Fiatallis FX300LC Crawler Excavator Operation & Maintenance Instrction Manual 59822021 - DOWNLOAD

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FX300LC CRAWLER EXCAVATOR

OPERATION AND MAINTENANCE / INSTRUCTION MANUAL

59822021 ISSUE 1 DECEMBER 1991

AVOID ACCIDENTS Most accidents, whether they occur In industry, on the farm, at home or on the highway, are caused by the failure of some lndivldual to follow simple and fundamental safety rules or precautions. For this reason MOST ACCIDENTS CAN BE PREVENTED by recognizing the real cause and doing something about it before the accident occurs.

Regardless of the care used in the design and construction of any type of equipment there are conditions that cannot be completely safeguarded against without Interfering with reasonable accesslb!ltty and efficient operation.

A careful operator is the best insurance against an accident.

The complete observance of one simple rule would prevent many

thousand serious injuries eech yeer.

That rule is:

Never attempt to clean, oil or adjust a machine while it is in motion.

WARNING On machines having hydrauflcally, mechanically, and/or cable controlled equip-

ment (such as shovels, loaders, dozers, scrapers, etc.) be certain the equipment is lowered to the ground before servicing, adjusting and/or repairing. If it is necessary to have tha hydraulically, mechanically, and/or cable controlled equipment partially or fully raised to gain access to certain items, be sure the equipment is suitably supported by means other than the hydraulic lift cylinders, cable and/or mechanical devices used for controlling the equipment

CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

COPYRIGHT BY FIATALLIS

• Al! rights reserved. Reproduction of text and mustratlons ln whole or in part, is strictly prohibited.

AVOID ACCIDENTS Most accidents, whether they occur in industry, on the farm, at home or on the highway, are caused by the failure of some individuals to follow simple and fundamental safety rules or precautions. For this reason MOST ACCIDENTS CAN BE PREVENTED by recognizing the real cause and doing something about it before the accident occurs.

Regardless of the care used in the design and construction of any type of equipment there are conditions that cannot be completely safeguarded against without interfering with reasonable accessibility and efficient operation.

Carefully read instructions, cautions and safety warning quoted in the "SAFETY RULES" section.

A careful operator is the best insurance against an accident.

The complete observance of one simple rule would prevent many thousand serious injuries each year.

The rule is:

Never attempt to clean, oil or adjust a machine while it is in motion.

WARNING On machines having hydraulically, or mechanically, controlled equipment be certain the equipment is lowered to the ground before servicing. adjusting and/or repairing. If it is necessary to have the controlled equipment partially or fully raised to gain access to certain items, be sure the equipment is suitably supported by means of proper devices other than those used for controlling the equipment.

CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

COPYRIGHT BY FIATALLIS All rights reserved. Reproduction of text and illustrations in whole or in part, is strictly prohibited.

59822021 ISSUE 1, DECEMBER 1991

FX 300 LC

MANUALE USO E MANUTENZIONE MANUAL DE USO Y MANUTENCION

Manuale n.

9822021

del 12/91

INTRODUCTION

In this file you will find most valuable information concerning operation, lubrication, and maintenance of your FIAT HITACHI excavator.

Observe the instructions in this manual for: • your personal safety - operating safety - ready and efficient performance of your excavator.

Periodic preventive inspections and maintenace are the surest means of keeping the machine in proper working order.

Prompt detection and correction of minor irregularities, and immediate replacement of worn out or broken parts will prevent failures and avoid expenses. Replace damaged graphics.

Observe safety precautions to prevent injury and damage.

If you find errors when reading this manual or if you have some suggestions or hints please contact:

FlAT HITACHI STABILIMENTO OI IMOLA. Strada Statale 610 Selice, 43/A W026 lmola (BO) - ITALY rEL: 0542/601111 -TELEFAX: 0542/640381 - TELEX: 511285 BENEX

lilote:

rne informations given in this manual are based on the development state of the machine at the tlme when his manual was written. )eviations in technical qata, illustrations, and dimensions are possible, due to the progress in technical levelopment )amages and defects caused by incorrect operation and maintenance are not covered by the manufacturers 1uarantee.

>ellvery of the excavator 'he excavator is delivered ready for work including ten per cent fuel and hydraulic oil. All lubrication points re greased. the excavator has been coated wlth a paint protection (preservation wax) in the plant, this coating must ot necessarily be removed. It offers an additional corrosion prevention. he paint protection may be removed with:

SAFETY INSTRUCTIONS - - - - - - - - - - - -

- cleaning agent, e.g. Comad solvent RV 5339 E 45430, - solvents, e.g. Allpur 150 K or Purtex 65, - vapour blast apparatus.

Prior to first operation, inspect the excavator thoroughly with our service engineer.

Note: If the excavator is equipped with a fire suppression system, make sure that the system is ready for operation.

For your spare part orders please referto the "Information for use ofthe catalogue• on the pages of the spare parts catalogue.

USE ONLY GENUINE FIAT HITACHI SPARE AND WEAR PARTS! For all questions related to your excavator please contact our FIAT HITACHI STABIUMENTO DI !MOLA Service Department indicating the model and serial number of your excavator.

This manual contains instructions tor the correct care and maintenance of the machine.

Note:

The informations given in this manual are based on the development state of the machine at the time when this manual was written.

Deviations in technical data, illustrations, and dimenslons are possible, due to the progress in technical development Damages and defects caused by incorrect operation and maintenance are not covered by the manufacturers guarantee.

Service points: Unit or system where the prescribed maintenance work has to be performed (e.g. engine, lubrification point).

Service intervals: Number of operating hours after which the maintenance work has to be performed ( e.g. every 10 Operating Hours, at 10, 20, 30 hours, etc ...).

General recommendations Thoroughly clean all grease fittings, caps and plugs before lubricating.

Replace oil drain plugs and oil !eve! plugs seals before removing filters.

Fill up fuel tank at the end of every workday to prevent condensation of moisture.

It is recommended to carry out oil change in assemblies when they are still at operating temperature to speed up draining.

II

Flre- prevention Important

In order to prevent risks of possible fire break out observe the following items: 1) Keep the excavator clean, especially from inflammable materials. Clean the excavator after servicing the hydraulic system. engine and fuel system by means of a steam jet 2) Clean engine compartment. hydraulic pump department and service platform of the superstructure.

Thereafter check fuel lines, engine oil lines and hydraulic oil lines for leakage, loose fastenings and damage.

If any leakage, damage. or loose fastening is found, corrective action must be taken immediately.

3) Check an electrical cables terminals and connections for loose fastenings, damage and wear. Replace or repair defective or worn parts without delay.

4) Check the turbocharger for correct mounting and tight exhaust. intake and lube oil connections. Carry out all necessary repairs without delay.

5} On machines equipped with a fire detection and suppression system refer to the following: for correct maintenance and inspection refer to the manufacturers Service Manual when cleaning the power compartment take care the heat detection sensors do not come in contact with

hot steam or other hot agent Otherwise the fire suppression system may be triggered. ,) Make sure fire extinguishers are charged and ready for use. r) On delivery the excavator is not equipped with a fire suppression system, or estinguishers. Provide for installation of such devices.

m

- - - - - - - - - - - - SAFETY INSTRUCTIONS - - - - - - - - - - - -

SAFETY INSTRUCTIONS Before starting any lubrication and maintenance work, lower the equipment to the ground, disconnect all hydraulic control levers, stop the engine and remove key.

Note: Some checks and adjustments can only be done with engine running. For such jobs two men are necessary since the controls must not be left unattended during lubrication and maintenance work.

The man in the operator's seat must keep constant visual contact with the other one and they must agree on suitable communication signals before they start their work.

- A warning plate must be fixed in the operator's cab before lubrication and maintenance work is started.

- Switch off battery main switch and remove key before working on the electricai system.

- Cycle all hydraulic control levers to relieve all pressure before servicing the hydraulic system. Make sure all connections are tight and hoses and lines are In good condition.

To locate a leak under pressure use a small piece of cardboard or wood. Never use hands.

Hydraulic fluid escaping under pressure can have enaugh force to penetrate the skin. Hydraulic fluid may also infect a minor cut or opening in the skin. If injured by escaping fluid, see a doctor at once.

- Block the machine to prevent machine movement.

- Keep work area organized and clean. Wipe up or spills of any kind. Keep tools and parts off the floor.

Eliminate the possibility af a fall which could result in a serious injury.

• Wear safety clothing, goggles, respirator and other safety devices, whenever working conditions make this necessary.

- Never allow unauthorized persons access to the machine during lubrication and maintenance work.

- Work which influences operational and traffic safety must be carried out only by trained servicemen.

- Oily cloth and inflammable material must be removed from the machine. Clean the excavator before starting maintenance work.

- Oil drained must be collected In containers, preventing that it enters the groundwater.

- When using an acetylene torch akways wear welding goggles and gloves. Keep a •charged• fire extinguisher within reach. Be sure the acetylene and oxigen tanks are separated by metal shield and are chained to the cart. Do not weld or heat areas near fuel tanks or fuef tines and utilize proper shielding around hydraulic lines.

- Always use safety devices to block hydraulic cylinders. Never rely on the machine hydraulic system to hold when working on loaders, etc. A hydraulic line or cylinder could fail or someone could accidently strike the control levers causing the loader to fall. ~ Be sure to reinstall safety devices, guards or shields after adjusting and/or servicing the machine.

- After servicing, be sure au tools, parts, or servicing equipment are removed from the machine.

IV

Clean the excavator with a steam jet, especially after servicing the fuel system, and system. ~ Observe safety instructions during every servicing.

Afier cleaning the excavator lubricate all lubrication points by means of central lube """1rom or Lubricate slew ring gear alter drying by means of the automatic spray grease system or manually.

Repair weldings Before carrying out repair weldings contact our Service Department in order to avoid improper welding :,peratlons and unnecessary expenses.

Note: f cracks are found in the steel construction of your excavator, please inform our Service Department as soon as possible. Attach suitable information material (photos, respective cm,a1~,1ue drafts) showing the ocation and nature of the crack. f you have questions concerning your machine, please contact our Service Department:

=tAT HITACHI STABILIMENTO DI IMOLA ,pare parts and service department )PERAT!NG HEAD OFFICE fia S.S. 610 Selice N°10/C r0020 BUBANO DI MORDANO (BO) ·et (0542) 601111 • 640251 ·e!ex 511242 BENSER• I ·e1efax (0542) 51256 fEAO OFFtCE & WORKS 'ia S.S. 610 Selice N"' 43/A • 40026 IMOLA ~ !TALY ·e1. (0542) 601111 • 640251 ·etefax (0542} 640381 elex 511285 BENEX • I .

V

INDEX

Pag.

1

2 - TECHNICAL SPECJF!CATIONS

"

3

3 -IDENTIFICATION

"

20

4 - CONTROLS ANO INSTRUMENTS

"

21

5 - SAFETY PRECAUTIONS

.

31

6 - USE OF THE MACHINE

".

32

7 - SAFETY PRECAUT[ONS FOR MAINTENANCE

"

40

8 - FIRST PERIOD OF MA[NTENANCE ANO USE

.

