.

Do not refuel the machine while the engine is running.

Do not use matches, cigar lighters or torches as light source on the machine.

1

F24564

• Ensure the machine is parked on a level surface.

• Rest the bucket to the ground.

• Switch off the auto-idle, fully turn the engine speed manual control anticlockwise, stop the engine, remove the ignition key and move the safety lever in the locked position (LOCK).

NOTE: Refuel using decanted fuel. Transfer fuel from the storage container to the machine tank using the electrical pump.

We advise to fill the tank at the end of the working day, to prevent condensation formation overnight.

Check that the tank does not run out of fuel, because this would cause air seepage in the fuel system and air should then be bled from the fuel tank.

• Check fuel level using the external sight glass (1).

• Open the filler neck (2) by using the key supplied and refuel.

• Then check indicator (1) to determine the level of fuel reached

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-10

MAINTENANCE

WINDSCREEN WASHER TANK (Check) Located outside the operator’s seat, inside the l.h. side tank compartment. Check the detergent level and fill if necessary.

NOTE: during winter, use suitable detergent mixed as necessary according to the outside temperature.

YY

S

WARNING

YY

The pure detergent liquid catches fire easily when in touch with combustive substances or in presence of incendive sources (sparks, open flames). Avoid smoking during windscreen washer liquid refuelling.

F24038

FUEL PRE-FILTER (Cleaning)

3

Draining the water When indicator light comes on, drain the water trapped inside the fuel pre-filter (1) operating as follows: • Open engine hood.

• Remove clogging sensor (2) by pressing the relevant securing band.

• Turn slowly ring-nut (3) and drain the water into an appropriate container. When only the fuel starts flowing out, shut the ring-nut.

• Install the clog sensor (2) and close engine hood.

1

2 F24039

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-11

MAINTENANCE

ENGINE COOLING SYSTEM (Coolant visual inspection and topping up)

YY

S

CAUTION

YY

Never remove coolant recovery tank or radiator cap when engine is hot: danger of burns.

If a check is performed at the end of the working period, follow the indications herebelow: • Park the machine on a level surface.

• Rest the bucket to the ground.

• Switch off the auto/idle, fully turn the engine speed manual control anticlockwise, stop the engine, remove the ignition key and move the left safety lever in the locked position (LOCK).

• Open the cover of the radiators’ bay and lock it in raised position • Check for coolant inside the recovery tank (1).

• If the level is low, or, below the half of tank, remove plug (2) and restore level.

• Apply plug (2) and close panel.

IMPORTANT: in case of top-up, keep to the water and coolant ratio contained in the system. Use clean water and possibly free of chloride compounds (see FILLING CHART in this chapter).

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-12

MAINTENANCE

MACHINE LUBRICATION AND MAINTENANCE GENERAL TABLE SERVICE INTERVALS (HRS) ITEMS TO BE CHECKED

PAGES

100 500 1000 1500 2000 2500 3000

1234567 1234567 1234567 1234567 1234567 1234567 1234567 1234567 12345

Bucket links

4-14

Boom and arm

4-15

Stabilizers or blade

4-15

Outer and inner circulation air cleaners

4-17

Air cleaner: outer element (*)

12345 12345 12345 12345 12345 12345 12345 12345 12345 12345 12345 12345 12345 12345 12345 12345 12345 12345

4-19

Slew reduction gear oil

1234567 1234567 1234567 12345 1234567 1234567 12345

12345 12345 12345 12345 12345 12345 12345 12345

1234567 1234567 1234567 1234567 1234567 12345

4-20 / 4-59

Oil for axle reduction gears

4-21

Front and rear axle oil

4-22

Transmission oil

4-22

Hardware tightening torques

4-23

Tyres

4-30

Fuel tank

4-31

Hoses, lines and connections

4-32

Fuel hoses

4-40

Hydraulic oil tank

4-41

Engine oil and filter (*)

4-42

Fuel filter

4-44

Hydraulic system oil filter

4-46

Slewing ring bearing

4-48

Slewing ring teeth

4-49

Front axle

4-50

12345 12345 12345

Engine cooling system (*) Accumulators charge

4-52

12345 12345 12345 12345

Brake and pilot system oil filter

4-53

Air conditioning system

4-54

Air cleaner: outer element

4-55

Fuel pre-filter

4-56

Alternator - fan belt

4-58

Transmission oil, axles oil

4-61

Air cleaner: inner element (*)

4-65

4-51/ 4-63

123456 Hydraulic system oil (**) 123456 123456 123456 Engine valves

4-66 4-72

(**) IMPORTANT: if the machine has been refilled with biodegradable hydraulic oil HYDRAULIC EXCAVATOR FLUID BIO (on demand), be informed this oil cannot be mixed with mineral hydraulic oil.

Replace Lubrication

( * ) Service to be carried out when the relative warning light comes on.

Cleaning

12345678 12345678 12345678 12345678 12345678

123456 Check 123456 123456 123456

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-13

MAINTENANCE

AFTER 100 HOURS OF OPERATION ITEMS TO BE CHECKED

Replace

Lubrication

Cleaning

Check

Bucket links Arms and swing unit Stabilizers or blade

BUCKET LINKS (Lubrication) • Ensure the machine is parked on a level surface.

• Rest the bucket to the ground.

• Switch off the auto/idle, fully turn the engine speed manual control anticlockwise, stop the engine, remove the ignition key and move the left safety lever in the locked position (LOCK).

Using a grease gun, inject grease of the specified type (see FILLING CHART in this chapter) in the grease point of the links shown.

IMPORTANT: We recommend to lubricate every 10 working hours if the machine has been operated in water or mud.

F24729

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-14

MAINTENANCE

BOOM AND ARM (Lubrication) • Ensure the machine is parked on a level surface.

• Rest the bucket to the ground and position the boom to obtain easy access to all greasing points shown.

If necessary, use only special safety ladders during lubrication.

• Switch off the auto/idle, fully turn the engine speed manual control anticlockwise, stop the engine, remove the ignition key and move the left safety lever in the locked position (LOCK).

Through a grease gun, apply the suggested grease (see FILLING CHART in this chapter) in the grease points of all cylinders fitted on arms (see the figures).

F24532

STABILIZERS OR BLADE (Lubrication) • Park the machine on a level surface.

• Rest the bucket to the ground.

• Switch off the auto/idle, fully turn the engine speed manual control anticlockwise, stop the engine, remove the ignition key and move the l.h. console to the locked position (LOCK).

Using a grease gun, inject grease of the specified type (see FILLING CHART in this chapter) in the grease nipples of stabilizers and blade.

F24533

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-15

MAINTENANCE

AFTER 500 HOURS OF OPERATION ITEMS TO BE CHECKED

Replace

Outer and inner circulation air cleaners Air cleaner: outer element

Lubrication

Cleaning

Check

123456789012345678 123456789012345678 123456789012345678 123456789012345678 123456789012345678 123456789012345678 123456789012345678 123456789012345678 123456789012345678 123456789012345678 123456789012345678 123456789012345678 12345678901234 123456789012345678

12345678901234 12345678901234 12345678901234 12345678901234 12345678901234 12345678901234 12345678901234 12345678901234 12345678901234 12345678901234 12345678901234 12345678901234 12345678901234 12345678901234 12345678901234 12345678901234 12345678901234 12345678901234 12345678901234 12345678901234 12345678901234 12345678901234 12345678901234 12345678901234 123456789012345678 123456789012345678

Slew reduction gear oil Oil for axle reduction gears Front and rear axle oil Transmission oil Hardware tightening torques Tyres

123456789012345678 123456789012345678 123456789012345678 123456789012345678 12345678901234

Fuel tank

12345678901234 12345678901234 12345678901234 12345678901234 12345678901234 12345678901234 12345678901234 12345678901234 12345678901234 12345678901234 12345678901234 12345678901234

Hoses, lines and connections Fuel hoses Hydraulic oil tank Engine oil and filter Fuel filter Hydraulic system oil filter Slewing ring bearing Slewing ring teeth Front axle

123456789012345678 123456789012345678 123456789012345678 123456789012345678 123456789012345678 123456789012345678 12345678901234 123456789012345678 12345678901234

Engine cooling system

12345678901234 12345678901234 12345678901234

Accumulators charge

12345678901234 12345678901234 12345678901234 12345678901234 12345678901234 12345678901234

Brake and pilot system oil filter Air conditioning system

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-16

MAINTENANCE

OUTER AND INNER CIRCULATION AIR CLEANERS (Cleaning)

YY

S

CAUTION

YY

Keep people not involved in the maintenance work outside the working area. Wear adequate protective clothes and glasses with side shields as a protection against flying debris.

• Rest the bucket to the ground.

• Switch off the auto/idle, fully turn the engine speed manual control anticlockwise, stop the engine, remove the ignition key and move the l.h. console to the locked position (LOCK).

F24729

1

Removing the rear storage shelf • Move the driver’s seat fully forward.

• Remove the fixing knobs (1) of the storage shelf (2) and take off the same from its seat.

2

1

Installing the storage shelf

• Install the storage shelf as follows: - Position the storage shelf (2) into its seat and secure it using the screws (1).

F19962

Removing the inner circulation air cleaner (*)(5)

• Remove filter as follows: - remove knob (3). Lift grid carrying filter (4) and remove filter (5). (*) This filter is fitted only if the machine is equipped with the air conditioning system.

5 4

Removing the outer air cleaner (6) • Remove filter as follows: - Remove knobs (7) and cover (8); - remove filter (6).

3

IMPORTANT: clean the filters using compressed air at a pressure value lower than 0.2 MPa, (2 kg/cm2). Otherwise, filters would be damaged.

F19963

Cleaning the outer (6) and inner (5) circulation air cleaners • Clean the filters using compressed air at a pressure lower than 0.2 MPa (2 kg/cm2) or water.

7 8 7

F19964

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-17

MAINTENANCE • When cleaning using water, proceed as follows: - clean filters using clean water; - let the filter soak in a water and neutral detergent mixture for 5 minutes; - rinse the filter in clean water to remove remaining detergent, dust and dirt; - dry the filters.

6

Installing the outer air cleaner 6) (after cleaning or if new) • Install the filter as follows: - position the filter so that arrows (9) stamped on the filter itself are turned towards the inside of the cab.

F24537

Installing the inner circulation air cleaner (5) (after cleaning or if new) • Install the filter as follows: - reposition the filter into its grid (5).

• Install knob (3) again.

9

Filter replacement with new ones Filters should be replaced observing the following: • Outer air cleaner: after cleaning it 10 times; • Inner circulation air cleaner: when so clogged to make cleaning impossible.

F19966

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-18

MAINTENANCE

AIR CLEANER: OUTER ELEMENT (Cleaning) 1 IMPORTANT: operation to be performed also when the relevant indicator light is on.

YY

S

CAUTION

YY

Always wear safety glasses with side shields when using compressed air to clean parts to reduce the risk of personal injuries due to projected particles. Limit pressure to 0.2 MPa (2 kg/cm2).

