New Holland E16 E18 Operation & Maintenance Instruction Manual 6042141201 - PDF DOWNLOAD

Operation and Maintenance Instruction Manual

E16 E18 Operation and Maintenance Instruction Manual

E16 - E18

Print No. 604.21.412.01 English - Printed in France

PROVEN PERFORMANCE

PROVEN PERFORMANCE

E16 - E18 OPERATION AND MAINTENANCE INSTRUCTION MANUAL ENGLISH Print No. 604.21.412.01

Edition 07/2006 English - Printed in Italy Printed by Studio ti - 17706

S WARNING READ THIS MANUAL CAREFULLY BEFORE STARTING, OPERATING, SERVICING, REFUELLING OR CARRYING OUT ANY OTHER WORK ON THE MACHINE.

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

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

S WARNING 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 an ACCIDENT may occur. They are white with red borders and black lettering when they refer to a FORBIDDEN practice.

IMPORTANT: Data contained in this manual was current at the time of publication. It is the Manufacturer’s policy to constantly improve its products and such changes may affect information herein. If variances are observed, contact your Dealer and After-Sales Service.

S WARNING Read this manual before operating the machine Most accidents occurring during work are due to non-observance of simple safety norms and elementary precautions.

Many accidents can be avoided if the causes are known and opportune cautions taken beforehand.

There is no device or protection, no matter how advanced, that may prove so effective at avoiding accidents as a careful and attentive behaviour.

S WARNING Ensure that the attachment is safely resting onto the ground before repairing, adjusting or servicing machines fitted with hydraulically, mechanically or cable controlled attachments (such as, excavators, loaders, dozers, scrapers, etc.). Should it be necessary to partially or fully raise the hydraulically, mechanically or cable controlled attachment to gain access to certain items, make sure the attachment is adequately retained in the raised position by means other than the hydraulic lift cylinders, cables and/or mechanical devices used for controlling it.

EXCAVATOR MODEL

E16 E18

MACHINE SERIAL NO. ENGINE TYPE

YANMAR 3TNE74 - ENYBC

ENGINE SERIAL NO. NOTES

COPYRIGHT BY NEW HOLLAND KOBELCO CONSTRUCTION MACHINERY S.p.A. Strada di Settimo, 323 - S. MAURO T.SE (TO) ITALY

Z

TABLE OF CONTENTS SUBJECT

PAGE

SAFETY PRECAUTIONS SAFETY PRECAUTIONS .......................................................................................................................... S-3 SAFETY DECALS....................................................................................................................................S-35 1. FEATURES 1.1

FOREWORD ................................................................................................................................... 1-3

1.2

IDENTIFICATION DATA.................................................................................................................. 1-4

1.3

NOISE LEVELS (2000/14/EC)......................................................................................................... 1-5

1.4

OPERATOR PROTECTIVE STRUCTURE ..................................................................................... 1-6

1.5

SUMMARY PLATE FOR MAINTENANCE OPERATIONS.............................................................. 1-7

1.6

BASIC COMPONENTS OF THE MINI EXCAVATOR ..................................................................... 1-8

1.7

BASIC COMPONENTS OF THE MINI EXCAVATOR ..................................................................... 1-9

1.7.1

TECHNICAL SPECIFICATIONS ........................................................................................... 1-10

1.7.2

DIGGING PERFORMANCES (CANOPY) ............................................................................. 1-11

1.7.3

DIGGING PERFORMANCES (CAB)..................................................................................... 1-12

1.7.4

TRANSPORT DIMENSIONS (CANOPY) .............................................................................. 1-13

1.7.5

TRANSPORT DIMENSIONS (CAB)...................................................................................... 1-14

1.7.6

BUCKETS APPLICATION..................................................................................................... 1-15

2. OPERATING INSTRUCTIONS 2.1

SAFETY PRECAUTIONS FOR USING THE MACHINE ................................................................. 2-3

2.2

CONTROLS AND INSTRUMENTS ................................................................................................. 2-4