41

9- GENERAL MAINTENANCE ATTENTIONS

"

51

10 - LUBRICATION SCHEDULE

"

52

11 - ELECTRfCAL SYSTEM

.

54

12-HY0RAULIC SYSTEM

"

56

13 • STANDARD TORQUE SPECIFICATION

"

58

14 • ADAPTORS ASSEMBLY

.

62

15 - TROUBLES: PROBABLE CAUSES AND CURES

"

64

1 - DESCRIPTION

DESCRIPTION

1. DESCRIPTION 1.01

DESCRIPTION OF CRAWLER EXCAVATOR

The fully hydraulic crawler excavator consists of the following main sections: • Undercarriage with crawlers and final drive.

• Superstructure with drive motor, pump unit, control valves, swivelling gear, operator's cab, fuel tank, hydraulic oil tank. . Equipment with adjustable boom and mono-boom, dipperstick and backhoe bucket rhe superstructure is connected to the undercarriage through a ball bearing slewing ring.

6- rotating joint. installed on excavator swing axis connects the hydraulic system of the superstructure to he one of the undercarriage. rhe diesel hydraulic drive forms a sealed unit which is built onto the superstructure platform. It consists of 1 diesel engine coupled to a hydraulic pump, equipped with a power-sum governor at constant horsepower;

hat means at any moment of the operating cycle the power delivered by the two axial pistontype pumps viii be constant and the resulting advantages for the diesel engine and the operating cycte will be evident.

rhe mono-boom, and dipperstick together with the bucket are the basic structures to dig the ground. The nono-boom can be mounted on two different positions according to the prevailing job conditions. The Hpperstick is available as standard in three difflerent lenghts.

"he bucket is equipped with two positions for bucket linkage to suit different job requirements.

Read carefully ttw; SAFETY RULES

1.02 BASIC COMPONENTS OF THE CRAWLER EXCAVATOR

Fig. 1

1) Rotating upperstructure 2) Undercarriage 3) Mono-boom 4) Boom hydraulic installations 5) Oipperstick 6) Bucket 7) Hydraulic cylinders, boom lift 8) Hydraulic cylinder, dipperstick Hydraulic cylinder, bucket

10) 11 ) 12) 1 14) 15)

Linkage Linkage tie rod Power plant bonnet Travel reduction and hydraulic motor Slewing Cab and operator's compartment

Read carefuHy the SAFETY RULES

2

2. TECHNICAL SPECIFICATIONS 2.01 ENGINE

Vlake ....................................................CUMM!NS vtodel .............

BTA 5.9 :::::ylinders, number .............................................s :::::ycle...................................................................4 njedion ......................................................direct ~ross horsepower :sAE J 1349} at 2500 r.p.m ..... 180 HP (132 kW) ' Net flywheel horsepower :SAE J 1349) at 2250 r .p.m ..... 177 HP (130 kW} 3ore and stroke ........................... 102 :x: 120 mm. )isplacement ........................................ 5880 cm3 :;oo1ing system ..........................................;water :lectric starter ..............................................24 V ~spiration ....................................... turbocharged =uel consumption (max. output) ........ 152 g/HP h Net flywheel horsepower as specified in SAE J 349 under standard SAE conditions 25"'Cll7'"'F imbient temperature and 100 KPA/29,61 HG ,arometric conditions, using diesel fuel 1D or 2D ASTM) after deduction tor fan, air cleaner, fuel •ump, water pump, lubricating oil pump and :ltemator.

Fig.2

2.02 HYDRAULIC SYSTEM "BHS"

·wo axiaf•piston pumps with pilotwcontrolled ~lator giving variable flow at constant torque; 1yperbolic" control characteristics. The regulator utomatically adapts to the power used according ) the running speed of the diesel engine. ine,.piece, multi-function control valve (with logic alves) for pressure relief, port relief, cavitation, raking. Proportional hydraulic control. la:x:imum delivery.................... 2 x 215 litres/min ellet valve settings

igging implement circuits ........................300 bar ravel system .......................................... 300 bar wing system ............................................300 bar he pilot control circuit is fed by a gear pump with preloaded accumulator for movements with 1gine off. perating pressure .................................... 30 bar elivery .............................................41 litres/min ydrauUc cylinders, bore and stroke ::>om (2) .................................... 130 x 1100 mm. rpperstick (1) ............................ 160 x 1380 mm.

Jcket (1) .................................. 130 x 1100 mm.

Fig.3

Read carefully the SAFETY RULES

3

- - - - - - - - - - - TECHNICAL SPEC1FICATIONS - - - - - - - - - - -

FuUy hydrostatic type • each track: driven by an independent hydraulic motor through a threestage planetary final drive. Splash !ubrlcated. Oil/ water tight floating ring seals.

DrawbalJ puU .....................- ......-. .••••• 23100 kg.

Maximum travel speed at rated diesel engine rpm (forward and reverse) ............................ 2,8 km/h

100312

Fig.4

Two oH bath disc brakes are applied cm the input shafts of the final drives. They are spring-operated and released by the hydraulic disconnect control provided. When the machine stops. the brakes automatically come into action. The brakes are instantly released bypressingoneofthetwotrave! pedals. Two integrated brake valves prevent the travel motors from going out of control when machine is traveflng down steps slopes, thus ensuring maximum safety.

2.04 CONTROLS

Fully power-assisted controls: two single-lever joystick controls govern the digging equipment and the swing mechanism. Twopivot pedals control forward and revers travel and counter-rotation.

Two levers attached to the pedals allow machine travel to be manually controlled.

Moving the control levers dlagonal!y. the two safety functions can be performed simultaneously.

A safety lever on the left-hand side of the panel neutralizes the whole control system.

100412

Fig.5

2.05 UNDERCARRIAGE Specific undercarriage for crawler excavators.

Strong rolfertrame ideal for heavy-duty Jobs.

Hermetically sealed track. lifetime lubricated rollers and idlers.

Triple track-shoes.

Hydraulic track adjustment Front and central track guides.

Nr. rollers• each track ............................... 10 + 2 Nr. track-shoes • each track Standard track-shoe width ..................... 550 mm.

Total track lenght .................................4605 mm.

Gau~ mm.

Ground contact area Track-,shoes 5:s·O mm Track-shoes 650 mm Track-shoes 750 mm Track:..shoes650 mm ............................. 6,47 Track-shoes 900 mm

m2 m2 m2 m2 m2

Fig.6

2.06 SWlNG MECHANISM • 360"

Swing mechanism operated by a self-braking motor and a splash-lubricated case hardened gear drive. )ouble swing bearing with case hardened internal Jear. ~ing gear and main pinion grease lubricated in ank. ~o daily lubrication is requested. :iwing speed ......................................... 9,5 r.p.m. iwing torque ...................................... 7940 KgM.

bath multidlsk brakes automatically come into 1ction when control-lever is in neutral position.

)ii

006/2 1

Fig. 7

Read carafu!ly the SAFETY RULES

5

- - - - - - - - - - - TECHNICAL SPECIFICATIONS - - - - - - - - - - -

2.07 SERVICE REFILL CAPACITIES Fuel tank ................................................-38 litres Cooling system .................................,.... .40 litres

lubrication Engine oil (total) ...................................... 16 litres Final drives (each) .................................... 3 litres Swing drive ............................................... 5 litres Hydraulic system (total) ........................ 320 litres Hydraulic oil reservoir ........................... 212 litres

!007/2

Fig. 8

2.08 OPERATING WEIGHT

IDipperstick

Triple track-shoes 550mm 650mm 750mm 900mm

I

Fig. 9

J

2100 mm

29000

29400

29800

30400

2600mm

29080

29480

29880

30480

3100mm Specif. ground pressure dipperstick 2100mm

29160

29560

29960

30560

I

l

Io s9 bar

059 bar 052 bar 044 bar

Mach[ne equipped with mono-boom and 1300 mm. bucket.

Shipping weight- subtract: 10 Kg. (operator's wefght) i 270 kg. for the fuel tank (1<r'/4).

2.09 ST AND ARD EQUIPMENT - Alternator 38A. - Exhaust muffler.

- Standard 3800 Kg. counterweight - Dry-type air-cleaner.

- Electric hom.

- Cab with adjustable seat • Cab heating.

• Diesel engine instruments.

• Service warning lights.

• Hourmeter.

•All windows provided with windshield wipers and tinted safety glass. · Work lights.

• Lifetime lubricated roHers and idlers . . Hydraulic track adjusters •550 mm. triple-grouser track-shoes.

Front track guiding guard.

Central track guiding guard.

Tow eye.

Tool box.

Travel motor guard.

Automatic multidlsk emergency brakes, oil bath lubricated.

Refuelling pump. Sound suppression kit Cab top window.

1009/21

Fig. iO

2.1 OOPTlONAL EQUIPMENT Two-piece boom.

Mono-boom.

Triple articulation.

Long and extra-long dipperstick.

Backhoe buckets.

Bucket teeth.

Front loading stick.

Front loading buckets .

Track-shoe options.

Air conditioner.

Pressurizer.

Radio set. ;::ops.

Ditching boom. :;1amshell attachment -iydraulic hammer.

-iydraulic hammer system.

And cara!uily the SAFETY RULES

7

- - - - - - - - - - - T E C H N I C A L SPECiFfCATIONS - - - - - - - - - - -

Mono-boom recommended when job conditions require maximum reach and depth such as for trenching and sewerage digging. lts reduced weight results in increased lifting capacity.

Two-piece boom (on request) new design recommended where versatility and possibility of using different attachments is needed, as the intermediate arm can be connected to the pre-boom in two different positions. The intermediate arm can be extended or retracted to 3 different positions to vary reach and digging depth.

When retracted, buckets of larger capacity can be used whilst. when fully extended, the working performance is the same as for a mono-boom.

Olpperstlck available in a choice of three different leghts allows to cope with prevamng job demand, from high tearout force to maximum reach.

With the short stick a bucket of larger capacity can be used.

Mono-boom with possibHity of front and rear mounting hole this special arrangement allows to increase by approximately 25% the hydraulic lifting capacity.

This feature gives great advantages when a face shovel attachment is fitted or when the maximum depth is not needed.

Read Clilf&ful!y w, SAFETY RULES

8

2.11 WORKrNG DIAGRAM

1 1--+-+-.

6 1---1--,:-4£....

s 4

3

2

2 l

1

0

0

1 2 3

1G

109876543210

9

S

7

6

S

4

3

2

I

0

Fig. 11

Fig. 12

Working diagram ajth mono-boom in front mounting

Working diagram with mono-boom ln rear mounting hole (Pos. 2).

hole (Pos. 1).

Mono-boom m. 5,58 Front mounting hole

dipperstick

m2,1

m2,6

m 3,1

=teach, ground level

m.

9,30

9,80

10,30

Jigging depth

m.

5,85

6,35

6,85

)ump height

m.

6,00

6,20

6,40

3reakout force (SAE J 1179)

kg.

17900

17900

17900

\.rm crowd force (SAE J 1179)

kg.

17000

14800

13100

Read carefully the SAFETY RULES

- - - - - - - - - - - TECHNICAL SPECIFICATIONS - - - - - - - - - - -

2.12 TRANSPORT DIMENSIONS

I

oJ

Fig. i3

A

8

C

D

E

F

G

H

4605

3000·3350

550•900

500

1200

3010

2700

3150

3100

10210

2,6m.