F24538

Proceed with the cleaning of the outer element of the cleaner operating as follows: • Park the machine on a level surface.

• Rest the bucket to the ground.

• Switch off the auto/idle, fully turn the engine speed manual control anticlockwise, stop the engine, remove the ignition key and move the l.h. console to the locked position (LOCK).

• Open engine hood.

• Loosen wing nut (1) and extract cover with outer element.

• Clean outer element (2) using compressed air.

Direct the air jet from the inside to the outside of the filter.

• Check that there are no holes or cuts in the filter placing a proper light inside the filter. The light shows holes or cuts in the filter. In this case replace it.

• Insert outer element (2), making sure that it is well fitted and secure it with wing nut (1).

2

F20464

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-19

MAINTENANCE

SLEW REDUCTION GEAR OIL (Check)

YY

S

WARNING

YY

Never service or inspect slew motor circuits with the machine parked on a slope.

This circuit is under high pressure due to machine weight.

YY

S

CAUTION

YY

Slew reduction gears and oil therein can reach high operating temperatures. Therefore, while carrying out this operation with the machine still hot, the body must be protected with suitable clothing and protections to avoid burns and personal injuries.

F24729

• Park the machine on a level surface.

• Rest the bucket to the ground.

• Switch off the auto/idle, fully turn the engine speed manual control anticlockwise, stop the engine, remove the ignition key and move the l.h. console to the locked position (LOCK).

• Wait until the oil is cold.

• Check oil level in the reduction unit using the dipstick (2).

• Level should be between the MIN and MAX marks shown on the dipstick.

• If oil level is low, top it up through filler neck (1).

1

IMPORTANT: do not top up with oil having different specifications than the one already contained in the reduction gear (see the FILLING CHART in this chapter).

F24539

2

MIN.

MAX

F20466

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-20

MAINTENANCE

AXLE REDUCTION GEARS OIL (Check)

YY

S

WARNING

YY

Do not loosen the oil drain/level screws, unless reduction gear oil pressure is first relieved.

• During the bleeding operation, stay in a shielded position with respect to the reduction gear and wear safety glasses or goggles.

• Loosen the level/drain screws slowly of some turns, to enable trapped air to escape.

1

• Park the machine on a level surface with the engine warm.

• Rest the bucket to the ground.

• Switch off the auto/idle, fully turn the engine speed manual control anticlockwise, stop the engine, remove the ignition key and move the safety lever in the locked position (LOCK).

1

Position the reduction gear as shown and check the oil level in the four cases (one to each wheel) which should reach plug (1); if necessary, makeup through plug opening.

F24540

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-21

MAINTENANCE

FRONT AND REAR AXLES OIL (Check)

YY

S

WARNING

YY

Do not loosen the oil drain/level screws unless reduction gear oil pressure is first relieved.

• When draining an axle, do not place yourself in front of it and always wear safety glasses or goggles to protect your eyes.

• Loosen the level/drain screws slowly of some turns, to enable trapped air to escape.

1

F24542

• Park the machine on a level surface with the engine warm.

• Rest the bucket to the ground.

• Switch off the auto/idle, fully turn the engine speed manual control anticlockwise, stop the engine, remove the ignition key and move the l.h. console to the locked position (LOCK).

Check the oil level in the differential casing of each axle: it should reach plug (1); if necessary, top up through plug opening.

TRANSMISSION OIL (Check)

• Park the machine on a level surface with the engine warm.

• Rest the bucket to the ground.

• Switch off auto/idle, fully turn the engine speed manual control anti-clockwise, stop the engine, remove the ignition key and set the l.h. console in the locked position (LOCK).

1 Check level of oil in the gearbox which should reach plug (1); if necessary, top up through same.

F24541

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-22

MAINTENANCE

HARDWARE TIGHTENING (Check) • Park the machine on a level surface. To assist checking the fuel tank and hydraulic oil reservoir mounting bolt tightening, slew the upper structure by 90°. Remaining checks can be performed with the upper structure parallel to the undercarriage.

• Rest the bucket to the ground.

• Fully turn the engine speed manual control anticlockwise, stop the engine, remove the ignition key and move the l.h. safety lever in the locked position (LOCK).

• Tightening torques should be checked using a suitably pre-set torque wrench.

F24729

ENGINE FIXING BOLTS

YY

S

WARNING

A

YY

Always make sure that engine hood is correctly locked in the open position. danger of personal injuries.

• Open engine hood and lock it in the open position as detailed in the paragraph “HOOD AND ACCESS COVERS”.

• Check tightening torques of the following bolts: A) Engine elastic supports retaining bolts (front side): Screw: M16 x 2 Torque: 21 ± 2 daNm Bush: 24 mm B) Engine elastic supports retaining bolts (rear side): Screw: M16 x 2 Torque: 21 ± 2 daNm Bush: 24 mm C) Engine supporting bracket fixing screws (rear side): Screw: M12 x 1.75 Torque: 11 ± 1 daNm Bush: 19 mm D) Engine supporting bracket fixing bolts (front side) Screw: M12 x 1.75 Torque: 11 ± 1 daNm Bush: 19 mm

B D

C

F24544

• Close the engine hood.

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-23

MAINTENANCE OIL TANK FIXING SCREWS • Reach machine underneath and loosen the protection panel retaining bolts near the hydraulic oil tank, then remove panel.

• Check bolt tightening torque as follows: - Screw: M16 x 2 - Torque: 21 ± 2 daNm - Bush: 24 mm • Reinstall protection panel and relevant fixing screws.

F24545

FUEL TANK FIXING SCREWS • Reach machine underneath and loosen the protection panel retaining bolts near the fuel tank, then remove panel.

• Check bolt tightening torque as follows: - Screw: M16 x 2 - Torque: 21 ± 2 daNm - Bush: 24 mm • Reinstall protection panel and relevant fixing screws.

F24546

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-24

MAINTENANCE HYDRAULIC PUMP-TO-ENGINE FLANGE FIXING NUTS • Open engine hood.

• Check hydraulic follows: - Screws (A): - Torque: - Bush:

pump fixing screws torque as M10 x 1.5 5 ± 0.5 daNm 17 mm

- Screws (B): - Torque: - Bush:

M20 x 2.5 22 ± 2 daNm 30 mm

A

B

• Once the operation is over, close the door.

F24547

CONTROL VALVE-TO-SUPPORT FIXING SCREWS • Check the torque, hereunder indicated, of the control valve to bracket fixing screws: - Screw: M14 x 2 - Torque: 18 ± 2 daNm - Bush: 22 mm

F24548

COUNTERWEIGHT FIXING SCREWS • Check the torque, hereunder indicated, of the bracket fixing screws to the frame: - Screw: M24 x 2 - Torque: 60 ± 5 daNm - Bush: 36 mm

F24549

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-25

MAINTENANCE SLEW REDUCTION UNIT FIXING SCREWS • Check torque of the slew reduction unit fixing screws (A) and (B) as follows: A

Engine fixing screws (A): - Screw: M8 x 1.25 - Torque: 3 ± 0.3 daNm - Bush: 6 mm Gear motor fixing screws (B): - Screw: M16 x 2 - Torque: 21 ± 2 daNm - Bush: 24 mm

B

F24550

BATTERY BRACKET FIXING SCREWS • Remove battery protection.

• Check bracket fixing screw torque as follows: Side bracket - Screw: M10 x 1.5 - Torque: 5 ± 0.5 daNm - Bush: 17 mm

F25295

SWIVEL JOINT FIXING SCREWS - Screw: M12 x 40 - Torque: 11 ± 1 daNm - Bush: 19 mm

F24551

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-26

MAINTENANCE CAB FIXING NUTS • Raise the rubber mat covering the cab floor to gain access to the mounting nuts fixing the cab to machine frame.

• Check tightening torque, hereunder indicated, of cab fixing nuts: - Nuts: M16 x 2 - Torque: 21 ± 2 daNm - Bush: 24 mm

SLEWING RING FIXING SCREWS • Check torque of the slew bearing to under structure screws (A) and slew bearing to upper structure screws (B) as follows: Slewing ring-to-undercarriage fixing screws (A): - Screw: M16 x 2 - Torque: 33 ± 3 daNm - Bush: 24 mm

A

B

Screw (B) fixing slewing ring to upper structure: - Screw: M16 x 2 - Torque: 33 ± 3 daNm - Bush: 14 mm

F24552

REAR AXLE FIXING NUT - Nut: M24 x 3 - Torque: 70 ± 7 daNm - Bush: 36 mm

FRONT AXLE FIXING NUT - Nut: M20 x 2.5 - Torque: 50 ± 5 daNm - Bush: 30 mm

F24553

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-27

MAINTENANCE FIXING SCREWS FRONT AXLE LOCK CYLINDER WX95 - Screw: M16 x 2 - Torque: 21 ± 2 daNm - Bush: 24 mm WX125 - Screw: M18 x 2.5 - Torque: 30 ± 3 daNm - Bush: 27 mm

F24554

HYDRAULIC TRAVEL MOTOR FIXING SCREWS WX95 - Screw: M12 x 1.75 - Torque: 11 ± 1 daNm - Bush: 19 mm WX125 - Screw: M 16 x 2 - Torque: 21 ± 2 daNm - Bush: 24 mm

F24555

WHEELS FIXING NUTS - Nuts: M22 x 1.5 - Torque: 50 ± 4 daNm - Bush: 32 mm

F24557

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-28

MAINTENANCE BLADE AND STABILIZERS FIXING SCREWS WX95 - Screw: M20 x 2.5 - Torque: 50 ± 5 daNm - Bush: 30 mm WX125 - Screw: M24 x 3 x 50 - Torque: 60 ± 5 daNm - Bush: 36 mm

F24556

FIXING SCREWS OF CONTROL VALVE SUPPORT PLATE - Screw: M14 x 40 - Torque: 18 ± 2 daNm - Bush: 22 mm

F24615

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-29

MAINTENANCE

TYRES

WX95

(Pressure check)

YY

S

WARNING

YY

• Deflate tyres before removing any foreign objects from treads. In any case, you should deflate them before disassembly.

YY

S

WARNING

Type

Engine maker

Assembly

Inflating pressure

8.25-20 EM PR14

BARUM

coupled

6.75 bar

single

6 bar

coupled

6.9 bar

500/45-20 ALLIANCE PR18

YY

8.25-20 14PR MT54

• Make sure tyres are correctly inflated according to pressure vales recommended by the Manufacturer.

• Check tyres periodically for damages.

• Check pressures exclusively when tyres are cold, so to prevent scarce inflation.

• During inflation, stand next to tyre and pay attention.

• Never inflate tyres with flammable gases, nor use air derived from pneumatic systems based on alcohol injectors.

• Always check wheel bolts and/or clamp blocks between ring and flange. If necessary, re-tighten as instructed and as required.

TVS

WX125 Type

Engine maker

Assembly

Inflating pressure

10.00-20 PR14

BARUM

coupled

6.5 bar

single

6 bar

coupled

7.6 bar

600/40-22.5 ALLIANCE PR18 10.00-20 16PR MT54

Improper inflation greatly contributes to tyre troubles and failure.