2.2.1

LEFT SAFETY LEVER ............................................................................................................ 2-5

2.2.2

KEY-START SWITCH ............................................................................................................. 2-5

2.2.3

TRAVEL CONTROL LEVERS................................................................................................. 2-6

2.2.4

TRAVEL SPEED SELECT SWITCH ....................................................................................... 2-7

2.2.5

RIGHT-HAND CONTROL LEVER........................................................................................... 2-8

2.2.6

LEFT-HAND CONTROL LEVER ............................................................................................. 2-8

2.2.7

BOOM SWINGING PEDAL ..................................................................................................... 2-9

2.2.8

TOOL PEDAL .......................................................................................................................... 2-9

2.2.9

HORN CONTROL ................................................................................................................. 2-10

2.2.10

BLADE CONTROL ................................................................................................................ 2-10

2.2.11

ACCELERATOR CONTROL ................................................................................................. 2-10

2.2.12

CRAWLER FRAME WIDTH ADJUSTMENT (ADJUSTABLE CRAWLER FRAME WIDTH VERSION) ................................................................................................................ 2-11

2.2.13

LEFT PANEL ......................................................................................................................... 2-13

2.2.14

RIGHT PANEL....................................................................................................................... 2-14

2.2.15

OPERATOR’S COMPARTMENT .......................................................................................... 2-17

2.3

CAB ............................................................................................................................................... 2-19

2.3.1

VENTILATION AND HEATING SYSTEM.............................................................................. 2-19

2.3.2

VENTILATION/HEATING CONTROLS ................................................................................. 2-19

2.3.3

STORAGE AND OTHERS .................................................................................................... 2-19

2.3.4

DOOR.................................................................................................................................... 2-20

2.3.5

FRONT WINDSCREENS AND WINDOWS .......................................................................... 2-21

1

TABLE OF CONTENTS 2.3.6

INNER CEILING LIGHT......................................................................................................... 2-22

2.3.7

EMERGENCY EXIT............................................................................................................... 2-22

2.3.8

WINDSCREEN WIPER ......................................................................................................... 2-23

2.3.9

WINDSCREEN WASHER ..................................................................................................... 2-23

2.4

USING THE MACHINE.................................................................................................................. 2-24

2.4.1

REFUELLING ........................................................................................................................ 2-25

2.4.2

CHECKS BEFORE ENGINE START-UP .............................................................................. 2-26

2.4.3

MACHINE WARM-UP............................................................................................................ 2-27

2.4.4

KEY-START SWITCH ........................................................................................................... 2-27

2.4.5

STARTING THE ENGINE...................................................................................................... 2-28

2.4.6

CHECKS AFTER ENGINE START-UP ................................................................................. 2-29

2.4.7

STARTING THE ENGINE AFTER PROLONGED STORAGE .............................................. 2-29

2.4.8

COLD WEATHER WARM-UP ............................................................................................... 2-30

2.4.9

STARTING THE ENGINE USING BOOSTER BATTERIES.................................................. 2-31

2.4.10

STOPPING THE ENGINE ..................................................................................................... 2-32

2.5

OPERATION NORMS ................................................................................................................... 2-33

2.5.1

EMERGENCY BOOM LOWERING PROCEDURE ............................................................... 2-33

2.5.2

EXCAVATOR REMOVAL ...................................................................................................... 2-35

2.5.3

SAFETY LEVER .................................................................................................................... 2-37

2.5.4

CONTROL LEVERS .............................................................................................................. 2-38

2.5.5

ENGINE SPEED HAND CONTROL ...................................................................................... 2-39

2.5.6

TRAVEL SPEED SWITCH .................................................................................................... 2-39

2.6

OPERATING THE MACHINE ........................................................................................................ 2-42

2.6.1

MAJOR OPERATING NORMS.............................................................................................. 2-43

2.6.2

PRECAUTIONS DURING OPERATION ............................................................................... 2-48

2.6.3

PARKING THE MACHINE..................................................................................................... 2-49