4605

3000-3350

550-900

500

1200

3010

2700

3150

3250

10260

3,1 m.

4605

3000-3350

550-900

500

1200

3010

2700

3150

3400

10310

Boom

1017/2

Fig. 14

In all buckets the attaching link can be in two different positions. In the outer position maximum crowd force ls obtained whilst, when attached in the inner position, an increased bucket rotation allows to dig vertical walls up to maximum depth.

Bucket teeth with different design to cope with different digging applications.

The size of bucket connection to the dipperstick and linkbar is standard. This allows the buckets to be fitted in a backating position for light-duty digging and/or tor front loading.

Read carefully the SAFETY RULES

10

l

2.13 BUCKETS RANGE

0

(:g '

0

0 mm.

Width

550

700

850

1000

1150

1150

1300

1450

1600

,.

Capacity (SAE J 296)

ml n"

Number of teeth

Kg.

Weight

0,40

0,60

0,75

0,90

1,10

1,30

1,50

1,75

1,95

3

3

4

4

5

5

5

5

5

510

580

670

760

830

850

930

1010

1090

0

0

0

0

0

0

0

0

0

0

0

0

0

1:::.,,

0

0

0

0

0

1:::.,,

□

digging m 2, 1

~

□

digging m 2.6

€,o

·

D

~

digging m 3, 1

[o

~0"7

3uckets for use with bulk material weights:

0

=2 ton/m3

1:::.,,

=1,8 ton/m3

D = 1,5 tonlm3

fi.;}ad camfu!!y th$ SAFETY RULES

11

2.14 l!FTING CAPAClTIES DIAGRAM - MONO-BOOM POSITION 1

15/A

15

Read carefully the SAFETY RULES

12

POSITION 1 ELBOW (A) ~II lifting capacities are in metric tons, over ends and sides (360"). They do not exceed 75'%, of oad in compliance with DIN 15019. /Vhen using a load hook on the stick~where bucket, bucket~inder and unl<',~ni::. must be removed 1 may be added to the loads in the CRANE~CAPACITY CHART. Mon~boom 5580 mm Diwerstick (A) 2100 mm Bucket 1.75 m3

Radius (m)

-feight m

1,0

.

1/J

1,0

7,S l

u

1,0

.

.

$,$

IS,O

.

4,5

4,0

a.a

3,M)

'3,44*

3.52'

.

3.43'

3,52"

3,114'

.

3,42"

3,W

3,$4'

3,e:/1"

4,04•

4,5

s,w

3.82"

3.00-

4,0Z'

4.31•

4,ee+

4,0

3.52

3,1$'

$,116*

4,21:l'

4,62"

s,ar

s.ro-

$,54'

.

z.s

M

. r.re· 0,0$'

3,S

3,02

3,47

3.00

-4,11"

4,52"

4,115•

S,52"

$,29"

7,31•

3,0

UI&

3,41

3,!11

4,38"

4,78"

S,29"

S,96'

s.ae•

e.ro-

.

2.$

2.114

3.35

3,63

4,38

$,03

7,43*

$,IW

.

2.90

3,7S

4.28

4,90

s.e us

6.31'

3,2li!

6,$1

7,72

9,20

1,5

2,66

3.24

3.(if

4,18

4,7&

S,50

6,311

7J/;0

!:l,95

1,0

2.!12

3,HI

3,61

4,10

4,611

s,:ie

fl.24

7,34

8,79

.

9,51•

2.0

:u

3,42"

$,$

s.s s.o

3,$

.

o.s

2,711

3,1$

3,SS

4,03

4,60

5.29

6,14

7,23

$,70

0

2,77

3,H

3,51

SM

4.$4

5,22

6,06

7,1ft

!:!,66

10.&9

-0,S

.

3.00

3.48

3.94

4,50

S,17

6,(rl

7,13

e.es

10,93

10.as·

·1.0

.

a.m

3,41

U2

4,47

S,!S

6,00

7,12

8,61)

10,98

12,90"

10,75'

. . . .

. .

3,47

U2

4,47

5,15

$,01

1,14

S,72

11,06

12.18'

ta,24•

12,o.1·

a.so

$,114

4,4&

S,11

6,04

1,11!1

S,79

10,74'

12.211"

14,04'

14,Zl"

3,98

4,$2

S,21

6,00

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6,58"

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4,64

"Hydraulic~ system pressure is the !imlting factor.

Raad carefully the SAFETY RULES

3

- - - - - - - - - - - TECHNICAL SPECIFICATIONS

POSITION 1 ELBOW {B)

Al! lifting capacities are in metric tons, over ends and sides (360°). They do not exceed 75% of tipping load In compliance with DIN 15019.

When usilg a load hook on the stick-where bucket, bucket-cylinder and linkage must be removed 1,53 t -may be added to the loads in the CRANE-CAPACITY CHART. ~

Mono-boom 5580 mm Dipperstick (B) 2000 mm - Bucket 1.50 m3

~

Radius (m)

Height

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11,42'

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4,44

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10,90"

12,73'

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3,94

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a,411'

9,73'

11.25•

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16,12"

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" Hydraullc - system pressure is the limiting factor.

Raad carefully th& SAFETY RU!.IES

14

.

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a,19•

POSITION 1 ELBOW (C) a.II lifting capaclties are in metric tons, over ends and sides (360°). They do not exceed 75% of tipping oad in compliance with DIN 15019.

Nhen using a load hook on the stick-where bucket, bucket-cylinder and linkage must be removed 1,38 t may be added to the loads in the CRANE-CAPACITY CHART. •Mono-boom 5580 mm Dipperstick (C} 3100 mm Bucket 1.30 m3

Radius {m)

ight t,O

7,5

s.s

7,0

5,0

2.53

<4,111"

2.50

•.w

5,03"

2.46

4.92"

5,.50"

us

5,29'

2.39

5,62"

3,5

6.28"

1.ss•

s.w

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8.13'

us-

1.«J'

U)"

3,0

1,5

1,0

1.11·

7,2D'

1,u•

9,311'

U7"

8.29"

1o.87'

9,96"

9,53"

2,5

.... a.a:.,+

10.SS-

2.36 2,33

i,47'

4,0S

5.15

6,01

7,1<4

8.70

tt.00

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1t,42"

10,114'

15,7-4•

14,15"

12,97"

12.23' 13,70'

5.19

6,06

7,2'J

8.79

10.53'

12,36+

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4,511

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4.68

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9,()6"

10,50*

12,45•

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11,13"

6,99"

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4.21'

S,04•

S.82"

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1,67"

4.62"

• Hydraulic • system pressure is the limiting factor.

Rad car&My the SAFETY RULES

15

- - - - - - - - - - - TECHNICAL SPECIFICATIONS - - - - - - - - - - -

POSITION 2

7

5 .__ __.,_ _ _ _ _ _ __ 10

9

7

Fig.16

16/A

Raad carefully the SAFETY RULES 16

POSITION 2 ELBOW (A) All lifting capacities are in metric tons, over ends and sides (360"'). They do not exceed 75% of tipping load ln compllance with DIN 15019.

When using a road hook on the stick-where bucket, bucket-cylinder and linkage must be removed 1 t -may be added to the loads in the CRANE-CAPACITY CHART. - Mono-boom 5580 mm - Dipperstick (A) 2100 mm - Bucket 1.75 m3

Radius (m)

Height a,o

m

s.o

.. .

$,5

.

5,0

.

u

:

u

...

J.5 :I.I)

Ml

1,0

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.

1.0

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6,0

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s.o

4,S:

4.0

3,S

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.

:i,o

5,$4•

4.25

4,96

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4,99

S,S1•

4,91

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.

.

.

.

4-Zl

4,92

S,74

ll.23•

3,61

4,18

4,85

5,64

6,411'

7,0S·

3$1

4,12

4,76

5.52

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1,43'

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3,53

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.

"Hydraulic• system pressure is the limiting factor.

Raad car&fully Iha SAFETY RULES

17

- - - - - - - - - - - T E C H N I C A L SPECIFICATIONS - - - - - - - - - - -

POSITION 2 ELBOW {B) Ail lifting capacities are in metric tons, over ends and sides (360°). They do not exceed 75°/o of tipping load in compliance with DJN 15019.

When using a load hook on the stick•where bucket, bucket-cylinder and linkage must be removed 1,53 t -may be added to the loads in the CRANE-CAPACITY CHART. - Mono.boom 5580 mm - Dipperstick {B) 2600 mm - Bucket 1.50 m3

Radius {m)

Height In

a.s

M

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7,f/:

6,$

4,42

4,93•

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"Hydraulic - system pressure is the limiting factor.

A$ad carefully !he SAFETY RULES

18

2.5

4,95'

1,0

u

,,o

.

POSITION 2 ELBOW (C) All lifting capacities are in metric tons, over and sides {360<>). They do not exceed 75% of tipping load in compliance with DIN 15019.

When using a load hook on the stick-where bucket, bucket-cylinder and linkage must be removed 1 -may be added to the loads in the CRANE-CAPACITY CHART. • Mono-boom 5580 mm - Oipperstlck (C) 3100 mm • Bucket 1.30 m 3

Height

Radius (m) 1,5

l.fc

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" Hydraulic ~ system pressure is the limiting factor.

Raad carefully the SAFETY RULES

19

- - - - - - - - - - - - - DIRECTIONS FOR U S E - - - - - - - - - - - -

3. IDENTIFICATION In case of maintenance assistance It shall be necessary to inform our technical Service Department {or any authorized Repair Shop).

To facilitate a fast and efficient service in case of possible failures. itis advisable to quote the following details for reference of our Service Department: a) model of excavator (fig. 17) b) serial number (fig. 18) c) serial number of diesel engine (fig. 19) d) number of hours worked · e) purchase date of excavator

Fig. 17 Model of excavator

Fig. 18 Serial number

Fig. 19 Serial number of diesel engine

Read carefully the SAFETY RULES

20

4. CONTROLS P0Sm0N 4.01 OPERATOR'S COMPARTMENT

ig.20 1Control lever dipperstickand upperstructure slewing

Control lever boomlift and bucket 1 Travel control pedal , Automatic idling speed control , Hand lever, disconnects all controls Hand accelerator Hourmeter 1

8) Engine coolant gauge 9) Engine oil manometer 1O) Instrument control panel 11) Control switches 12) Lighting switch and hom 13) Ignition switch and starter 14) Seat

Read carefully the SAFETY RULES

21

- - - - - - - - - - - - DIRECTIONS FOR U S E - - - - - - - - - - - -

4.02 CONTROLS

Fig. 21 Control lever - DIPPERSTICK AND UPPERSTRUCTURE SLEWING (pos. 1 fig. 20)

00414

003/4

lever in pos. B DIPPER ARM RETRACTS

Lever in pos. A DIPPER ARM EXTENDS

006/4

005!4

Lever in pos. C UPPERSTRUCTURE SLEWS ANTICLOCKWISE

Lever in pos. D CLOCKWISE

Read carefully th& SAFETY RULES

22

UPPERSTRUCTURE SLEWS

ig. 22 Control lever - 800M LIFT AND BUCKET (pos. 2 fig. 20)

~ver in pos. E BOOM LOWERS

lever in pos. F BOOM RAISES

010/4

,ver in pos. G BUCKET IN

01114

lever in pos. H BUCKET EXTENDS

Read eamfully tl'lEI SAFETY RULES

23

- - - - - - - - - - - - - OiRECTIONS FOR U S E - - - - - - - - - - - -

N.B.: lever in position N has no motion. (Neutral) POSSIBILITY OF TWO MOVEMENTS AT THE SAME TIME Control lever in intermediate position will make possible two movements at the same time according to required positions.