If inflation pressure is poor, the tyre ply will get damaged. A continuous tyre sideways bending may eventually cause cuts and detachment from tyre plies.

Avoid also inflation with excessive pressure. To carry out work on very soft terrains, the machine floating can be improved, by decreasing the tyres inflation pressure. The recommended pressure should be applied on cold tyres. Should the machine be used over continuous working shifts of 24-hours, and therefore pressure cannot be checked on perfectly cold tyres, a correction factor has to be defined as follows: check pressure on cold tyres several time, then check it again after two hours of operation. The average difference must be added to the recommended pressure when checking the tyres during constant operation. Continuous operation of machine builds up heat inside tyres, thus increasing inner pressure.

During the tyre planning phase such normal increases have been considered.

TVS

A

C

B

F5640

IMPORTANT: check wheel nuts tightening to prevent possible loosening.

Tighten wheel nuts according to the following value: 50 da Nm.

Inflation pressure in travel conditions (cold).

Tyre inflation A. Insufficient B. Correct C. Excessive

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-30

MAINTENANCE

FUEL TANK (Condensate drain)

YY

S

WARNING

YY

Due to flammable vapours, all smoking materials and naked flames should be extinguished before checking fuel level, refuelling the machine, replacing the filters, or removing the condensate drain plug.

If a check is performed at the end of work, follow the indications herebelow: • park the machine on a level surface with the upper structure turned by 90° in order to make access easier.

• rest the bucket on the ground; • fully turn the manual accelerator control knob anticlockwise. Stop the engine, remove the start-up key and move the safety lever to the LOCK position.

• Reach the fuel tank under the upper structure and remove the access panel.

• Slowly remove plug (1) and let condensate and deposits drain into a suitable container, until only clean fuel comes out.

1

F24579

NOTE: When the temperature is above 0°C draining can be done before engine start-up. When working with temperatures below 0°C, the tank should be drained at the end of working shift, after engine shut-down, as water might freeze and not drain properly.

• Fit plug (1) and cover when the operation is over.

Handle and dispose of the water mixed with fuel oil according to current legislation. Use only authorised disposal procedures. For any doubt, apply to authorities concerned.

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-31

MAINTENANCE

HOSES, LINES AND FITTINGS (Check and assembly instructions)

YY

S

WARNING

YY

Always make sure that engine hood is correctly locked in the open position. danger of personal injuries.

• Escaping fluid under pressure can penetrate the skin causing severe injuries. Avoid such risks by looking for leaks using a cardboard.

• Protect hands and body from high pressure fluids.

In case of accidents, seek immediate medical care and apply to specially skilful doctors. Any fluid penetrated under the skin should be surgically removed within few hours as gangrene may result.

• Hydraulic oil and lubricant leakage may cause a fire, with consequent serious injuries.

• Start servicing the hydraulic system components only after such components, hydraulic oil and lubricants have completely cooled down and after releasing any residual pressure.

• Keep in mind that servicing overheated hydraulic components under pressure may cause pressure oil to escape suddenly, thus leading to personal injuries.

• Keep body parts and face far from plugs and bolts during removal.

• Hydraulic components may be under pressure even after cooling down.

• Never service or inspect travel or swing motor circuits on slopes. They are under high pressure due to machine weight.

• Always wear protective clothing, safety glasses with side shields and oil-proof gloves.

• Fluid under pressure. Always lower the hydraulic attachment to the ground. Stop the engine and press the pressure release button located on the hydraulic tank prior to starting any maintenance operation.

• Hydraulic components may become very hot during operation. Before starting inspection or maintenance operations, wait until the machine has cooled down.

F3636

F3637

F1471

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-32

MAINTENANCE • Park the machine on a level surface.

• Rest the bucket to the ground.

• Fully turn the engine speed manual control anticlockwise, stop the engine, remove the ignition key and move the safety lever to the locked position (LOCK). Wait until the machine has cooled down • Open engine hood and the air filter bay, hydraulic pump bay, and battery/radiator bay covers. Latch covers in the open position as detailed in paragraph “ENGINE HOOD AND ACCESS COVERS”.

Hoses and lines check • Check hose clamps and fit then if missing, check possible twisted hoses, flexible lines or hoses touching between them, damaged oil cooler, and loosened oil cooler flange screws. Moreover, through this check possible leaks may be detected.

• Check the hoses, lines and oil cooler by especially observing the points listed below. In this way possible damages causing future leaks may be detected. If any fault is found, replace or tighten the connections.

• Tighten, repair or replace all damaged, loose or missing clamps. Check the hydraulic oil cooler, cooler sleeves and companion flanges which should be free from leaks. Replace damaged or worn hoses and lines.

• Never bend or hit high pressure lines.

• Never install hoses or lines if damaged or bent.

• When connecting hoses and/or lines, pay attention to keep sealing surfaces clean from dirt and not to damage them. Observe following precautions: - wash pipes and hoses, both inside and outside, with washing fluid. Thoroughly dry them before reconnection.

- use exclusively O-ring seals without damages or faults. Pay attention not to damage seals during assembly.

- avoid hose twisting while connecting them. Duration of twisted hoses is drastically reduced.

- Carefully tighten the low pressure hose clamps by observing the suggested 0.6 ÷ 0.7 daNm torque.

Do not over tighten.

F24729

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-33

MAINTENANCE FLANGES ASSEMBLY PRECAUTIONS • Make sure that the sealing surfaces are clean and not damaged. Grooves and roughness may cause leaks and gasket wear. Possible differences in height may cause gasket extrusion. Replace the component when no repair is possible.

F21467

• Make sure that only the prescribed O-rings are used.

Check O-rings for possible damages. Pay attention not to file O-ring surfaces. While assembling an Oring in its groove, apply grease to keep it in position.

• Assemble the loosened half flanges. Make sure that the central groove is centrally and perpendicularly arranged with respect to the passing hole. Manually screw the fixing screws so to retain the pieces. Do not pinch the O-ring.

WRONG

F21435

• An even tightening is obtained by alternatively and diagonally tightening the screws, as indicated. Do no use air-operated wrenches. They could cause a complete screw tightening before the other ones are tightened, thus damaging the O-ring or causing uneven tightening.

F21436

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-34

MAINTENANCE PRECAUTIONS FOR SCREWS AND NUTS TIGHTENING

WRONG

CORRECT

• Correctly assemble all safety plates.

Firmly bend along the edge

IMPORTANT: Do not use safety plates again. Do not try to bend them on the same point.

Do not bend by a curve Firmly bend along the

edge F21437

• Correctly assemble all safety split pins.

IMPORTANT: Do not use split pins again. During tightening, align holes inside the screw and the nut without slackening.

CORRECT

CORRECT

CORRECT

F21438

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-35

MAINTENANCE PIPE CONNECTION PRECAUTIONS Union joints • Sealing metal surfaces (4) and (5) of adapter (1) and hose (2) touch so to maintain oil pressure. Union joints are used to connect any pipe characterized by a small diameter.

1

4

IMPORTANT: Do not exceed while tightening connection nuts (3).

The excessive force applied to the sealing metal surfaces (4) and (5) would otherwise crack adapter (1). Make sure that connection nut (3) is well tightened according to the prescribed torque.

Grooves or other damages on sealing surface (4) or (5) could cause oil leaks on the connection. Pay special attention during union connection and disassembly.

3

5

2

Connection body F21439

• Keep to the following tightening torques:

Male connection

Type

Connection 37°-type connection

Wrench dimension

Female connection

Tightening torque

Connecting nut

Body

Nm.

kgf m

19

17

29

3

22

19

39

4

27

22

78.5

8

36

30.32

157

16

41

36

205

21

50

46

255

26

NOTE: Tightening torque for male non-union 37°-type connections is the same as for female union 37°-type connections.

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-36

MAINTENANCE Connection with O-ring • O-ring (6) rests onto the extreme adaptor surfaces (7) to maintain the oil pressure.

7

IMPORTANT: Make sure that O-ring (6) is being replaced with a new one during reassembly. Before tightening connection nut (9), check that O-ring (6) is properly fitted on groove (8). An out-of-place connection nut (9) tightening with O-ring (6) cause damages and oil leaks.

Avoid damaging O-ring seat (8) or sealing surface (10). A possible O-ring damage (6) would cause oil leakage. Should the connection nut (9) be loosened, thus causing oil leakage, do not tighten again to eliminate the leak. On the contrary, replace O-ring (6) with a new one and tighten connection nut (9) after checking that O-ring (6) is properly seated.

6

8

9

10

Connection body F21441

Keep to the following tightening torques:

Wrench dimension

Tightening torque

Connection nut

Connection body

Nm

kgf m

27

22

93

9.5

36

30.32

175

18

41

36

205

21

50

46

320

33

Tightened connection

PF

PT

• Make sure that both pitch and screw-thread type (taper or straight) are properly connected before using a tightened connection.

30°

Keep to the following tightening torques:

Taper male screw-thread Wrench

Taper male screwthread

Tightening torque

Connection body

Nm

kgf m

17.19

34

3.5

19.22

49

5

27.22

93

9.5

36.32

157

16

41

205

21

50

320

33

60

410

42

Straight male screwF21442 thread

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-37

MAINTENANCE PRECAUTIONS WHEN USING THE SEALING TAPE Inner thread • The sealing tape is used to seal the clearance between male and female thread, in order to avoid lickings. Make sure that only the strictly necessary quantity of tape is used. Do not exceed with tape appliance.

Play Outer thread

F21388

• Verify that the thread surface is clean, without dust or damages. Apply the tape around the threads, as showed. Wind the sealing tape in the same direction of the threads.

Leave one or two thread pitches uncovered

F21390

CLIPS ASSEMBLY PRECAUTIONS

T-type screw

Worm-type screw

• The tightening torque of the clips for hoses under low pressure differs according to the type of clip. See, herewith, the correct tightening torque of each clip type for hose under low pressure.

Clamp with T-screw to tighten clips: 4.4 Nm (0.45 kgf m) Clamp with worm screw to tighten clips: 5.9 a 6.9 Nm (0.6 a 0.7 kgf m)

F21391

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-38

MAINTENANCE HOSES ASSEMBLY PRECAUTIONS • When replacing hoses, make sure to use only original spares. If you use different hoses, oil may lack, hoses may brake and seals may get loose with the hazard of fire spreads. Do not fit winded hoses.

The use of oil under high pressure, vibrations or hitting a winded hose could cause the breakage of the same or the loosening of the seals.

• If hoses rub one against the other, they could wear up to breakage. Take necessary measures to protect hoses and to avoid that they get in touch. Avoid that hoses come in touch with movable parts or sharp objects.

CORRECT

WRONG

F21392

WRONG

CORRECT

Hoses rubbing

F21393

CORRECT

WRONG Little bracket

Little bracket

Rubbing F21394

WRONG

CORRECT

Rubbing Little bracket F21395

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-39

MAINTENANCE

FUEL HOSES 2

(Check)

YY

S

WARNING

YY

1 1

Never use gasoline, solvents or other flammable fluids to clean parts. Use only proprietary certified solvents, non-flammable and non-toxic.