2.6.4

PRECAUTIONS FOR TRAVELING ON SLOPES ................................................................. 2-50

2.7

HANDLING OF OVERHEAD LOADS ............................................................................................ 2-52

2.7.1

READING KEY FOR THE LIFTABLE LOAD CHART LOCATED IN THE CAB .................... 2-52

2.7.2

LIFTABLE LOADS TABLE AT THE BUCKET CONNECTION PIN ....................................... 2-53

2.8

BUCKET INSTALLATION.............................................................................................................. 2-54

2.8.1

BUCKET TEETH ................................................................................................................... 2-55

2.8.2

LOWER ROLLER EXCHANGE ............................................................................................. 2-57

2.9

ROAD TRANSPORT ..................................................................................................................... 2-58

2.9.1

NORMS FOR TRANSPORT.................................................................................................. 2-58

2.9.2

NORMS FOR LOADING/UNLOADING THE MACHINE ON A TRAILER ............................. 2-58

2.9.3

LOADING THE MACHINE ON A TRAILER........................................................................... 2-59

2.9.4

UNLOADING THE MACHINE FROM A TRAILER ................................................................ 2-60

2.10 SEA TRANSPORT......................................................................................................................... 2-61 2.10.1

CRANING THE MACHINE FOR SEA TRANSPORT ............................................................ 2-61

2.11 PRECAUTIONS IN COLD WEATHER .......................................................................................... 2-62 2.12 PROLONGED MACHINE INACTIVITY.......................................................................................... 2-63 2.13 USING THE MACHINE AFTER PROLONGED STORAGE .......................................................... 2-64 2.14 DECOMMISSIONING OF THE MACHINE .................................................................................... 2-64

2

TABLE OF CONTENTS 3. OPTIONS AND VARIANTS 3.1

HYDRAULIC BREAKER.................................................................................................................. 3-3

3.1.1

HYDRAULIC BREAKER SELECTION AND INSTALLATION ................................................. 3-3

3.1.2

PRECAUTIONS WHEN USING THE HYDRAULIC BREAKER .............................................. 3-3

3.1.3

HYDRAULIC BREAKER CONTROL ....................................................................................... 3-7

3.2

NIBBLER ......................................................................................................................................... 3-8

3.2.1

NIBBLER SELECTION AND INSTALLATION......................................................................... 3-8

3.2.2

PRECAUTIONS TO BE OBSERVED WHEN USING THE NIBBLER..................................... 3-8

3.2.3

NIBBLER CONTROL............................................................................................................. 3-10

3.2.4

HYDRAULIC OIL AND FILTER ELEMENT SERVICE INTERVAL........................................ 3-11

4. MAINTENANCE 4.1

SAFETY PRECAUTIONS DURING MAINTENANCE ..................................................................... 4-3

4.2

GENERALITIES............................................................................................................................... 4-4

4.2.1

CHECKING THE HOUR-COUNTER REGULARLY ................................................................ 4-5

4.2.2

SERVICE REMINDER PLATE ................................................................................................ 4-5

4.2.3

PREPARING THE MACHINE FOR MAINTENANCE.............................................................. 4-6

4.2.4

HOOD AND ACCESS COVERS ............................................................................................. 4-7

4.3

EXTERNAL VISUAL INSPECTION ................................................................................................. 4-8

4.4

CHECKS BEFORE STARTING DAILY WORK ............................................................................... 4-9

4.4.1

ENGINE OIL ............................................................................................................................ 4-9

4.4.2

ENGINE COOLING SYSTEM ............................................................................................... 4-11

4.4.3

HYDRAULIC SYSTEM OIL ................................................................................................... 4-12

4.4.4

FUEL TANK........................................................................................................................... 4-13

4.4.5

WINDSCREEN WASHER TANK........................................................................................... 4-14

4.4.6

FUEL PRE-FILTER ............................................................................................................... 4-14

4.5

MACHINE LUBRICATION AND MAINTENANCE GENERAL CHART.......................................... 4-15

4.6

AFTER 50 HOURS OF OPERATION............................................................................................ 4-16