Es. lever (fig. 22) in position F.H. will make possible boom raising and extension bucket.

Fig. 23 TRAVEL CONTROL PEDALS

IMPORTANT NOTE - The following instructions, relevant to controls use, shall be referred to rear drive-motors as to running condition... Right", "Left'\ .. Forward", "Reverse", "Clockwise", "Anticlockwise", indications shall be referred to the correct operator's position.

Read carefully t1m SAFETY RULES

24

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _0_1314___.

pedalsinpositionA~ EXCAVATORTRAVELS WARD

---------------'---' ~dal in positlon A. Sx pedal in position B

j014/4

Both pedals in position B ~ EXCAVATOR TRAVELS BACKWARDS

ITTM

WATOR TRAVELS BACKWARDS TO LEFT

ITTM

Sx pedal in position A. Ox pedal in position B. EXCAVATOR TRAVELS BACKWARDS TO RIGHT

4.03 HANO ACCELERATOR LEVER (6, fig. 20) .ever in position as shown in figure 20, the engine will run at idling speed; to accelerate, move the lever 1s shown by the arrow.

4.04 HANO LEVER, DISCONNECTS ALL HYDRAULIC CONTROLS (5, fig. 20) .ever in position as shown in figure 20, all main controls can be operated, moving the lever as shown by 1rrow, it will not be possible to operate any excavator service.

IMPORTANT NOTE NEVER LEAVE THE EXCAVATOR BEFORE HAVING DISCONNECTED THE CONTROLS BY MEANS OF THE DISCONNECT LEVER.

Read carefully the SAFETY RULES

25

- - - - - - - - - - - - - OIRECTiONS FOR U S E - - - - - - - - - - - -

4.05 DASHBOARD

Fig. 24 FUXE BOX (22. fig. 24) A) B} C) 0) E} F}

+ + +

+ + +

Optional acessoiy (8A) Optional acessoiy (12V 8A) {Radio Main head!lght (BA) light (8A) Working headlight boom (8A) Warning electric horn (8A)

G) H) I) L) M) N)

+ + + +

+ +

Read carefully th& SAFETY RULES

26

Optional acessoiy (8A) (lighter) Optional acessory (8A) (hammer) Windscreen wiper motor (8A) Switches and warning lights (BA) Optional acessory (25A) (Diesel oil pump} Starting engine

GNITION AND STARTER SWITCH {1, fig. 24) Vhen the key is in position •o• all circuits are off; when the key is turned to position·,• al! circuits are on; urning the key to position •2· operates the thermostart unit; turning the key operates the starter urning the key to position •o- all circuits are off again. ~UTOMATIC IDLING SPEED CONTROL (2, fig. 24) >ushing this control device, the automatic idling speed function is on .

.iGHTING SWITCH {3, fig. 24) ·11is control device has various functions: ) · e switch lever clockwise, it will control the dashboard lights. ') 2 it will operate the traffic lights; in position 3 it will operate the main headlight located on the right front of 1per·strt1cture. ) Pressing the • it will operate the warning horn.

'HERMOMETER, ENGINE COOLANT (4, fig. 24) 'his instrument indicates the temperature of coolant of diesel engine.

1ANOMETER, ENGINE OlL PRESSURE (5, fig. 24) 'his instrument indicates the engine oil pressure. iARNING LIGHT, ALTERNATOR (6, his warning Ught ·oN•, indicates the

. 24}

rnator is discharged.

/ARNING LIGHT, AJA CLEANER CLOGGING (7, fig. 24) his warning light ·oN•, will indicate the air filter is clogged. /ARNING LIGHT, HYDRAULIC OIL TEMPERATURE (8, fig. 24) his warning light, "ON", indicates the engine lubrication is fault: stop any operation until the problem is Jrrecied.

/ARNING LIGHT, FUEL LEVEL (9, . 24) · !ht''OJ',J", indicates them um fuel level. It is advisable to avoid it, as it wou!d be necessary re bl feed system. fARNING UGHT, HEATING (10, fig. 24) his warning light, "ON", indicates the heating is functionning.

rARNING LIGHT, TRAFFIC LIGHTS (11, fig. 24) fhen ·ow, indicates the light on the right and on the left front upperstructure.

'ARNING LIGHT, MAIN HEADLIGHTS (12, fig, 24) 'hen "ON", indicates the high light on the right and on the left front upperstrucure. rARNING LIGHT, AUTOMATIC IDLING SPEED (13, fig. 24) 'hen •oN•, indicates the automatic idling speed is connected.

'ARNING LIGHT, WORKING HEADLIGHT (14, fig. 24) 'hen "ON", indicates the lighting of working headlight 'ARN!NG UGHTS (15, lese warning lights can

) used for optional accessories.

NITCHES (18, 19,20, fig.24} t Working headlight i Heating equipment 1 Windscreen wiper )URMETER (21 fig.24 iis instrument will be an efficient guide to check maintenance and inspection operations listed in this anual. This instrument is connected only when diesel engine is working.

Read carefully the SAFETY RULES

27

- - - - - - - - - - - - - OIRECTiONS FOR U S E - - - - - - - - - - - -

4.06 SEAT ADJUSTMENT (14, fig. 20) A correct adjustment of operator's seat wm assure the best comfort during working hours.

Sit on the seat and control the indicator position (3, fig.

25).

In case the seat is in the right position, the key indicator should be in Pos. a. !fit is shown in Pos. b, press the adjustment lever (1) marked with+.

Put your left thumb on key indicator and as soon as you have the Pos. a you will have the right position.

If as shown in Pos. c control the adjustment lever (1} marked with ~ and move to the right position.

(The right position shall be obtained only if the operator is well~sitted).

01!1!4

Fig. 25 SEAT SQUAB ADJUSTMENT

Be correctly sitted. Press one of two levers {2) and adjust your squab in one of the three positions, finally release the catch.

FORE AND AFT ADJUSTMENT

Move the lever until desired inclination is reached, then release the locking lever to previous position.

SEAT CUSHION ADJUSTMENT

Front and rear sides shall be regulated separately.

Raise catch and adjust the seat cushion to the desired position.

Move the lever to the previous locking position.

Four positions are available.

This operation will allow different positions and inclinations.

Read cam!ully the SAFETY RULES

28

4.07 OPERATOR'S CAB

l\

I \ I \ I I

\ \

\ \

\

01914

=ig. 26 ndustriat cab in compliance with ISO, guarantees best comfort during working hours. The windows :fimensions allow a good visibilty all around.

)OOR To get into the operator's compartment from the outside, after freeing the sturdy lock. pull handle (1, fig.

26) to open the door from the inside, pull handle (2, fig. 26) you can keep the door open during work Open until door is automatically locked against the cab through the pivot pin.(3, fig. 26).

Unlock it moving lever (4, fig. 26), inside the cab.

Read earefully the SAFETY RULES

29

- - - - - - - - - - - - - OiRECT!ONS FOR U S E - - - - - - - - - - - -

WINDSCREEN - The front windscreen slides in the cab garret.

- To open the windscreen, unlatch it by means of left and right sliding bolts (5, fig. 26).

Ralse the windscreen, slide it as far as it latches down through lock (6, fig. 26), then secure it to the rear part with bolts (5,fig. 26).

- To close the windscreen, unlatch bolts and handle block lever (8, fig. 26).

Slide the windscreen to its previous locking position securing it by means of left and right bolts (5, fig. 26}.

PAY THE UTMOST CARE TO THE REVERSAL WlNDSCREEN. THE BASE SUPPORT MAY ACT AS SHEARING DEVICE.

LOWER FRONT WlNDOW - The lower front window can be completely removed and properly placed in the left rear part of the cab.

- Unlatch the window using right and left bolts (7, fig. 26), place it in its proper compartment on operator's left side, then lock it with bolts.

Raad caretufty the SAFETY RULES

30

5. SAFETY RULES 1) First get accustomed with the location and operation of all controls, instruments

alarm devices.

2) Keep the operator's compartment, steps and grips always dean and free from grease, oil, mud and or whatever can be obstacle.

3) Never make use of controls and hoses, they are flexible and they cannot be used as support devices.

Any control shifting may cause an accidental movement of the machine.

4) Never leave the excavator before having disconnected the controls by means of proper disconnecUever

(5, fig. 20).

5) Inspect the working area to verify height, width and weight limits and be sure the excavator does not exceed these limits.

6) Check the exact gas and water piping. or telephone cables, sewers, electric lines either over or underground and any other possible obstacle.

7) Always be sure there is space for rotation of rear end of excavator .

8} Do not exceed the lift excavator capacities.

All load capacities shall be referred to the excavator placed on level surface and not on sloping terrain.

9) Before starting engine, make sure the controls have been connected by means of proper lever (5, fig. 23) O) Before starting engine, always be sure that nobody is standing in the working area; on the contrary, stop immediately any type of operation.

1) Never start engine in closed places but only in airy places.

2) Never carry passengers.

3) Always operate having a clear view of the working area.

O Inspect the working area to locate the possible presence of dangers: slopes, rocky terrains, lands subject to landslides, ditches.

5) For any possible tow of the excavator, make only use of proper draft gear and be careful to the towing phase.

S) This machine and its components shall be used only by qualified operator.

1') Pay the utmost care to the reversal front window. The base support may cause act as shearing device.

Read carefully the SAFETY RULES

37

- - - - - - - - - - - - - DIRECTIONS FOR U S E - - - - - - - - - - - -

6. USE OF THE EXCAVATOR

ON DELIVERY OF THE EXCAVATOR, THE RESPONSABLE FOR SALE DEPARTMENT Will GIVE THE USER THE MAIN OPERATING AND MAINTENANCE INSTRUCTIONS.

6.01 DIESEL ENGINE INSPECTION

INSPECTiONS BEFORE STARTING THE DIESEL ENGINE Before starting the engine, a general inspection of the excavator shall be necessary for your own safety and to ensure a long and proper service life to the machine, conforming to the safety hints.

Check all the excavator to discover anypossJble!oose bolts, oil or water leakages, condition of boom, bucket and dipperstick.

STARTING THE DIESEL ENGINE It shaU be necessary to inspect that the safety lever is in vertical position as to avoid accidental movements of the excavator during start•up phase.

Tum ignition key to position H. Toe change alternator warning light shall be lighted up.

Tum ignition key to position m to start diesel engine.

In cold periods tum the switch to position 11,mantein this position for about 10 seconds, tum ignition key to position mand start diesel engine.