Always make sure that engine hood is correctly locked in the open position. danger of personal injuries.

YY

S

WARNING

3

4

YY

5

You are reminded that the engine can reach a high temperature during operation. Protect body and limbs with appropriate clothing and protections, since there is a danger for burns and personal injuries.

6

• Park the machine on a level surface.

• Rest the bucket to the ground.

• Fully turn the engine speed manual control anticlockwise, stop the engine, remove the ignition key and move the safety lever to the locked position (LOCK).

• Wait until the machine is cold.

• Open the engine hood and lock it in open position as described by paragraph “HOOD AND ACCESS COVERS”.

• Check the hoses to identify and eliminate wrinkling and that they are free from signs of rubbing which could cause leakages.

• Check the hoses in the points indicated in the table to identify and eliminate eventual leakages or any other damage which could result in a future leakage.

In the event troubles are found on hoses, they must be replaced or tightened, as indicated by the table.

• Repair or change all hoses which result to be loosen or damaged. Never install bent or damaged hoses.

7

NOTE: please refer to the illustrations on the side for each check point or for the description of the trouble. Use genuine spare parts only.

F21418

Check points

Troubles

Remedy

Hose end

Leakage (1)

Tighten or replace

Cracking(4)

Replace

Metal sleeve Rubbing (2)

Replace

Tearing (3)

Replace

Bending (5)

Replace

Folding (6)

Replace (use an appropriate bending radius )

Deformation or corrosion (7)

Replace

Hose

• Close the rear door and the engine hood.

Hose end and joints

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-40

MAINTENANCE

HYDRAULIC OIL SYSTEM RESERVOIR (Check)

YY

S

WARNING

YY

The hydraulic oil reservoir is under pressure. Press the pressure relieve button on the filler plug to relieve pressure before maintenance. Danger of personal injuries.

F24729

IMPORTANT: do not run the engine without hydraulic oil in the reservoir.

• Park the machine on a level surface with the upper structure turned by 90° in order to make access easier.

• Rest the bucket to the ground.

• Switch off the auto-idle, fully turn the engine speed manual control anticlockwise, stop the engine, remove the ignition key and move the safety lever in the locked position (LOCK). Wait until the oil is cold.

• Untighten tank filling plug (1) in order to release the pressure inside the tank.

YY

S

1

F24559

CAUTION

YY

Do not loosen the drain plug until oil has properly cooled down. Contact with hydraulic oil at working temperature may cause burns and personal injuries.

• Loosen the retaining bolts (4) of protection panel (3), located under the upper structure near the hydraulic oil reservoir and remove it.

• When oil is cold, release the drain plug (2) to drain condensation water and sediments into a suitable container. Do not fully remove the plug, release it enough to allow condensation and sediments to drain. Otherwise, also hydraulic oil would be drained out.

• when the operation is over, fit plug (2) and reassemble the cover located under the upper structure.

4

3

F25256

Handle and dispose of water mixed to hydraulic oil according to current regulations. Use only authorised disposal procedures. For any doubt, apply to authorities concerned.

2

F25257

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-41

MAINTENANCE

ENGINE OIL AND FILTER (Replacement)

YY

S

DANGER

YY

Do not run the engine in closed spaces without proper ventilation and/or an adequate system capable to remove noxious exhaust gases.

YY

S

WARNING

YY F24729

Remember that engine and oil can reach high working temperatures. Therefore, while carrying out this operation when the engine is still hot, protect your body with suitable clothing and means so to avoid burns and personal injuries.

YY

S

CAUTION

YY

Avoid prolonged repeated skin contact with exhaust engine oil as skin diseases or other syndromes may result. If this happens, thoroughly wash the area of contact.

3

• Park the machine on a level surface.

• Rest the bucket to the ground.

• Fully turn the engine speed manual control anticlockwise, stop the engine, remove the ignition key and move the l.h. safety lever in the locked position (LOCK).

• Open engine hood and lock it in the raised position as detailed in the paragraph “HOOD AND ACCESS COVERS”.

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

• Untighten plug (3).

• Screw manually the fitting and hose assembly (4) (supplied with the machine) onto the valve body (5).

This action will cause the body (5) inner valve to open and drained oil to flow into a suitable container.

• After draining, remove the fitting and hose assembly (4), reinstall plug (3) to the valve body (5).

F24560

5

4 F24561

1

2

F24035

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-42

MAINTENANCE To replace filter (6) proceed as follows: • open engine hood; • remove the support area and the area around the filter; • untighten filter (6) using a universal tool; • lubricate the seal of the new filter with engine oil; • tighten the filter by hand until the seals touch the support (8).

• tighten further by 3/4 of a turn using a universal tool; • close engine hood.

8

6 4

Handle and dispose of engine oil filters according to current regulations. Use only authorised disposal procedure. If in doubt, contact authorities concerned.

F24562

1

Refill using oil of type, grade and quantity specified (see the FILLING CHART in this chapter). Proceed as follows: • Pour new engine oil through the filler neck (1) until it reaches the maximum level shown on the dipstick (2); • then screw on the filler plug (1) and insert the dipstick (2); • start the motor, let it turn some minutes and then switch it off; • Using the dipstick (2), check oil level again and top up if different from previous check.

2

F24035

NOTE: insert the dipstick slowly into its seat, so as to avoid that the pressure alters the level check.

• Close the engine hood.

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-43

MAINTENANCE

FUEL FILTER (Replacement)

YY

S

WARNING

YY

Never use gasoline, solvents or other flammable fluids to clean parts. Use only proprietary certified solvents, non-flammable and non-toxic.

Always make sure that engine hood is correctly locked in the open position. danger of personal injuries.

YY

S

CAUTION

YY

We remind you that engine and oil can reach in operation very high temperatures, therefore, the body must be protected with suitable clothing and protections to avoid burns and personal injuries.

YY

S

WARNING

F24729

YY

Pay attention, during the removal phase, to avoid spilling the fuel inside the filter: there is a danger of fires.

2

• Park the machine on a level surface.

• Rest the bucket to the ground.

• Switch off the auto/idle, fully turn the engine speed manual control anticlockwise, stop the engine, remove the ignition key and move the l.h. console to the locked position (LOCK).

• Wait until the machine is cold.

• Open the engine hood as described in chapter “HOOD AND ACCESS COVERS”.

1

F25184

Replace the filter(s) proceeding as follows: clean the area around filter (1) and support (2); • Remove the filter(s) using an appropriate wrench or a universal tool.

• Fill the new filter(s) with clean fuel and tighten by hand until their seals touch the body of the support.

Tighten the filters further by 1/2 turn.

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-44

MAINTENANCE AIR BLEEDING • Then bleed the air that may have reached the fuel system during the replacement of the filter. Perform this operation as follows: - untighten fuel filter bleed screw (1) to let air bleed; - repeatedly press button (2) located on the filter to circulate fuel inside the fuel system; - continue priming until a minimum amount of fuel free of bubbles comes out of the loosened bleed screw (1). Close the screw; - then perform the engine start-up.

• Close engine hood.

1 2

Handle and dispose of used fuel filters according to current regulations. Use only authorised disposal procedure. If in doubt, contact authorities concerned.

F24158

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-45

MAINTENANCE

HYDRAULIC SYSTEM OIL FILTER (Replacement)

YY

S

CAUTION

YY

Do not carry out this operation if the machine is still very hot.

Contact with hydraulic oil at working temperature may cause burns and personal injuries.

• Park the machine on a level surface.

• Rest the bucket to the ground.

• Switch off the auto/idle, fully turn the engine speed manual control anticlockwise, stop the engine, remove the ignition key and move the l.h. safety lever in the locked position (LOCK).

• Wait until the machine is cold.

YY

S

WARNING

F24729

YY

The hydraulic oil reservoir is under pressure.

Press the pressure relief button on the filler plug to relieve pressure.

2 4

• Remove tank venting plug (1) in order to release the residual pressure inside the tank.

YY

S

WARNING

1

YY

Under the cover (2) there is a loaded spring (6).

Therefore slowly untighten screws (4) in order not to release the spring.

4

• Loosen the bolts (4) which retain the cover (2) as follows: - untighten four of the six screws (4); - hold the cover (2) down and loosen the last two bolts (4). This is to avoid sudden release of the spring (6); - remove cover (2).

• Remove spring (6) and filter element (5).

2 3 6 5

F24037

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-46

MAINTENANCE

NOTE: Check the filter element for possible metal or rubber chips to be examined to determine their origin.

In this manner the hydraulic system components involved can be immediately overhauled and repaired, if necessary.

2 4 1

• Replace the filter element (5) and the O-Ring seal (3).

• Install the new filter element (5) and spring (6) into the reservoir seat.

• Install cover (2) with a new O-Ring seal (3).

• Install the six cover (2) retaining bolts (4) and tighten to 5 daNm. 4

Handle and dispose of hydraulic system return oil filter according to current regulations. Use only authorised disposal procedure. If in doubt, contact authorities concerned.

2 3 6 5

F24037

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-47

MAINTENANCE

SLEWING RING BEARING (Lubrication)

YY

S

WARNING

YY

The lubrication of the slew ring, of the gear and the upper structure slew should be carried out by only one person.

Before lubricating the slewing ring, move people away from the operation area of the machine.

Before leaving the cab, arrange machine and controls as follows: F24729

• Park the machine on a level surface.

• Rest the bucket to the ground.

• Switch off the auto/idle, fully turn the engine speed manual control anticlockwise, stop the engine, remove the ignition key and move the l.h. console to the locked position (LOCK).

• With the upperstructure stationary, inject grease of the specified type (see the FILLING CHART in this chapter) through the two grease fittings (1).

• Start the engine, raise the bucket approximately 20 cm from the ground and slew the upper structure by 45° (1/8 of a turn).

• Lower the bucket to the ground.

Repeat the procedure above three times. Observe safety precautions detailed at the beginning of this paragraph.

• grease should be injected until it is seen coming out of the seals. Do not inject grease excessively. Quantity of grease necessary for this operation ~ 0.30 litres.

1

F24565

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-48

MAINTENANCE

SLEWING RING TEETH (Lubrication)

YY

S

WARNING

YY

Addition and/or replacement of grease into the slewing ring teeth and upperstructure swing should be carried out by a single person.

Have all people outside the machine operating range prior to starting these operations.

Before leaving the cab, arrange machine and controls as follows: • Park the machine on a level surface.

• Rest the bucket to the ground.

• Switch off the auto/idle, fully turn the engine speed manual control anti-clockwise, stop the engine, remove the ignition key and move the console in the locked position (LOCK).

• Untighten plug (1) • Surfaces of the slewing ring teeth should appear lubricated and visible grease should be free from impurities.

• If needed, add 0.5 litres of grease.

• If grease looks contaminated, replace it.

• Reinstall plug (1).

F24729

IMPORTANT: refer to the chapter “MAIN OPERATING RULES” if water or mud are found in the slewing ring.