After engine starts, release ignition that automatically moves to position U, leaving dashboard under voltage.

THE ENGINE STARTS It shall be advisable to keep the engine at idling speed at least for 5 minutes, considering ambient temperature, without operating any excavator service.

Verify au lights are OFF; on the contrary. immediately switch the engine off and inspect the causes.

Move the safety lever to the horizontal position; your excavator will be ready.

STOPPING In case the engine has uu-,1r""1 under service load conditions, do not stop it at once, but let lt operate at no,. load for 1~2 minutes as to obtain normal operating temperature.

To stop the engine, move accelerator to idling speed position, then rum the ignition key to pos. I, Always remove ignition key whenever you leave the excavator.

Read eamfu!ly !ha SAFETY RULES

32

6.02 AUTOMATIC IDLING SPEED CONTROL logic element (1, fig. 28/A), and a pressure switch (2, fig. 28/A) are located under the cab floor. The latter :,nstantly monitors the pressure present in the system (whether or not there is pressure). a.ck of pressure (when the machine is not moving) is detected by the pressure switch which transmit an :ectric signal to the electronic timer (1, fig. 28) that, in tum, after the sat time has elapsed, activates the :ectromagnet (1, fig. 27). The latter win than start the diesel engine idling. fhen working. the pressure switch does not sand any signals to the timer. The electromagnet is thus aactivated and the diesel engine runs at the speed determined by the hand-acoelerator (6, fig. 20). ha operating range of the electronic timer can vary from 2 to 20 sec. However, it is normally set to 6 sec. o adjust it, use a 4-mm screwdriver, that is to be used as shown in fig. 28. Tum it to the right to increase ie delay time, and to the left to decrease il o cut off automatic Idling speed system, push control device (2, fig. 24) on dashbord, near warning light 3, fig. 24) indicating it is "ON•.

g.27

Fig. 28

J. 28/A

Read earefully the SAFETY RULES

33

- - - - - - - - - - - - - DIRECTIONS FOR U S E - - - - - - - - - - - -

6.03 BATTERY BREAKDOWN

The excavator is equipped with battery breakdown device (1, fig. 29).

Before starting the engine. be sure there is cootact It is advisable to disconnect all contacts if the excavator will be not used for long periods.

6.04 RIGHT WORK POSITION

Fig. 29

Fig. 30 • Shows the right position of the excavator during the digging phase; this will improve your stability as the reduction gears act as counter weight; do not overload the reduction gears and mainly if you need to go away from the working area because of ground subsiding, backing will be Instinctive.

6.05 ROAD TRANSPORT OF EXCAVATOR

The excavator shall be transported by means of proper trailers, it shall be advisable to avail of speciaUzed transport companies.

005/fi Totransporttheexcavatorwithnoescort, according Fig. 30 to the road traffic regulations in force, it shall be necessary that the loading gaugeof the trailer does not exceed the allowed dimensions. In Italy they are as follows: - max. width 2.50 m.

- max. height 4 m.

• max. lenght 15 m.

As for weight of the machine and its dimensions, refer to the technical specifications listed in this instructional Manual.

The precautions listed below should be observed when loading and securing the excavator to the trailer: - loading ramps shall be equipped with timber in planks.

- excavator track shoes shall be free from mud, snow and ice before climbing the loading ramps.

- lean front end of traks against the upper side of low-bed trailer and fix the other end by means of wedges firmly adjusted between the tracks and loading platform ot trailer.

- fasten tracks and excavator frame to trailers hooks by means of chains and hooks.

- according to trailer dimensions, disassemble all excavator attachments or part of them.

Read carelully the SAFETY RULES

34

6.06 TRAVELLlNG WITH THE EXCAVATOR =ig. 31 - Correct position of the excavator: always ravel with travel reduction gears in rear position and ¥ith the boom element drawn up as far as possible md with the bucket nearby 30-40 cm above the 1round. You would have a maximum stability and the 'leSt load distribution; furthermore the control working ,hall be instinctive. Moving ahead the travel pedals he same does the excavator.

3efore moving or transferring the excavator, stop any otation upperstructure movement to avoid accidental novements. Be careful in sloping terrains. Keep the ,ucket in a position as to obtain grip to the ground in :( :ase of slipping. During travelling on sloping terrains :eep the upperstructure at the same level of trucks. ,void any type of travelling in transversal way. Never ravel your excavator in a crowded area, without 1aving at least a person that guides the operator.

Fig. 31 Aake use of electric warning horn before starting. t shall be necessary to verify the load and dimension limits; they shall never be exceeded.

11e height, width and weight of the excavator shall be well known to the operator. In narrow spaces avail ,f special person who makes signamngs.

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35

- - - - - - - - - - - - - DiRECT!ONS FOR U S E - - - - - - - - - - - -

6.07 GENERAL OIRECT[ONS FOR USE

For any digging operation it shall be advisable to facilitate the bucket penetration into the ground, not only by use of bucket cylinder, but also making use of dipperstick and boom lift cylinder, always try to operate with the cylinder at the same time in order to improve your excavator performance.

In case the bucket may not penetrate into the ground or into the rocks, change bucket edge angle; do not continue ff the ground does not yield, you would have an overheating of the hydraulic oil. It will be better to change the digging technique than insisting on a wrong manouvre.

A good operator never makes the hydraulic cylinder reach the end of their stroke.

Once you become familiar with the excavator, It will be easy to realize when the cylinders are next to end stroke. You will reduce working cycles and not overheat the hydraulic system.

To brake the upperstructure during the slewing phase it will be sufficient to move the slew control lever back to central position; once you get used to braking distance it will result easy to brake your excavator; never stop the slewing upperstructure by use of counterrotation: the hydraulic engine will be uselessly overloaded.

This move will be correct only in an emergency.

Piece the excavator as a function of loading and unloading area so as to slew to left in order to load material and to get the best visibility.

Never make use of bucket or any other implement to lift persons or carry passengers.

Never use the excavator as working platform or stage. The excavator shall never be used for different purposes (such as. to push or tow freight cars, trucks or different vehicles). Pay particular attention to person in working area.

Never translate or stop the bucket, different charges or implements over persons and excavators cabs.

Before loading a truck, be sure the operator is in a safe place.

Always load trucks from back or side part.

Use the correct model of bucket of the excavator and material handling, loading particulars and heaping of material. type of ground and other required working conditions.

In transferring phase with baded bucket, keep the bucket retracted and the booms in the lowest allowable position.

Mantein the speed according to the load and terrain conditions. Move only loads we!! placed in the bucket.

Pay particular attention to the overhanging loads.

Never translate your bucket over persons. Avoid translating the bucket on slopes, as this manouvre would reduce the control stability. Always load the bucket from up side.

Read caroful!y the SAFETY RULES

36

oads to be lifted shall be exclusively hung up to the proper attachment The excavator is not a lift or a ansport mean and it shall not be used to place loads. On the contrary you shall have to follow these recautions: . Loads clamping to be lifted by use of chains or ropes properly fixed to hook attachment . No person shall be under loads or in the working area of the excavator. \forking on peed.

is dangerous,

to level the working area. If it iS not possible, reduce the working cycle

,void working with the bucket to upside.as ba!losts would reductthe control stability on slope and increase 1e possibillty of overturning. >n slopes it shall be better to work with bucket to down side, after checking the stability of the machine with ff load bucket and swinging slowly the upper structure. · 'lace the undercarriage in a vertical way as to slopes, rocky terrains to facilitate the final manouvre. e careful in case the driving gears should be on front side of the machine, the direction is reverse as to the perator. .!ways inspect the job conditions as to the terrain eep the· excavator to a proper distance from the digging area. lever dig under the machine.

is necessary, always be sure the digging area sides have been propped in order to avoid the landslip or Lil of the excavator.

•o not rotate the upperstructure, lift the load or stop the machine suddenly, because it could cause accidents. efore starting the work near gas pipes ·or any other utility service, it shall be advisable: To get in contact with the local Gas Utility, before starting any work. look up the local telephone directory.

To fix the proper precautions to be followed in order to guarantee the safety.

Decrease the working speed. The reaction time could be too slow and the diStances could be calculated wrongly.

Have a specific person who makes signals. He shall be responsable to observe the approach of the excavator or any other implement to Gas pipeline. This person shall be in direct contact with the operator; the operator shall pay particular attention to signalling.

Read carefully the SAFETY RULES

37

- - - - - - - - - - - - DIRECTIONS FOR U S E - - - - - - - - - - - -The above mentioned responsabilities shall involve, beyond the Gas Utility, if informed in advance, the operator himsel. the excavator owner and/or any other physical person that has rent or lent the machine and he shall be responsable in that particular moment.

Jn proximity of electrical cables particular precautions shall be followed. It shall be advisable to mantein the safety distanoe without exceeding the minimum distance. Be sure to observe the local or National Safety Rules concerning work near electrlcal cables.

Before starting any work, in proximity ot electrlcal cables You shall: - Get in contact with the local electrical Supply Company. Look up the local telephone directory. ~ Determine Ile proper precautions to guarantee the safety.

- All cabtes shall be considered functionning, even if it is well known the cable is out of order and clearly connected on the ground.

-Reduce working speed. The reduction time could be too slow and distances could be calculated in a wrong way.

-Warn every person to be away from-the excavator. In case the load has to be for laying refer to Electrical Utility company as to know the precautions have to be followed.

- Aµpoint a person for signallings. This person shall be responsable to observe in a clearer way than the operator, any approach of the machine or part of it to the electrlcal cable. He shall be in direct contact with the operator. who has to pay particular attention to signallings.

Working in wells or in proximity of these. in trenches or other similar ones, always be sure the walls have been propped as to avoid the landslip.

Outing digging phase it does exist landslide or cave-in perit Inspect the terrain conditions or material to be removed.

Prop wherever can be necessary so as to avoid landslldes or cave-in, including: - in proximity of previous diggings, fill by means of back-filling .

• ln case terrains conditions are not good.

- When diggings can be subject to vibrations caused by railways. raod traffic or excavator machines.

38

6.0SSTOP

1y time you stop working, inspect for any reason, all controls are in neutral position and safety !ever in utdown position so as to guarantee the next starting with no risk. rver leave the excavator if moving. Before leaving the driving seat and after controlling there are no rsons near the excavator, move the implements to ground in safety position. Move possible additional plements to safety positions and verify all controls are in neutral position. Move the drive controls to stop sition. Disconnect the starting commutator. Refer to the Operation and Maintenance Manual.

:rk the excavator in a safety area and choose a level surface. On the contrary. place the machine in a rpendicular position to the slope and be sure there is no landslide risk. caseyou have to park your excavator in traffic lanes, it shall be advisable to adopt the following signals dangers: flags. barriers, flashlights and other signals of danger. In addition, provide for additional danger 1nallings on traffic lanes so as to signal in advance the danger to coming vehicles. !\lays disconnect the starting commutator, before cleaning, repairing or parking the excavator to avoid :::idental and unauthonzed startings.

1ver lower the implement or additional attachments from any position except for the operator's rnpartment Make use of warning horn.

6,09 MACHINE REMAINS INOPERATIVE FOR LONG PERIODE

he excavator is not used for !ong periods,follow the directions below: ark the machine in a sheltered and attended area. erform a general cleaning and lubricate all the parts fitted with grease fittings, osition the boom so that the cylinder rods are fully retracted. ubricate the cylinder rods by using a suitable lubricant ompletely fill the tank in order to order to prevent rust from forming. :.1bricate the gaskets on the outside of the machine body. in order to prevent them from deteriorating. isconnect the battery terminals by using the device provided. Remove it, if necessary. erform all that is required to store the machine in the best possible way.

Road camfully the SAFETY RULES

39

MAINTENANCE

7. SAFETY PRECAUTIONS FOR MAINTENANCE

Follow the Operation and Maintanance Manual carefully and read the safety plates iocateci on the excavator and its components before any repair or maintenance on the excavator.

GENER.Al RULES

- Do not permit unauthorized persons to fix or service.

- Do not operate the excavator or use the implements from any position except for the operator's compartment seat

- Do not lubricate, repair or adjust machines when motor ls running unless 1t has been expressely required

by Operation and Maintenance Manual.

- Never wear an outfit that might get caught in the machine controls.

- Make use of proper tools to al!ign holes, do not use hands.

- In case of operations or repair not accessible from the ground. make use of step ladder or platform in conformity with safety rules.

- Do not check or fill tanks and set batteries in proximity of inflammable materials or any flames.

- Lilt and handle all heavy parts by means of proper lifting adjustment Be sure all parts have been correctly slung by proper connection hooks.

- Start engine only in airy places.

- In case of repairs with the engine running, it shall be necessary, while the mechanic is working the operator seats on his correct place.

KEEP HANDS AND CLOTHING FAR FROM PARTS IN MOTION

IMPORTANT NOTE: IN CASE OF PREASSURED TANK, LOOSE THE PLUG PLACED ON FLUID RESERVOIR BEFORE ANY SERVICE ON THE HYDRAUUC SYSTEM. ALWAYS TIGHTEN THE CAP AFTER THE OPERATION.

React camfufly the SAFETY RULES

40

a. ftRST PERIOD OF USE AND MAINTENANCE 8.01 FIRST PERIOD OF USE t shall be necessary a running in period at least of 60 working hours, following these instructions carefully:

. after ti.Nery cold start, make the excavator working at idling speed for some minutes; do not keep the excavator at maximum power for a long time;

inspect frequently for any possible leakage. >uring the first period beSides the periodical maintenance attentions, it is advisable to carry out additional heckings. not necessary afterwards, or they could be made as follows: After first 20 working hourc: oil engine and filter elements renewal.

Within the first 100 working hours:

fuel filter cleaning;

hydraulic filter cartridges renewal; checking of tightening screws clamping slewing rod; inspection of fuel feed system and engine valves backlash; control of tightening hydraulic system connections.

Rud carefully th& SAFETY RULES

41

MAINTENANCE 8.02 MAINTENANCE 1) Hourmeter (l. fig. 20) will check when maintenance and inspection operations have to be performed.

2) lubricants and their change intervals are the

result of accurate testings and long experience. Therefore it is advisable to follow carefully the sultabie directions.

3) The oil level checking shall be always made with the excavator placed on a lever surface.

4) Oil engine and reduction units renewal shat! be always made when the machine is warmed up. tt wm enable an easier drainage of of the oil and deposits.

5) Before connecting the greasing pump. clean every lubrication device carefully.

This operation w.11 avoid any 1mmission of impurity.

8.03 OIL ENGINE Check daily engine lubricant level (1 O working hours), extract dip--stick (1, fig. 32), dry it with a clean rag then put the dip-stick into its tube. extract it again and check correct oil level: this should be between upper and tower mark of the dipstick. Top up as necessary through filler cap (2. fig. 32).

Fig.32

Change diesel engine lubricant and filter element after 20, then 250 working hours. Unscrew drain plug (3. fig. 32) then empty throughly the oil.

Carefully clean drain plug then fit it again placing a new gasket and tighten it.

Apply a sufficient quantity of lubricant to the sealing ring of the new filter, replace and tighten it by hand.

Removeoilfillercap (2, fig.32)and keep theievel dipstick away in order to reset the level. Fill it. using the correct oil, up to upper mark of dipperstick.

Refit filler cap, start the engine and let it run under no load for a short time. Stop engine and check oil level again that should be to the upper mark of the dipperstick.

Check engine for possible leakages.

Fig. 33

Rud camfully the SAFETY RULES

42

8.04 E'NGtNE COOLANT

IMPORTANT NOTE - UNDER PRESSURE FLUID~ BEFORE REMOVING CAP, SWING IT SLOWLY TO RELEASE ALL PRESSURE. TO AVOID BURNS DO NOT LOOSE RADIATOR FILLER CAP WHEN ENGINE IS WARM.

1e system consists of a radiator and a baok frigerant tank (4, fig. 34). While recovering :ceeding increased coolant inside the radiator, U turns it as soon as the volume itself decreases ter temperature falling.

1is system avoids coolant leakages.

1eck coolant level in the back refrigerant tank on e level indicator MAX/MIN. Change of coolant >Giant should be changed every 2000 working ,urs and not over than 2 years. ive the excavator on a level surface, and stop the \gine.

1move the radiator filler cap ( 1, fig. 34) and open :, in bottom of radiator (2, fig. 34). ain througly the cooling system than flush it with !an water. ➔fit plug (2, fig. 34) and fill with coolant art the engine and run it for about 1o minutes; eek coolant level again and top up as necessary.

Fig. 34

Filling I completely the radiator through the valve plug (1, fig. 34) and through hose (3, fig. 34), reach proper rel (MAX) in back refrigerant tank. · EVERY CHANGE, CHECK THE VALVE PLUG IS FUNCTIONNING PROPERLY (1, fig. 34) 1 delivery

the excavator is provided with additive coolant to lower freezing temperature from

o to •20°.

Read carefully !he SAFETY RULES

43

MAINTENANCE

8.05 FUEL FILTER ELMENTS Replacing fuel The replacement be pertormed every 250 working Unscrew (1, 35) , apply a sufficient quantity of lubricant to the sealing rings of new filters. Replace the filters and tighten them by hand.

Overtightening may cause severe damage to filters.

too

IMPORTANT: before setting the machine to work (before engine starting-up), drain the water~fuer separator by loosening plug (2, 35).

Fig. 35

Eliminating air from fuel system (bleeding) After any maintenance as described above, in case the engine has been standing ld!e for long or in case of leaks in the pipe system or when the runs to complete run out of tank.

The fuel system should be bleed of air as follows: loosen the bleed screws (3, fig. 35) on dual filters, operate the lever on the fuel pump {4, fig. 35) until the fuel free from air dubb!es issues from bleed screws.

Repeat in the same way for other bleed screws of injection pump; loosen bleed screws (5, fig. 35), operate on the lever of the pump (4, fig. 35) untH the fuel is completely free from air bubbles; tighten bleed screws.

i Raad camfu!ly the SAFETY RULES

8.06 BELTS

~heck diesel engine belts for correct tension t should be carried out every 1000 working hours. tis of the most importance to verify these belts are 1 good conditions as correct operation of the water ,ump and aJtemator depends on their proper

torking conditions. >ress by thumb pressure on back side of belts on K>int (1, fig. 36); correct tensioned belts should be , approx. 1Omm. ·he belts require no manual adjustment since they ire provided with an automatic device.

tMPORTANT NOTE >Jever check the tenison or adjust the bells if the engine is running. Pay particular attention to fans. Keep clear from belts or fan blandes on operaton.

Fig. 36

8.07 ELECTRIC PUMP FOR DIESEL FUEL TANK FILLING

'he machine is equipped with a self-priming electric ump that can be used to operate the filling of the iesel fuel tank: Loosen the plug (1, fig. 37} of the tank.

Remove the plug (2, fig. 37) and connect the movable suction unit (3, fig. 37), plunging the other duct end with filter into the diesel drum.

Insert the key (4, fig. 37) and keep contact through it.

Fig.37

Read camfully tlw SAFETY RULES

45

MAINTENANCE

8.08 AIR CLEANER ELEMENT Check, cleaning and renewal of air filter elements The air filter is equipped Gf clogging indicator (1, fig. 38) and warning light on dashboard; if it is •ow it shall be necessary to clean the fdter etemenl To extract these elements. unscrew the knob (2. fig. 38), then extract the air filter elements. 1t will be sufficient to blow out from the inside with compressed air to external of filter; then clean the proper bowl which is in the cover. lf necessary to refit the elements do the same operation but in the opposite sequence.

00718

Fig.38

8.09 BATTERIES The batteries are of the "maintenance tree• type, therefore topping up with distiUed water will not be necessary.

Exceptionally, it will be possible to restore the level, by removing the plugs and adding distilled water up to the level, avoiding to exceed the top mark.

IMPORTANT NOTE - The batteries contain ACID. - Protect the eyes when working on batteries, to avoid spray of acid. Should the acid get intough with your srin, eyes or clothes, RINSE IMMEDIATELY FOR AT LEAST FIFTEEN MINUTES. Consult a doctor.

- Be sure to connect the connection cables (+ with +) e (- with -) to both ends. Avoid shortcircuiting the terminals.

- INFLAMMABLE VAPOURS. Extinguish all smoking material before checking or recharge the batteries . Never check the batteries causing sparks.

IMPORTANT NOTE The electric system of the excavator is 24 V, if necessary for radio setting up, use only a reduction unit to24 from 12V.

Read carefully til9 SAFETY RULES

46

8.10 SWING REDUCTION GEARS heck the swing reduction gear oil level every 500 c,rldng hours. Therefore, drive the excavator in a var.surface and move the cap so as to be parallel the ground (1, ftg. 39); off level shaU be between etwomarks. ,p up through the hole, set up the dippers.tick 1ain; control the efficiency of bleed. :>mplete change of swing reduction gear shaU be ade every 2000 wor,king hours.

•rovide a rubber hose with a bore of 26+30 mm. tnd a lenght of approximately 500 mm.

Jnscrew the cap (2, fig. 39).

IV'lth the aid of the rubber hose drain theoU off in lOfm.

>0rew the cap (2, fig. 39) then fiU again through he hole (1,fig. 39). ::heck the oil level as detailed previously.

Fig.39

8.11 TRAVEL REDUCTION GEARS ie check of travel reduction gears oU level shaU , made after every 500 working hours. Drive the cavatorin a level surface and move the cap so as be parallel to the ground (1, fig. 40); unscrew the p. OH level shaU skim the inferior part of the ,ened hole; top up through the same oil. ~fit the cap. ie change of travel reduction gear oU shaU be 1de every 2000 working hours.

Fig.40

CHECK DAILY (10 WORKING HOURS) ALL SEALS (PIPINGS, CONNECTIONS ANO FITTINGS).

Read carefully the SAFETY RULES

47

MAINTENANCE

8.12 TRACKS MAINTENANCE

010/8.

Fig.41 ~

To adjust track tension, it is necessary to bleed out or pump grease into the adjuster cylinder. (fig. 41 ).