1

2

• Remove plug (2) to check the tightening of the slewing ring bearing fastening screws.

F24566

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-49

MAINTENANCE

FRONT AXLE (Lubrication) • Park the machine on a level surface.

• Rest the bucket to the ground.

• Switch off the auto/idle, fully turn the engine speed manual control anticlockwise, stop the engine, remove the ignition key and move the l.h. console to the locked position (LOCK).

Using an appropriate gun, inject grease through the nipples of the front axle, as illustrated.

Repeat the operation on the opposite wheel.

F25188

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-50

MAINTENANCE

ENGINE COOLING SYSTEM (Radiators cleaning)

YY

S

WARNING

YY

Always make sure that engine hood is correctly locked in the open position. danger of personal injuries.

YY

S

CAUTION

YY

• Compressed air or pressure water jets will be used to perform this operation. Therefore, suitable clothing must be used to protect the body. In particular, wear glasses with side shields.

• Keep people not involved in the maintenance work outside the working area.

F24729

• Park the machine on a level surface and turn the upper structure by 90° to obtain easy access.

• Rest the bucket to the ground.

• Switch off the auto/idle, fully turn the engine speed manual control anticlockwise, stop the engine, remove the ignition key and move the l.h. console in the locked position (LOCK).

• Open the engine hood as described in chapter “ HOOD AND ACCESS COVERS”.

• Get under the machine, loosen the lower panel (1) retaining screws (3), panel located on the radiators and remove it from its seat.

• Now you can get access to the radiating masses (coolant radiator and hydraulic oil radiator) from both sides. Clean accurately using compressed air or pressure water.

1

3

F24567

IMPORTANT: use compressed air or pressure water not exceeding 0.2 MPa (2 kg/cm2). This in order not to damage the tubes and fins of the cooling radiators.

• If the machine is equipped with air conditioning, condenser (2) is also provided. Clean the condenser using compressed air or pressurized water.

• This operation completed, close the hood, the access panels and reinstall the protection located under the machine, fastening it with the relative screws.

IMPORTANT: When the machine works in particularly dusty conditions, check every day that condenser (2) is free from restrictions and impurities. If restricted or dirty, remove and clean.

2 F25192

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-51

MAINTENANCE

ACCUMULATORS CHARGE (Check)

YY

S

WARNING

1

YY

Ensure that no one is under or near the front attachment before starting the boom lowering procedure.

• Park the machine on a level surface.

• Keep the attachment raised at about 1.5 m from the ground.

• Switch off the auto/idle, fully turn the engine speed manual control anticlockwise, stop the engine.

• Operate the right control lever forward. If accumulator (1) is operating, the boom will lower.

• Lower boom to rest the bucket to the ground.

YY

S

WARNING

F24570

YY

If boom remains still, have accumulators pressure checked by an after-sales centre.

F24569

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-52

MAINTENANCE

BRAKE AND POWER CONTROLS OIL FILTER (Replacement)

YY

S

CAUTION

YY

Do not carry out this operation if the machine is still very hot. Contact with hydraulic oil at working temperature may cause burns and personal injuries.

• Park the machine on a level surface.

• Rest the bucket to the ground.

• Switch off the auto/idle, fully turn the engine speed manual control anticlockwise, stop the engine, remove the ignition key and move the l.h. console to the locked position (LOCK).

• Wait until the machine is cold.

F24729

1

YY

S

WARNING

YY

The hydraulic oil reservoir is under pressure. Press the pressure relief button on the filler plug to relieve pressure.

• Remove tank filling plug (1) in order to release pressure inside the hydraulic oil tank.

YY

S

WARNING

F24559

YY

Never use gasoline, solvents or other flammable fluids to clean parts. Use only proprietary certified solvents, non-flammable and non-toxic.

For replacement, disassemble the element as follows: • Untighten case (3) .

• Pull out the filtering element and O-ring (2) and replace them.

• Retighten case (3) by hand being careful not to make it too tight.

3

Handle and dispose of pilot system/ brake oil filter according to current regulations. Use only authorised disposal procedure. If in doubt, contact authorities concerned.

F24571

2

3

F20111

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-53

MAINTENANCE

AIR CONDITIONER - OPTIONAL (Check) Check the coolant quantity contained in the air conditioning system as follows: • Start the engine, place the machine on a flat ground and set the bucket to the ground.

• Place the throttle manual lever at the middle speed.

• Adjust the quantity of air released by the outlets to max. value by pushing button (1).

• Set the temperature to min. value by pressing switch (2).

• In the gear box bay, check the coolant level by means of visual check (3) located on the dryer (4), which will deliver following visual indication: - Quantity of suitable coolant: on the visual check appear some bubbles. Further on the visual check will appear transparent and then misted.

- System overloaded: on the visual check never appear bubbles.

- Quantity of coolant insufficient: on the visual check appear constantly bubbles.

IMPORTANT: in case of overloaded system B or insufficient quantity of coolant C, address to Dealer.

4

A

B 3 C F25260

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-54

MAINTENANCE

AFTER 1000 HOURS OF OPERATION ITEMS TO BE CHECKED

Replace

Lubrication

Cleaning

Check

Air cleaner: outer element

AIR FILTER: OUTER ELEMENT (Replacement) IMPORTANT: The normal maintenance interval prescribes the replacement of the outer element of the air cleaner any 1000 hours. Under particular environment conditions, (very dusty areas) it is recommended to reduce the replacement interval of 50 %.

Proceed with the replacement of the air cleaner outer element as follows: • Park the machine on a level surface.

• Rest the bucket to the ground.

• Stop the engine, remove the start-up key and set the l.h. console to the (LOCK) position.

• Open engine hood.

• Loosen wing nut (1) and pull out the cover with outer element (2).

• Check that dust ejection valve (3) is clean.

• Insert inside the filter housing the new outer element, making sure that it is correctly seated.

• Tighten wing nut (1).

• Close engine hood.

F24729

2

1

3

F24572

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-55

MAINTENANCE

AFTER 1500 HOURS OF OPERATION ITEMS TO BE CHECKED

Replace

Lubrication

Cleaning

Check

Fuel pre-filter Alternator - fan belt

FUEL PRE-FILTER (Replacement)

YY

S

WARNING

YY

Pay attention, during the removal phase, to avoid spilling the fuel inside the filter: there is a danger of fires.

8

Proceed with the replacement of the fuel pre-filter, operating as follows: • Park the machine on a level surface.

• Rest the bucket to the ground.

• Switch off the auto/idle, fully turn the engine speed manual control anticlockwise, stop the engine, remove the ignition key and move the l.h. console to the locked position (LOCK).

• Wait until the machine is cold.

• Open the engine hood as described in chapter “ HOOD AND ACCESS COVERS”.

• remove cover (8).

• Replace the filter as follows: - clean the area around filter (1) and support (2); - remove connector (3) pressing on release device (4) and untighten sensor (5); - remove the filter using the special wrench or a universal tool; - fill the new filters with clean fuel and tighten by hand until their seals touch the body of the support.

Tighten the filters further by 1/2 turn; - reinstall sensor (5) tightening by hand and fit connector (3).

F24563

7 2 1

5 4 3

F24053

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-56

MAINTENANCE AIR BLEEDING • Then bleed the air that may have reached the fuel system during the replacement of the filter. Perform this operation as follows: - loosen the bleeding screw (6) to allow air to bleed; - press repeatedly button (7) located on the fuel prefilter to let fuel flow in its circuit; - continue priming until a minimum amount of fuel free of bubbles comes out of the loosened bleed screw (6). Close the screw; - then perform the engine start-up.

• Reinstall the cover (8).

• Close the pumps and cooler bays doors.

6

7 2 1 F24054

Handle and dispose of engine oil filters according to current regulations. Use only authorised disposal procedure. If in doubt, contact authorities concerned.

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-57

MAINTENANCE

ALTERNATOR - FAN BELT (Replacement)

YY

S

WARNING

YY

Always make sure that engine hood is correctly locked in the open position. danger of personal injuries.

Do not approach with your body belts or rotating paddles. Be particularly aware near fans (alternator and radiator fan).

YY

S

CAUTION

1

YY

F19991

The engine, when in operation, can reach high temperatures. Thus, prior to performing these operations, cut-off the machine and let it cool-off.

In the event it is imperative to operate just the same on an hot engine, protect body and limbs with appropriate clothing and protections, since there is a danger of burns and personal injuries.

• Proceed with the replacement of the fan-alternator (1) belt operating as follows: • Park the machine on a level surface.

• Rest the bucket to the ground.

• Cut-off the engine, extract the starter key and move the l.h. console into (LOCK) position.

• Wait until the machine is cold.

• Climb on the superstructure and remove the upper protection of the engine bay.

• Install the 3/8” wrench with square connection into seat (2) and act in the direction of the arrow to move tensioner (3) and free the belt.

• Proceed with the installation of the new belt, making sure that it is arranged as indicated in the figure.

2 3

F19992

F20435

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-58

MAINTENANCE

AFTER 2000 HOURS OF OPERATION ITEMS TO BE CHECKED

Replace

Lubrication

Cleaning

Check

Slew reduction gear oil Transmission oil, axles oil Engine cooling system Air cleaner: inner element

SLEW REDUCTION GEAR OIL (Replacement)

YY

S

WARNING

YY

Never service or inspect swing reduction gear circuits with the machine parked on a slope. They are under high pressure due to machine weight.

YY

S

CAUTION

YY

Slew reduction gears and oil therein can reach high operating temperatures. Therefore, while carrying out this operation with the machine still hot, the body must be protected with suitable clothing and protections to avoid burns and personal injuries.

F24729

• Park the machine on a level surface.

• Rest the bucket to the ground.

• Switch off the auto/idle, fully turn the engine speed manual control anticlockwise, stop the engine, remove the ignition key and move the l.h. console to the locked position (LOCK).

• Remove the oil level dipstick (1).

1

F24539

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-59

MAINTENANCE • Get in front of the machine, loosen plug (2) installed at the end of the drain hose and allow oil to drain in a suitable container.

Reinstall plug (2).

2

F24058

• Refill using oil of type, grade and quantity specified (see the FILLING CHART in this chapter). Proceed as follows: pour new oil until it reaches the correct level which should be between the MIN and MAX marks on the dipstick.

• Reinstall dipstick (1).

1

Handle and dispose of slew reduction unit oil according to current regulations. Use only authorised disposal procedure. If in doubt, contact authorities concerned.

MIN.

MAX F19996

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-60

MAINTENANCE

TRANSMISSION OIL, AXLES OIL (Replacement) • Park the machine on a level surface.

• Rest the bucket to the ground.

• Switch off the auto/idle, fully turn the engine speed manual control anticlockwise, stop the engine, remove the ignition key and move the l.h. console to the locked position (LOCK).

F24729

Loosen filler/level plug (1) and drain plug (2) on the transmission housing; Drain oil completely.

After retightening drain plug (2), refill with oil through filling plug (1); Stop filling when oil flows out from the same plug.

In any case, the oil change is recommended at least once a year.