- To reduce track tension, unscrew the grease fitting {1, fig. 41) equipped with suitable drain holes and out grease as necessary. increase track tension, pump grease through the greaser bleeder valve (1, fig, 41) by using the grease gun with its spacial nipple. ~ A correct tension depends on job site different terrain conditions and as so should resutt somewhat loose on soft ground and tight when operating on quite rough underfooting.

- In general the tracks should be loose enough to provide a correct smooth forward travel of the machine. ~ !n case of operation on average ground condition, track sag should approximately 30 mm. in the track portion as shown on (fig. 41)

8.13 HYDRAULIC Oil FILTERS

Hydraulic filter level check shall be carried out every 125 hours. Drive the excavator on a level surface. than fully extend the cylinder rods up to the maximum of their stroke; stop the diesel engine.

Oil level should completely cover the inner indicator (3, fig, 42). Top as necessary with the addition of oil through the filler cap placed on filter cover (2, flg.

42).

ATTENTION: the oil level shall never be over the higher indicator (1, fig. 42).

The tank has been loosen the before carrying out any servicing (2, fig. 42).

Raad earelul!y the SAFETY RULES

48

"he mmpl•e hydrauffc fluid renewal shall be made every 2000 workmg hours. l\1arm 9 :hydraulic fluid to approx. 60"; drive the excavator on a level surface., fully retract the cylinder rod t$ltle llle~ers; then stop the diesel engine. ~ draiRp'lug (4. fig. 42) and drain oil in a bowl. aemove the t1imk cover loosening the retaining screws; clean the inner tank and dry it before refilfing. tefit t.e OGVer and drain plug; make the new filling through the pipe union placed on filters (2, fig. 42). ,tart engine and move a few times all the hydraulic cylinders. then check the level as detailed in previous . . .h. my lime the oil is changed also a new filter element shall be fitted.

U4 OltEOKWG, C-LEANING AND CHANGING RL'fERC,ARTfflOGES IN THE RESERVOIR

"he .,_.eartridges must be replaced in any case iterk IOOoperatinghours (running-in), thereafter ~ be ,renewed every 500 working hours. nova the reservoir cover (1, fig. 43) unscrewing w fastening screws (2, fig. 43). lA1eese lhe screws (3, fig. 43) which hold by 'leans of the clamps the bracicet. then rotate the lamps to r.elease the filter.

1ft the filter element assembly yet leaving the muser (7, fig. 43) into the reservoir. temove the fitter element by unscrewing the >eating nut (8, fig. 43) to release the spring cup (9, g. 43) and the spring {10, fig. 43); then withdraw 1e filter cartridge (11, fig. 43). :lean the magnetic dipstick (12, fig. 43) with the aid f a brush and air blows. he cartridges cannot be cleaned. Where the artridgesarefound tobe overcontamined, change tem at once.

Fig. 43

Read carefully the SAFETY RULES

49

MAJN!ENANCE

1.15 CHECK1NG, CLEANING CHANGING THE DEUVERY LINE 'FiLTER CARTRIDGES (OPTIONAL) filters are fitted with electrical clogging indicators (1, fig. 44) that energize a single wamkig light located on dashboard. time the warnirm light glows, U activates also an acustk:al alarm to monitor that needs servicing and the filter t>artridges must be cleaned (2, fig. 44).

Unloose the canister (3, fig. 44), withdraw the filter element. than remove al the impurities by washing the element with a suitable detergent.

Olp the metal fiber type cartridge for 30 minutes in a suitable detergent than btow it with compressed air.

Remove any possible water lett by dipping the cartridge iso-propylic alcool. , The cartridge treated in this way is than ready to be reinserted into tha screwable canister fig. 44).

Inspect the seal kit (4, fig. 44) for condition and replace should it be found damaged.

Grease after the seals have been housed. Screw tha canister (3, fig. 44) in the filter head (5, fig. 44} then tighten it by hand.

The cartridges may be re-used and do not need any renewal as long they wm not show any mechanical defect

44

8.16 GREASING

Greasing of al! pivot•polnts of the excavator shall be carried out daily (1 oworking hours). Items to be greased are tha following : mono.boom pivot.point, dipperstick pivot~point, bucket pivot point, levers pivot point , tie rod pivot point, all hydraulic cylinder piston rod eyes. Do not forget to grease, every 125 working hours, all excavator hinges and articulations of operator seat.

Greasing of slewing ring race shall be made daffy (10 working hours).

Greasing of race shall be made by means of proper grease nipples located on outer race of slewing race.

Greasing of slewing ling toothing shall be made by means of the grease contained in the proper tank that guarantees protection to slewing ling toothing and travel pinion.

Clean all greasing nipples, before greasing the excavator.

Read i::areru!!y th.I SAFETY RULES

50

9. GENERAL MAINTENANCE ATTENTIONS Every 10 working hou

2) Fuel injectors: checking of injectors setting

) Diesel engine: check oil level

3) Water radiator: cleaning and seal plug 4) Alternator coi'ltrol belts and fan: ·chooik \the

!) Booms and bucket linkages: grease all pivot•

points I) Slewing ring: grease external ring and lubricate inner races

I

Every 125 working hours:

Every 20010 "rorh,ing1 hours,:

} Hydraulic circuit: check oil level () Hood: grease all hinges

Every 250 working hours:

) :) i) )

I

1) Water radiator: change coolant 2) Hydraulic system: renew cartridges of two filter

groups placed on reversal hydraulic system; change fluid, clean the innertank 3) Altemator~ngine starter: brushes OOl9Gk 4) Swing and travel reduction gear: oil ,r'E!newiil1

I

Engine sump: oil renewal Diesei engine oil filters: renewal Cloth fuel filter:renew the cartridge element Screws fastening slewing ring: check tightening of bolts

Every 500 working hours:

) Travel reduction gears: check oil level ') Swing reduction gears: check oil level :) Hydraulic fluid filters: renew cartridge elements

Every 1000 working hours:

alternator control belts and fan conditions 5 Cooling engine circuit wash inner circuit 6) Air valve of oil taAk: renewal 7) Excavator: complete washing

j

EfiHODICAl ATTENTIONS 1) Air cleaner engine: clean filter elements and, if

necessary, change according to clogging indicator 2) Tracks: inspect the tension of chains does not exceed 3+4 cm between the support roller and idler roller 3) Idler roller and rollers: sealing check 4) Check tightening of bolts 5) Hydraulic oil delivery line filters: filter cartridges to be renewed according to clogging indicator information.

) Engine valves: verify on cold conditions the backlash of valves and rockers be regular.

Refer to Operation and Engine Maintenance

IMPORTANT NOTE DO NOT THROW DIRTY OIL AWAY IT WILL CAUSE POLUTION SOME FIRMS ARE SPECIALIZED IN RE-RERNING

Read carefully the SAFETY RULES

51

10. LUBRICATION SCHEDULE

~

[

I

Ia

~

i

I

I

l:!

J;;

(/)

Flg.45 $-••ll•,,,..l>tt9J

I0011111)

POS Number figure

1

I

!

2

fig.45

DIESEL Oil ENGINE

fig. 45

REDUCTION GEARBOX OIL

~

Jjj

~

Lubrie.

Type of points lubrleatlon

1

3

Filling

Filling

State of Type of lubricant Speelfleatlons excavator FIAT

Motionless AMBAASUPEA

Motionless

TUTELA W 140/M-DA IORAUUCAA AP51

3

fig. 45

HYDRAULIC FLUID

1

Filling

Motlonless

4

fig. 45

TRACK ROLLERS OIL AND TRACK ADJUSTER

2

FIiling

Motionless AMBRASUPER

5

fig.45

GREASE FOR ARTICULATIONS

14

Greasing Motionless

6

fig. 45

GREASE FOR SLEWING RING

3

7

fig.45

GREASE HYDRAULIC CYLINDER TRACK ADJUSTER

2

Controls

Mll•L·2104 D SAE30APICO MIL-L-2104E SAE15W API CE

Daily

Mll·l-2105 D SAE85W140

I

APIGl..5 oxept ASTM O 943 ISO

I

~ ~

Item

VOS& E!lODEGRAt.WII.E 00% CEC•L·:.l3-T·&2

fOOOPERATlON

HOURS

MlL·L-2104 D SAE30APICD

I

TUTELAMR2

NGU2

Dally

Greasing Motionless

TUTELAMR2

NGLl2

Daily

Greasing Motionless

TUTELAMR2

NGL.12

I

Replacement 250 OPERATION HOURS 2000 OPERATION

HOURS 2000 OPERATION HOURS

I

I I

I

ELECTRIC SYSTEM

11. ELECTRIC SYSTEM 1) Fuse OOX 2) Ignition and starter switches 3) lighting switch 4) Oyode

5) Alternator 6) Starter motor 7) Starter relay 8) Engine stop 9) Engine cutoff relay 10) Battery 11) Battery disconnection 12) Eiectric lighter 13) Clogging indicator 14) Fuer level 15) Wamlng light 16) Engine oil manometer 18) Right-handed front headlight 19) Boom headlight 20) Windscreen wiper switch 21) cab heating switch 22) Boom headlight switch 23) Beacon switch 24) Engine coolant temperature 25) Warning fight of generator 26) Clogging warning light 27) Hydraulic oil indicator 28) Fuel level indicator 30) Warning lght of traffic beam 31) Warning light of headlights 32) Warning fight of cab heating 33) Warning light of boom headlight

34) Hourmeter 35) Air horns 36) Air conditioner 37) Eiectric clutch 38) Cab heating motor 39) Radio set 41) Hammer push button 42) Hammer solenoid valve 43) Electric fan assembly 44) Fuel pump switch 45) Engine disoonnectin feeler 47) Fuel motor pump 48) Hydraulic oii temperature feeler 49) Engine coolant temperature feeler 50) Windscreen wiper motor 51) Socket fOf headlight 52) Hammer pedal 53) Electric horn re:lay 54) Reduction unit 56) Automatic idling speed warning light 57) Filters clogging indicator 58) Electric horns pedal 59) Automatic idling speed magnet 60) Automatic idling speed control 61) Automatic idling speed pressure switch 62) Automatic idling speed switching oox 63) Safety micro-lever 64) Electrovalve, cut out 65) Left•handed headlight 66) Fuel level manometer 67) Floating

Raad carefully too SAFETY RULES

14

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Fig. 46

ELECTRIC SY-STEM

55

HYDRAULIC SYSTEM - - - - - - - - - - - - -

12. HYDRAULIC SYSTEM 1) 2) 3) 4) 5} 6) 7) 8) 9} 10) 1

12) 13)

14) 15)

16) 17) 18) i 9)

Main pump Pump for servo controls Delivery oil filter optional Return ol! filter Pressure cap By-pass valve Cooler Accumulator for servo controls Cutoff cock Directional control valve Swing valve Swing hydraulic motor Travel hydraulic motor Joystick actuactor Pedal control Cylinders Main relief valve Throttle valve Bistable block

Read car1,fully the SAFETY RULES

56

~

SOLLrVAMENlO

JR, SCAVO

TUSUZIDNE ll

16

15

18

16

16

ROTA ZION[

16

-----------7

- --7

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TRASLAZlDNE

57

RULES--------------13 STANDARD TORQUE SPECIFICATIONS 13.01 STANDARD BOLTS TORQUE SPECIFICATIONS

The standard tightening torques for bolts and nuts are listed below.