1

2

F24573

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-61

MAINTENANCE

YY

S

CAUTION

YY

Never unscrew draining/level plugs unless pressure inside the axle body is relieved.

• When draining an axle, do not place yourself in front of it and always wear safety glasses or goggles to protect your eyes. Turn level/draining plugs slowly to loosen it, to relieve pressure, then loosen the level/draining plugs.

Unscrew following plugs: filling (3), level (1) and drain (2) plugs.

Drain completely the oil.

After refitting drain plugs (2), refill with oil through filling hole (3); Stop filling when the oil escapes from the plug (1).

Reinstall plugs (1) and (3).

• Set the side reduction gear so that plug (4) is located as indicated. The respect of this condition is essential for the correctness of the maintenance operation.

OIL DRAIN • After gear lubrication oil cooling, slowly untighten drain plug (2). Let oil drain completely.

OIL REFILLING • Position the reduction gear as shown.

• Fill with recommended oil (see FILLING CHART in this chapter) through plug (4) hole until oil comes out.

• Clean plug (4) and wrap threads with sealed band.

Refit the plug into its seat.

Handle and dispose of reduction gears oil according to current regulations.

Use only authorised disposal procedure. If in doubt, contact authorities concerned.

4

4

F24575

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-62

MAINTENANCE

ENGINE COOLING SYSTEM (Engine coolant replacement and system flushing)

YY

S

DANGER

YY

Do not run the engine in closed areas without proper ventilation and/or an adequate system capable to remove noxious exhaust gases.

YY

S

WARNING

YY

Always make sure that engine hood is locked completely open. Danger of personal injuries due to accidental closures.

F24729

YY

S

CAUTION

YY

• Liquid under pressure; turn the radiator cap slowly before removing it completely to relieve pressure.

Do not loosen the radiator cap when the engine is hot to avoid burn hazard.

• Do not perform this operation when the machine is still hot. Contact with engine coolant at working temperature may cause burns and personal injuries.

IMPORTANT: Never use sealant additives to stop leaks from the cooling system. Failure to observe this rule might cause system obstruction with consequent insufficient flow of coolant, temperature increase and engine overheating.

3

• Park the machine on a level surface.

• Rest the bucket to the ground.

• Switch off the auto/idle, fully turn the engine speed manual control anticlockwise, stop the engine, remove the ignition key and move the l.h. console to the locked position (LOCK).

• Wait until the machine is cold.

1

F25420

COOLANT DRAIN Replace engine coolant as follows: • Remove protection (3).

• Remove radiator plug (1) when the engine is cold.

• Open r.h. back door.

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-63

MAINTENANCE • Drain coolant into a container by opening cock (2) located on radiator lower part. Close the cock after finishing.

• Carefully inspect the sleeves for integrity and sealing (replace if necessary) and tighten possibly loose straps. Check the radiator for leaks, damages and/ or dirt build-up.

COOLING SYSTEM FLUSHING

2

Flush the system as follows: • Fill the engine cooling system with water and radiator detergent (we advise not to use alkaline detergents as they may corrode system components) through the plug housing (1). This will remove all residues of deposits (scale, rust, etc.). Then install plug (1) on the radiator.

• Start the engine and let it run at a speed slightly higher than idle. When the temperature gauge in the cab enters the “ GREEN” area let the engine run for approximately 10 minutes.

• Stop the engine and wait until it has cooled down.

• Drain water and detergent following the procedure detailed above.

• Fill the cooling system only with water and flush the system again. Repeat this operation until drained water looks clean.

F24576

FILLING THE COOLING SYSTEM Perform this operation as follows: • Check if radiator cock (2) is closed.

• Slowly pour coolant through the housing of plug (1) (see FILLING CHART in this chapter) until you reach the correct level. When the water touches the limit of filler neck (1), reinstall the plug.

• Start the engine and let it run for at least 15 minutes.

Check coolant level again, if low, add some up to reach right level.

• Reinstall the hood (3) and close the right back door.

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-64

MAINTENANCE

AIR CLEANER: INNER ELEMENT (Replacement) IMPORTANT: the normal maintenance interval prescribes the replacement of the inner element of the air cleaner every 2000 hours. Under particular environment conditions, (very dusty areas) it is recommended to reduce the replacement interval of 50 %.

Proceed with the replacement of the air cleaner outer element as follows: • Park the machine on a level surface.

• Rest the bucket to the ground.

• Switch off the auto/idle, fully turn the engine speed manual control anticlockwise, stop the engine, remove the ignition key and move the l.h. console to the locked position (LOCK).

• Open engine hood.

Loosen wing nut (1) and pull out the cover (5) with outer element (6).

Loosen wing nut (3) and extract inner element (4).

Clean the inside of the filter housing (7)and check that dust ejection valve (2) is clean.

Insert the new inner element (4) and secure it with the relevant wing nut (3).

• Insert the outer element and secure it with the relevant wing nut (1).

• Close engine hood.

F24729

1

F24538

5

1

6 3 4 8 7 2

F24578

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-65

MAINTENANCE

AFTER 2500 HOURS OF OPERATION ITEMS TO BE CHECKED

Replace

Lubrication

Cleaning

Check

Hydraulic system oil

HYDRAULIC SYSTEM OIL (Replacement)

YY

S

DANGER

YY

Do not run the engine in closed spaces without proper ventilation and/or an adequate system capable to remove noxious exhaust gases.

YY

S

CAUTION

YY

• Never use gasoline, solvents or other flammable fluids to clean parts. Use only proprietary certified solvents, non-flammable and non-toxic.

• Hydraulic system components and hoses can reach very high temperatures during operation. Shut-off the machine and wait until it has cooled down before starting inspection or maintenance.

• Prior to operating the machine and/or its attachments, check that bystanders are outside the machine operating range. Before getting on, walk around the machine to inspect it. Sound the horn.

• Never leave the machine unattended with the engine running • Never operate the machine from any position other than from the driver’s seat. Under all circumstances keep all parts of your body inside the operator’s compartment to minimise the risk of exposure to external dangers.

• Do not work near or under machine attachment if not adequately supported or locked.

• Fluid under pressure. Always lower the hydraulic attachment to the ground. Stop the engine, press the pressure release button located on the hydraulic reservoir prior to starting any maintenance work.

F24729

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-66

MAINTENANCE • Park the machine on a level surface with the upperstructure turned by 90° in order to make access easier.

• Fully retract the arm cylinder and fully extend bucket cylinder.

• Rest the bucket to the ground.

• Switch off the auto/idle, fully turn the engine speed manual control anticlockwise, stop the engine, remove the ignition key and move the l.h. console to the locked position (LOCK).

• Wait until the machine is cold.

• Apply the maintenance in progress card as shown on chapter “SAFETY PLATES ” to the safety lever.

2

1

F24580

Proceed as follows: OIL DISCHARGE • Clean the hydraulic oil reservoir upper side to prevent dirt contamination in the hydraulic system.

• Untighten plug (1)for tank venting.

• Remove lower panel under oil tank.

• Remove oil from filling plug (2) with a suction pump.

• Remove drain plug (3) to collect residual oil into a container.

3

F24558

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-67

MAINTENANCE OIL REFILLING T1 • Reinstall plug (3).

• Install the panel under the tank.

• Through flange (6) fill with oil having the recommended type, grade and quantity (see FILLING CHART in this chapter), until the level is included between the MIN and MAX references on the optical level indicator.

IMPORTANT: should the hydraulic pump remain without oil, it would be damaged in a few seconds after engine start-up.

• • • • •

• • •

F25261

Open the engine bay access panel.

Fill pump case through (T1).

Reinstall hydraulic connections.

Run the engine and let it turn at idle speed for 10 minutes in order to heat oil.

With engine at min. speed and machine stopped: an operator activates drive of hand lever located in the cabin, while the other one drains the hose (5) by screw (4).

Check the sight glass on the hydraulic oil reservoir.

If necessary, add hydraulic oil.

Remove the flange(6)as follows:

Yyy S

4

5

F25262

CAUTION

yyY

A loaded spring is located under flange (6). Therefore slowly untighten screws (7) in order not to release the spring. untighten four of the six screws (7); keep flange (6) pressed and untighten the last two screws (7). In this way the spring release is avoided; remove flange (6).

• Add oil.

• Install flange (6) with the O-ring (8).

• Install the six screws (7) fastening flange (6) and tighten the screws with 5 daNm tightening torque.

7 6 8 F25263

Handle and dispose of reduction gears oil and filters according to current regulations. Use only authorised disposal procedure. If in doubt, contact authorities concerned.

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-68

MAINTENANCE BRAKE AIR BLEEDING

YY

S

WARNING

YY

Do not work under or near attachment articulations or other machine parts, unless they are properly supported and blocked.

NOTE: The operation requires the intervention of at least two operators.

With engine idling and the machine stopped, one operator loosens bleeding screw (1), whilst the other operator pushes the brake control pedal.

Tighten the bleeding screw before releasing the pedal.

Repeat, if necessary, the operation until all the air is bled from the system.

Bleed the brake oil from all the other axles, in the same manner.

Place the machine on a flat surface with bucket firmly on the ground, stop the engine, and, if necessary, topup oil level.

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-69

MAINTENANCE BIODEGRADABLE HYDRAULIC OIL Specifications • Recommended oil HYDRAULIC EXCAVATOR FLUID BIO. Operating range • Ambient temperature: -20 ° C to 40 °C. • Oil temperature in the reservoir -20 °C to 95 °C. Instructions for use IMPORTANT: Biodegradable hydraulic oil must not be mixed with mineral hydraulic oil.

F21416

Oil change

Oil sampling for analysis

Every 2500 hours

Every 500 hours

• Oil samples to be analysed should be taken every 500 hours of operation using the sampling kit and related instructions supplied by the Dealer.

• The samples should be sent by the Customer to the Dealer , that will carry out necessary checks. The Dealer will inform the customer if the oil features necessary for use have changed.

IMPORTANT: If special equipments (hydraulic breaker, etc.) are used, oil sampling for analysis should be done every 250 hours.

IMPORTANT: if the Dealer informs the customer that the oil has exceeded the service limits, proceed to its replacement. Failure to observe this measure will invalidate the warranty and may cause damages to the machine.

• To change the bio-degradable hydraulic oil, please proceed as indicated in the preceding pages.

Replacing mineral hydraulic oil with biodegradable hydraulic oil.

IMPORTANT: when buying a machine filled with mineral hydraulic oil and wanting to replace it wit biodegradable oil (opt.), it is necessary to have the replacement operation carried out by the Dealer. This because an accurate drainage of mineral oil and a complete wash of the hydraulic system is necessary. Remember that mineral hydraulic oil must not be mixed with biodegradable hydraulic oil.

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-70

MAINTENANCE SERVICE REMINDER PLATE MAINTENANCE A summary decal (1) indicating the main lubrication, cleaning and replacement operations to be performed periodically, is located inside the tools compartment.

This decal differs from the one normally applied to the machine, since it lists the maintenance sequences related to biodegradable hydraulic oil.

1 F23976

F25453

Replacement of fuel prefilter

Replace power steering system oil filter

Lubrication Replace engine oil filters Replace reduction gear oil, axle oil and transmission oil

Replace engine coolant

Replace hydraulic oil Replace engine oil Replace hydraulic system return oil filter Replace air cleaner Replace fuel filters Oil sampling for analysis Replace alternator/fan belt Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-71

MAINTENANCE

AFTER 3000 HOURS OF OPERATION ITEMS TO BE CHECKED

Replace

Engine valves

Lubrication

Cleaning

Check

12345678901234 12345678901234 12345678901234 12345678901234 12345678901234

ENGINE VALVES (Valve check and adjustment)

YY

S

WARNING

YY

Always ensure that engine hood is correctly locked in the open position: danger of personal injuries.

YY

S

CAUTION

YY

The engine reaches high working temperatures. Therefore, it is necessary to let the machine cool down prior to carrying out this operation.

F20442

IMPORTANT: contact your authorised Dealer to perform this service.

• Valve clearance is as follows: - Intake: - Discharge:

0.25 ± 0.05 mm 0.50 ± 0.05 mm

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-72

MAINTENANCE

FILLING CHART MODEL WX95 RECOMMENDED FLUIDS AND LUBRICANTS

QUANTITY COMPONENT TO BE FILLED

Litres

AKCELA

SPECIFICATIONS MANUFACTURER’S SPECIFICATIONS

Cooling system engine

22

Premium Anti-freeze

Fuel tank

128

_

12.5

N° 1 Engine oil

MS 1121

3

Gear 135H EP

MS 1316

Gear box Rear axle Axle reduction gears (each) Front axle differential

0.8 7 8.8 0.9

Gear 135H EP LS

Hydraulic system (**)

100

Hydraulic Excavator Fluid

Engine

Slew reduction gear

SPECIFICATIONS INTERNATIONALS

NOTES

Protective fluid to be mixed with water at 50%. This mix has anticorrosive, antiscaling, and anti-foaming properties; does not freeze down to -35 °C.

MS 1710

_

_

Diesel ASTM N. 2-D type TT

_

API CH - 4 ACEA E5

Multigrade oil for aspirated or turbochargerd diesel engine of every types and powers.

API GL 5 MIL-L-2105 D

Gear oil with Extreme Pressure (E.P.) performance.

Gear oil with Extreme Pressure (E.P.) performance.

API GL 5 MIL-L-2105 D

High viscosity lubricant for excavators and earthmoving machine hydraulic controls.

_

MS 1230

+

_

Lithium-based grease containing molybdenum disulphide, resists to water, low temperature and high loads; NLGI 2 consistency

_

Detergent diluted in water from 10% to 50%. The mix has anti-freezing properties until -22 °C.

_

Pressure grease fittings

Moly Grease

251 EP-M

5 Kg

Slew ring teeth (*)

TUTELA 3

Windscreen washer

PROFESSIONAL

SC35

Oil quantities shown are necessary for periodical changes following discharging and filling procedures detailed for each assembly. (*) First filling only.

(**) MPORTANT: if the machine has been refilled with biodegradable hydraulic oil HYDRAULIC EXCAVATOR FLUID BIO (on demand), be informed this oil cannot be mixed with mineral hydraulic oil.

FIELD OF USE (ROOM TEMPERATURE °C)

LUBRICANT TYPES AKCELA

VISCOSITY

Engine

N° 1 Engine oil

SAE 15W - 40 SAE 10W - 30

Slew reduction gear

Gear 135H EP

SAE 80W - 90

Gear 135H EP LS

SAE 80W - 90

Hydraulic Excavator Fluid

ISO VG 46

REFILL

Front and rear axle differential Axles and gear box reduction gears Hydraulic system

-30

-20

-10

0

10

20

30

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-73

40

50

MAINTENANCE

FILLING CHART WX125 RECOMMENDED FLUIDS AND LUBRICANTS

QUANTITY COMPONENT TO BE FILLED

Litres

AKCELA

SPECIFICATIONS MANUFACTURER’S SPECIFICATIONS

_

_

Diesel ASTM N. 2-D type TT

_

API CH - 4 ACEA E5

Multigrade oil for aspirated or turbochargerd diesel engine of every types and powers.

API GL 5 MIL-L-2105 D

Gear oil with Extreme Pressure (E.P.) performance.

22

Premium Anti-freeze

Fuel tank

162

_

12.5

N° 1 Engine oil

MS 1121

3

Gear 135H EP

MS 1316

Gear box Rear axle Axle reduction gears (each) Front axle differential

0.8 7 8.8 0.9

Gear 135H EP LS

Hydraulic system (**)

115

Hydraulic Excavator Fluid

Slew reduction gear

Protective fluid to be mixed with water at 50%. This mix has anticorrosive, antiscaling, and anti-foaming properties; does not freeze down to -35 °C.

MS 1710

Cooling system engine

Engine

SPECIFICATIONS NOTES INTERNATIONALS

Gear oil with Extreme Pressure (E.P.) performance.

API GL 5 MIL-L-2105 D

MS 1230

High viscosity lubricant for excavators and earthmoving machine hydraulic controls.

_

_

Lithium-based grease containing molybdenum disulphide, resists to water, low temperature and high loads; NLGI 2 consistency

_

Detergent diluted in water from 10% to 50%. The mix has anti-freezing properties until -22 °C.

_

Pressure grease fittings

Moly Grease

251 EP-M

5 Kg

Slew ring teeth (*)

TUTELA 3

Windscreen washer

PROFESSIONAL

SC35

Oil quantities shown are necessary for periodical changes following discharging and filling procedures detailed for each assembly. (*) First filling only.

(**) MPORTANT: if the machine has been refilled with biodegradable hydraulic oil HYDRAULIC EXCAVATOR FLUID BIO (on demand), be informed this oil cannot be mixed with mineral hydraulic oil.

FIELD OF USE (ROOM TEMPERATURE °C)

LUBRICANT TYPES AKCELA

VISCOSITY

Engine

N° 1 Engine oil

SAE 15W - 40 SAE 10W - 30

Slew reduction gear

Gear 135H EP

SAE 80W - 90

Gear 135H EP LS

SAE 80W - 90

Hydraulic Excavator Fluid

ISO VG 46

REFILL

Front and rear axle differential Axles and gear box reduction gears Hydraulic system

-30

-20

-10

0

10

20

30

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

4-74

40

50

5 - TROUBLESHOOTING

TROUBLESHOOTING

ENGINE Problem

Cause

Solution

The engine turns, but it fails or is difficult to start

Lack of fuel

Add fuel. Bleed air. Drain fuel tank and refill with fuel of correct type.

Fuel not suitable

Drain fuel tank and refuel with clean fuel.

Contaminated fuel

Charge or install new batteries.

Low battery power Injection pump

Contact the Dealer.

Defective wiring connections

Clean and tighten battery and starter motor terminals.

Faulty starter motor

Contact the Dealer.

Wrong type of engine oil

Drain oil and replace with oil of correct type.

Air filter clogged

Replace filter elements.

Fuel filters clogged

Replace filters and check fuel tank for impurities.

Poor engine compression

Contact the Dealer.

Dirty injectors or badly operating

Contact the Dealer.

Faulty engine stop solenoid wiring

Check and/or repair wiring connections.

Fuel system leakage

Check fuel system hoses and fittings.

Air in the fuel system

Bleed air.

Low engine oil level

Add oil

Low engine oil pressure

Contact the Dealer.

Air intake system clogged

Clean filter and system.

Fuel injection pump timed wrongly

Contact the Dealer.

Fuel filters clogged

Install new filters.

Low engine coolant temperature, thermostat defective

Contact the Dealer.

Air, impurities or water in the fuel system

Bleed air from the fuel system.

Drain water from fuel tank and filter/sedimentor.

Dirty or faulty injectors

Contact the Dealer.

Engine noise or erratic operation; engine stalls

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

5-1

TROUBLESHOOTING

ENGINE Problem

Solution

Cause

Replace filter elements.

The engine does not Air filter clogged develop full power Fuel lines kinked

Repair or replace fuel lines.

Contaminated fuel

Drain fuel tank.

Fuel filters clogged

Refill with clean fuel.

Install new filters.

Vent hole on fuel tank plug clogged

Clean or install a new plug.

Dirty or faulty injectors

Contact the Dealer.

Engine to fuel injection pump timing

Contact the Dealer.

Fuel not suitable

Use correct type of fuel.

Engine oil not suitable

Use correct type of engine oil.

Faulty turbocharger

Contact the Dealer.

The fuel injection pump needs calibration

Contact the Dealer.

Exhaust tube obstructed

Replace silencer and let the engine run.

Engine too hot or too cold

See next point.

Engine faulty

Contact the Dealer.

Air intake or exhaust system leakage

Contact the Dealer.

Add coolant.

The engine overheats Low coolant level Thermostat

Contact the Dealer.

Engine overload

Check hydraulic system safety valves.

Faulty radiator cap

Install a new cap.

Inner parts of coolant radiator or hydraulic oil radiator clogged.

Clean the coolant radiator and hydraulic oil radiator.

Radiators protection mesh obstructed

Clean mesh.

Fuel injection pump out of timing

Contact the Dealer.

Damaged fan

Replace fan.

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

5-2

TROUBLESHOOTING

ENGINE Problem

Cause

Solution

The engine overheats Air filter clogged

Clean the air cleaner.

Loose fan belt

Adjust belt tension or install a new belt.

Damaged pulley grooves

Contact the Dealer.

Dirty cooling system passages

Clean the cooling system.

Coolant temperature warning light or temperature sensor

Contact the Dealer.

Too low coolant tem- Thermostat perature Coolant temperature warning light or temperature sensor

Contact the Dealer.

Excessive engine oil Oil leak consumption Too high engine temperature

Check for leaks

Wear of enggine inner components

Excessive fuel con- Dirty or clogged air intake system sumption Wrong type of fuel

Contact the Dealer.

Check the cooling system.

Contact the Dealer.

Clean air intake system.

Use specified fuel.

Fuel injectors

Contact the Dealer.

Fuel injection pump out of timing

Contact the Dealer.

Excessively black or Wrong type of fuel grey exhaust smoke Air intake or exhaust systems dirty or clogged

Use specified fuel.

Clean air intake and exhaust systems.

Fuel injection pump out of timing

Contact the Dealer.

Dirty or faulty injectors

Contact the Dealer.

Faulty engine

Contact the Dealer.

No electrical circuit is Batteries powered

Recharge or replace.

No electrical circuit is Battery relay powered (except the hour meter)

Replace relay.

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

5-3

TROUBLESHOOTING

ENGINE Problem

Cause

Solution

Run down batteries

Loose or corroded connections

Clean and tighten, or replace batteries.

Loose alternator belt

Tension belt or install a new one.

The alternator does not charge

Contact the Dealer.

Fuse

Replace fuse.

Faulty key-start switch

Contact the Dealer.