The tightening torque values shown apply to bolts previously dipped in engine oil~bath.

This torque data does not apply to the bolts with which nylon packings or other non-ferrous metal washers are to be used, or which require tightening to otherwise specified torque.

Unless otherwise specified in the assembly instructions, bolts should be tightened without using Loctite.

The strength rating of each screw, is indicated on each screw head (fig. 48)

GGGG e Fig.48

REFERENCES TO TABLE ONE = diameter {mm} p = pitch (mm) s, = section of strength (mm 2) pk = coefficient of friction R. = Yield strenght (N/mm2) P = preloading (N) M = tightening moment (mN) 8. 8 = strength rating d

Read carefully th& SAFETY RULES

58

PRE.LOADS P ANO TIGHTENING TORQUES M FOR ISO METRIC THREAD BOLTS

=

kxd x P

1000

• has been obtained assuming that the friction factor between sliding surfaces is equal to 0, 14.

dxp

s,

k:

0,7 R, p

= 224 0,7 R, = 280 0,7 R, = 448 0,7 R,

= 530 0,7 R,

"' 756

M

p

M

p

M

p

M

p

M

N

mN

N

mN

N

mN

N

mN

N

mN

mm

mm2

3x0,5

5,3

0,189

1130

0,67

1400

0,84

2550

1,5

3170

1,9

3800

2,3

4x 0,7

8,78

0, 195

1970

1,5

2500

1,9

3930

3,1

5530

4,3

6640

5,2

5x0,8

14,2

o. 189

3180

3

4000

3,8

6360

6

8950

8,5

10700

10, 1

6x1

20,1

0,192

4500

5,2

5600

6,5

9000

10,4

12700

14,6

15200

17,5

8 x 1,25

36,6

0,188

8200

12,3

10250

15,4

16400

24,6

23100

34,7

27700

41.6

8x1

39,2

0,185

8780

13

11000

16,3

17600

26

24700

36,6

29600

43,9

10 X 1,5

58

0,193

13000

25,1

16200

31,3

26000

50,1

38500

70,5

43900

84,6

10x 1,25

61,2

0,191

13700

26,2

17100

32,7

27400

52,4

38500

73,6

46300

89,4

12 X 1,75

84,3

0,187

18900

42.4

23600

53

37800

84,S

53000

119

63700

143

12 X 1,25

92.1

0,183

20000

45,3

25800

56.6

41300

90,6

58000

127

69600

153

14x 2

115

0,187

25800 • 67.4

32200

84,3

51500

135

72500

190

85900

228

14 x 1,5

125

0,153

26000

71,7

35000

89,6

50000

143

78800

202

94500

242

16x2

157

0,182

35200

102

44000

128

70300

205

98900

288

119000

346

16 x 1,5

167

0,179

37400

107

40000

134

74800

214

105000

302

126000

362

18x 2,5

192

0,183

43000

142

53800

177

86000

263

121000

388

145000

478

18 X 1,5

216

0,177

48400

154

60500

193

96800

308

136000

434

163000

520

20x 2.5

245

0,182

54900

200

68800

250

110000

400

154000

562

185000

674

20x 1.5

272

0,177

60900

216

76200

270

122000

431

171000

607

206000

728

22 X 2,5

303

0,178

67900

266

84800

332

136000

532

191000

746

229000

897

22x1,5

333

0,174

74600

266

93200

357

149000

571

210000

803

252000

984

24x3

353

0,182

79100

245

98800

432

158000

691

222000

971

267000

1170

24x2

384

0,177

86000

265

108000

457

172000

731

242000

1030

290000

1230

27x3

459

0,182

103000

505

129000

631

206000

1010

289000

1420

347000

1700

27x2

496

0,178

111000

534

139000

667

222000

1070

212000

1500

375000

1800

30x 3,5

561

0,182

126000

666

157000

857

251000

1370

353000

1930

424000

2310

30x2

621

0,177

139000 • 738

174000

923

227800011480

391000

2080

479000

2490

Read carefully the SAFETY RULES

59

RULES--------------14. BSP (GAS) OR METRIC SCREW..THREAD WITH CHECK-WASHER ADAPTORS ASSEMBLY

Fig.49 Lubricate the 0-rlng sprinkling on it a light oil layer, completely screw nut to free relief of the thread and visually check if the tab washer can reach the position shown in figure.

Fig.SO

Fit the union on its proper without forcing it, till the tab washer or the check washer - according to the kind of assembly - are connected to the working surface.

Fig. 51

Correct the positioning by turning the connection anticlockwise, not overcoming one turn, in order to reach the desired direction. then lock with the nut maintaining the position with a spanner.

Fig.52

Read carafu!Jy the SAFETY RULES

14.01 ADAPTORS OIMENSfONS wmt SEAL ON CYLINDRIC METRIC SCREW-THREAD

D

I

Fig.53

Measurements in mm.

I !

imensions F

10x1 12x1,S 14x1,S 16x1,S 18x1.S 20x1,S 22x1,5 26x1,S 27x2

max. 0/0

10

8,9

min. J/0

1g

A

1

B

8

B,

33x2

42x2

48x2

12

14

16

18

20

22

26

27

33

42

48

10,3

12.3

14,3

16.3

18,3

20,3

24.3

24,8

30,8

39,8

45,8

1,5

1,5

1,5

2

2

2,5

2,5

2.5

2,5

2,5

2,5

12

12

12

12

14

14

16

16

18

20

22

13,5

18,5

18,5

18,5

18,5

20,5

20.5

22,5

24

26

28

30

o.,

10

12

14

16

18

20

22

26

27

33

42

48

0

15,5

18,5

19,5

23

26

28

30

35

36

43

53

60

o.

16,5

20

21,5

24,5

27,5

30

31,5

36,5

37,5

45

55

62,5

01

! 7,66 9,13

s

!

1,78

2,62

15,08 17,13 18,72 23,47 23,4

10,78 13,t0 2.62 I' 2,62

I !

2,62

2,62

2,62

2,62

3,53

29,75 37,69 44,04 3,53

3,53

3,53

Read carefully the SAFETY RULES

63

--------------TROUBLES-------------11. TROUBLES, PROBABLE CAUSES AND CURES This chapter has been arranged to assist the qualified maintenance personnel and make easy research of the most common troubles. Thls list includes the routine maintenance of 1he most common troubles.

TROUBLES

Failure to start of diesel engine

PROBABLE CAUSES

CURES

Switch batteries is disconnected. Close 1he ignition switch.

Batteries are down.

Recharge.

Terminals are loosen.

Clean; grease with petroleum and tighten the terminals.

Starter does not run or too slowly

Inspect 1he control starter and control the starter.

Oil too thick in cold temperature.

Oil renewal.

There Is no fuel.

Fill~ deareate.

Filter of precleaner oil is clogged.

Clean the preclaner, deareate.

The fuel filter is dirty and in cold temperature ft clogs due to paraffin deposit

Change the filter, make use of correct fuel in winter period.

Leakages from fuel piping.

Smoky engine

The engine runs but with no eficiency

Cold engine.

Warm up the engine for 5-1 o minutes 011 half accelerator.

Faulty injectors.

Control and set the injectors.

Insufficient compression due to stuck or broken rings or irregular backlash of vatves.

and inspect the rings.

Insufficient feed.

Renewal of fuel filters.

Dirty filter elements.

Clean the filter element of precleaner.

Look for possible loosen connections.

Control the fuel quality.

Raad carofu!ly !ha SAFETY RULES

64

Check the back lash of valves

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~ ~

l"

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l

TROUBLES

CURES

PROBABLE CAUSES

Too tight backlash of valves.

Inspect the backlash valve.

Srol<en valve spring.

Change the valve spring.

Clean and set injectors.

Clean the suction air filter.

Engine pings

Engine stops

Insufficient oil pressure STOP IMMEDIATELY

Faulty injectors.

Overhaul the injectors.

Advanced injection.

Check the injection phase of pump.

There is no fueL

Fill and deareate.

Air in pipes.

Eliminate the air infiltration

Dirty fuel filter.

Clean the precleaner and change filter elements.

No alr due to clogged air filter.

Clean the air filter.

There is no oil in crankcase sump.

Check and top up to level.

Oil leak from connectors.

Inspect for causes in connections and oil pipes.

No correct oil quantity.

Renewal of oil and filters by use of proper oil.

Breakdown Manometer

Renewal.

Breakdown oil pump.

Renewal.

Valve on breakdown pump.

Renewal.

Overworked engine due to bush-I Refer to authorized Repair Shop. ings. i Refer to authorized Repair Shop.

Fused bushing

Excess of oil pressure

I

Not suitable oil with external temf Renewal of oil and filters. perature.

Raad carefully the SAFETY RULES

65

- - - - - - - - - - - - - - TROUBLES--------------

I TROUBLES

Excess of heating engine STOP !MMED!ATEY

Ignition of warning light_ generator

Excess of oil engine consume

Excess of hydraulic fluid over heating

Too noisy hydraulic pump.

PROBABLE CAUSES

Clogged radiator.

Clean radiator.

Faulty injectors.

Control and set injectors.

Too delivery of injection pump

Register the pump.

Faulty fart

Refer to Repair Shop.

The generator does not charge due to faulty belts.

Belt inspection.

Faulty generator.

Checking by a filling station.

Maximum oil lever.

Level restoration.

Super overheating.

Radiator cleaning.

Ambient temperature over 45°.

Attenuate the work conditions.

Not correct oil level.

Adel or remove oil to right level.

Valve c!ear.

Setva!ves.

Foam y oiL

Check the oil level. The infiltrations to be eliminated in aspiration pump.

Use of excavator not in conformity.

Use the excavator in a proper way.(Oo not insist on movements to end stroke).

Two low oil level.

Check the oil level and ellmi nate the system leaks.

Air inside the circuit connections.

Eliminate air infiltrations in

Too thick oil.

ChangeoiL

Faulty pump.

Change pump seals.

Read carefully !he SAFETY RULES

66

CURES

TROUBLES

PROBABLE CAUSES

Reduction of power

Arms not in regular position but lower slowly

Too slow arms to lift

CURES

The pump is broken or damaged.

Change the damaged parts or the pump.

Faulty distributor.

Eliminate the trouble to distributor.

Misadjustment of one or more vat. ves.

Set the valve again.

Faulty hydraulic cylinders.

Eliminate the trouble in hydraulic cylinder.

Excess of ~ow-by between piston and hydraulic cylinder.

Renewal of inner seals of hydraulic cylinder.

Distributor with inner ~ow-by.

Control the part of distributor.

Too low valve setting or foreign matters inside valve.

Clean and set valves again.

Overworked pump.

Inspect the pump.

Inner seepages in cfistributor system. Check the part of distributor.

No response of servocontrols.

Valve clear.

Set valve.

Noisy braking rotation.

Hydraulic engine cavitation.

Set by-pass valve.

Irregular braking rotation.

Rotation clear valve.

Set valve

Locking or excess of backless of arm piston pins.

No or irregular greasing.

Regular greasing.

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I Read carefully the SAFETY RULES

67

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