Faulty or run down batteries

Recharge or replace batteries

Bad contact between battery cables

Clean connections.

Fuse

Replace link fuse.

Key-start switch

Contact the Dealer.

Starter relay

Contact the Dealer.

Starter solenoid

Contact the Dealer.

Starter motor

Contact the Dealer.

Starter motor pinion seized with flywheel teeth

Contact the Dealer.

Starter faulty

Contact the Dealer.

Poor connection to batteries or to starter motor

Clean connections.

Low battery charge

Recharge or replace batteries

Starter motor pinion gear does not engage with flywheel teeth

Contact the Dealer.

Pinion displacement device locked or inoperative

Contact the Dealer.

Battery cables damaged or broken inside

Inspect or replace cables.

Loose or corroded battery connections or starter motor cables

Clean or tighten connections.

Fuel not suitable

Drain fuel tank. Use correct type of fuel.

Engine cold

Let the engine turn until it warms up.

Faulty thermostat or too “cold”

Contact the Dealer.

The starter motor does not turn

Starter solenoid vibrates

The starter motor turns,but does not crank the engine

The engine turns slowly at start-up

White exhaust smoke

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

5-4

TROUBLESHOOTING

ENGINE Problem

Turbocharger excess noise or vibration

Oil leakage from turbocharger

Cause

Solution

Wrong injection pump timing

Contact the Dealer.

Coolant leakage into engine cylinders

Contact the Dealer.

Bearings not lubricated

Low oil pressure. Check turbocharger lubrication oil lines for kinking or obstruction.

Worn bearings

Contact the Dealer.

Air leaks into the engine from the intake or exhaust manifolds

Contact the Dealer.

Turbocharger excessively worn

Contact the Dealer.

Damaged or worn bearings and/or worn seal

Contact the Dealer.

Carbon deposits on compressor oil return hose near the exhaust manifold

Contact the Dealer.

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

5-5

TROUBLESHOOTING

ELECTRICAL SYSTEM Problem

Cause

Solution

At start-up the engine turns slowly

Batteries are discharged or fail to maintain charge

Replace batteries.

Excessive starter motor rolling resistance

Contact the Dealer.

Starter relay stuck

Contact the Dealer.

Starter solenoid stuck

Contact the Dealer.

Starter motor not releasing

Contact the Dealer.

Start-key switch

Contact the Dealer.

Loose or slipping alternator belt

Check belt tension and adjust if necessary.

Replace the belt if worn or slipping.

Low engine speed

Contact the Dealer.

Excessive electrical load due to additional accessories

Remove accessories or contact the Dealer.

Corroded or loose connections at the battery, ground braids, starter motor, alternator

Inspect, clean or tighten wiring connections.

Low battery voltage

Recharge or replace batteries.

Faulty alternator or regulator

Contact the Dealer.

Faulty warning light wiring

Contact the Dealer.

Worn drive belt

Replace belt.

Worn pulleys

Contact the Dealer.

Pulley misaligned

Adjust alternator support.

Alternator bearing

Contact the Dealer.

Fuse

Replace fuse.

Wiring cables

Contact the Dealer.

Printed circuit

Contact the Dealer.

Cables harness

Contact the Dealer.

Sensor

Contact the Dealer.

Fuse

Replace fuse.

The starter motor keeps turning after engine start-up

Battery charge warning light on with the engine running

Noisy alternator

All monitor panel lights are inoperative

Instrument panel gauges inoperative

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

5-6

TROUBLESHOOTING

ELECTRICAL SYSTEM Problem

Cause

Solution

Inoperative monitor panel light

Bulb

Replace bulb.

Fuse

Replace fuse.

Sensor

Contact the Dealer.

Faulty harness

Contact the Dealer.

Fuse

Replace fuse.

Bulb

Replace bulb.

AUTO/IDLE switch

Contact the Dealer.

Inoperative auto/idle switch light

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

5-7

TROUBLESHOOTING

CONTROLS Problem

Cause

Solution

No reaction activating control levers

Safety lever

Check if position is correct.

Power steering system

Contact the Dealer.

Upper structure fails to slew

Upper structure slew lock lever

Check if position is correct.

Power steering system

Contact the Dealer.

Control levers hard to move or irregular movement

Joints correded or worn

Contact the Dealer.

Control lever is not vertical in neutral position

Control lever valve

Contact the Dealer.

Insufficient or delayed braking

Brake discs worn

Contact the Dealer.

Brake valve

Contact the Dealer.

Brake valve

Contact the Dealer.

Parking brake

Contact the Dealer.

Low tyre pressure

Reset correct air pressure in tyres.

Power steering wheel

Contact the Dealer.

Tyres are too worn

Contact the Dealer.

Wheels misalignment

Contact the Dealer.

The machine remains braked

Steering valve hard motion

Vibrations on steering wheel

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

5-8

6 - ELECTRICAL SYSTEM

ELECTRICAL SYSTEM

GENERAL NOTES

YY

S

WARNING

IMPORTANT: • The electrical system of this machine is 24 V and is powered by two batteries connected in series.

• The machine is equipped with complex electric and electronic components which can be handled exclusively by qualified personnel.

• Do not run the engine with disconnected alternator threaded terminal.

• If the batteries have been recharged using an external equipment, they should then be reinstalled onto the machine paying attention to match terminals pertaining to the same sign (+ to + and - to -).

• This norm should be observed also when the engine is to be started using slave batteries.

• If repair using electrical welders is required on the machine, it is good practice to disconnect the batteries and alternator, and ground the welder as near as possible to the welding point.

YY

• Use exclusively grounded sources of power for heaters, battery-chargers, pumps and similar devices, si to minimise electrical shock hazard.

• Make sure to connect the cables to the correct poles (+ to + and - to -) at both ends.

• Do not short-circuit the terminals.

• If batteries are to be recharged or if booster batteries are needed for starting, remove battery cell plugs.

• FLAMMABLE VAPOURS. Extinguish all smoking materials and naked flames before checking, filling or charging the batteries.

• Avoid causing sparks while testing batteries.

IMPORTANT: • Improper radio-communications equipment and associated parts and/or improper assembly of radio-communications equipment affects machine electronic components with consequent unexpected machine movement. Consult your Dealer when installing radio-communications equipment or any additional electronic component, and when replacing an electric part.

• Do not disassemble or change electric or electronic components.

• Consult your Dealer to replace or change such components, if necessary.

NOTE: the electrical system is powered only when the keystart switch is turned to the ACCor ON positions.

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

6-1

ELECTRICAL SYSTEM

BATTERIES (Check)

YY

S

WARNING

YY

• battery gases may explode. Keep away sparks and flames. Use a pocket torch to check electrolyte level.

• Sulphuric acid contained in the electrolyte is poisonous. It can burn the skin, corrode clothes and cause loss of sight if sprayed into the eyes.

• To avoid dangers: - Top up the batteries in a well ventilated area.

- Wear protective glasses and rubber gloves.

- Avoid breathing vapours when adding distilled water.

- Do not spill or drip the electrolyte.

- When starting the machine with booster batteries, observe the procedures detailed in chapter OPERATING NORMS, in paragraph “STARTING THE ENGINE WITH BOOSTER BATTERIES”. Always ensure to connect cables to correct poles (+ to +) and (- to -) at both ends. Do not short-circuit the terminals.

• If acid comes to touch the skin: - Wash skin with water.

- If acid has reached the eyes, wash with water for at least 15 minutes. Immediately seek medical attention.

- If acid has been ingested, immediately seek medical attention.

• Batteries installed to this type of machine are maintenance-free, therefore they do not require top-ups with distilled water. In exceptional cases, however, it is possible to restore the electrolyte level by removing cell plugs and adding distilled water. The electrolyte level must lay between max. and min.notches of the battery. Charge the battery after topping up.

F1474

IMPORTANT: If it is necessary to add distilled water in freezing weather conditions, top up at the beginning of the working day. Otherwise the battery should be recharged.

F1464

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

6-2

ELECTRICAL SYSTEM

YY

S

CAUTION

YY

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

• Remove battery protection (1).

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

1

• Keep the terminals and plugs located on top of the battery clean at all times to prevent battery from discharging. Check battery terminals: clamps should not be loose and should not show signs of rust or oxidation. Apply petroleum jelly to the terminals to prevent corrosion.

F25264

• It is better not to shut the engine off in case of short stops. Let it idle as each start-up requires considerable power supply from the batteries.

• Observe the following norms to preserve battery efficiency: with the engine stopped, remove the ignition key to avoid progressive battery discharge; do not keep the lights switched on for a long time with the engine stopped or idling.

• If a battery in a 24V system is faulty, but the other is still operational, replace the faulty battery with a new one of the same type. For example, replace a maintenance-free type faulty battery with a new battery of the maintenance free type. Different types of batteries may be characterized by a different charging speed. Such difference could overcharge one of the batteries and damage it.

F5664

• Assemble battery protection (1).

Handle and dispose of batteries according to current regulations. Use only authorised disposal procedure. If in doubt, contact authorities concerned.

F25265

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

6-3

ELECTRICAL SYSTEM

FUSES

IMPORTANT: Always install fuses of correct rating to avoid overcharge damage to the electrical system.

• The fuse box is located behind the Operator’s seat.

There is a decal on the fuse box cover detailing location and rating of the fuses.

• Pull the fuse box cover upwards to remove. Under the cover there are the spare fuses.

• Moreover, in the air cleaner bay some high amperage fuses are fitted.

• Replace the faulty fuse after checking the associated circuit.

Fuse No

PROTECTED CIRCUIT

Value (A)

FUSES INSIDE THE CONTROL UNIT 1

Right and left console

5

2

Battery line

10

3

Steering mode system (opt)

3

4

Rotating light

7,5

5

Working light

15

6

Anti- tipping device

3

7

Heated seat

10

8

Cigarette lighter

10

9

12V socket and radio

10

10

Air cooler (optional)

15

11

Engine control unit

10

12

Hydraulic pumps

5

13

Key in position ON

10

14

Steering column

15

15

Windscreen wiper

7,5

16

Traffic beams

10

17

Upper beams

10

18

R.h.parking light

5

19

L.h.parking light

5

20

_

8

9

10

20

7

18

6

17

5

16

4

15

3

14

2

13

1

11

10

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

6-4

19

12

F20019

ELECTRICAL SYSTEM

BOX B

BOX A

FUSES IN RELAY BAY FUSE

Main power supply

1

locked

FUSE

Fuel transfer power

2

supply

FUSE

Starter

3

protection

FUSE

Alternator

4

protection

FUSE

Main control unit

5

protection

FUSE

Key-on

6

protection

40 20 50 80 40 F24582

40

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

6-5

ELECTRICAL SYSTEM NOTE:

Read carefully the SAFETY RULES (at the beginning of this manual) for personnel and machine safety reasons.

6-6

COPYRIGHT BY CNH FRANCE Rue des Meuniers, 60330 LE PLESSIS BELLEVILLE FRANCE

Reproduction of text or illustrations, in whole or in part, is strictly prohibited

Printed No. 6-82660 EN - XII - 2004