4.6.1

BUCKET LINKS..................................................................................................................... 4-16

4.6.2

SLEWING RING BEARING................................................................................................... 4-17

4.6.3

BOOM AND ARMS................................................................................................................ 4-18

4.6.4

ARM SWINGING CYLINDER................................................................................................ 4-19

4.7

AFTER 250 HOURS OF OPERATION TRACKS .......................................................................... 4-20

4.7.1

TRACKS ................................................................................................................................ 4-20

4.7.2

HYDRAULIC OIL TANK ........................................................................................................ 4-25

4.7.3

TRAVEL REDUCTION GEAR OIL ........................................................................................ 4-26

4.7.4

AIR CLEANER....................................................................................................................... 4-27

4.7.5

HARDWARE TIGHTENING TORQUES................................................................................ 4-28

4.7.6

HOSES, LINES AND CONNECTIONS ................................................................................. 4-34

4.7.7

FUEL HOSES........................................................................................................................ 4-37

4.7.8

TRAVEL MOTOR PINION, SLEWING RING TEETH ........................................................... 4-38

4.7.9

ENGINE OIL AND FILTER .................................................................................................... 4-39

4.8

AFTER 500 HOURS OF OPERATION.......................................................................................... 4-41

4.8.1

FUEL FILTER ........................................................................................................................ 4-41

4.8.2

ENGINE COOLING SYSTEM ............................................................................................... 4-43

3

TABLE OF CONTENTS 4.8.3 4.9

HYDRAULIC SYSTEM RETURN OIL FILTER ...................................................................... 4-44

AFTER 1000 HOURS OF OPERATION ........................................................................................ 4-46

4.9.1

AIR CLEANER....................................................................................................................... 4-46

4.9.2

FUEL PRE-FILTER................................................................................................................ 4-48

4.9.3

ALTERNATOR - FAN BELT .................................................................................................. 4-50

4.9.4

ENGINE COOLING SYSTEM................................................................................................ 4-52

4.10 AFTER 2000 HOURS OF OPERATION ........................................................................................ 4-55 4.10.1

TRAVEL REDUCTION GEARS OIL ...................................................................................... 4-55

4.10.2

HYDRAULIC SYSTEM OIL ................................................................................................... 4-57

4.10.3

BIODEGRADABLE HYDRAULIC OIL ................................................................................... 4-59

4.11 FILLING CHART ............................................................................................................................ 4-62 5. TROUBLESHOOTING 5.1

OPERATING.................................................................................................................................... 5-3

5.2

TRAVEL ........................................................................................................................................... 5-4

5.3

HYDRAULIC .................................................................................................................................... 5-5

5.4

GAUGE CLUSTER DISPLAY .......................................................................................................... 5-6

5.5

ENGINE ........................................................................................................................................... 5-7

6. ELECTRICAL SYSTEM 6.1

GENERALITIES............................................................................................................................... 6-3

6.1.1

BATTERIES............................................................................................................................. 6-4

6.1.2

FUSES..................................................................................................................................... 6-6

4

S. SAFETY PRECAUTIONS

S. SAFETY PRECAUTIONS

SAFETY PRECAUTIONS GENERALITIES 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 WARNING 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 operator’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.

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 upper structure 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.

STARTING Never start or operate a failed machine. Walk all around the machine before mounting.

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 operator’s seat for maximum riding comfort and control accessibility.

S-3

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

OPERATING 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 operator’s compartment free of foreign objects, especially if not firmly 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 the 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.

S-4

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

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.

Always inspect the working area to identify potential risks such as: 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 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 (possibly falling on the machine) and large roots (which may act as a leverage under the machine when up-rooted and cause the unit to overturn).

Position the machine dependent upon the loading and unloading areas in order to swing leftwards to load to obtain best visibility.

Never use the bucket or attachment as a man lift or carry riders.

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.

Ensure the truck driver is in a safe place before loading the truck.

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.

S-5

S. SAFETY PRECAUTIONS When travelling with a loaded bucket, keep it as rolled-back as possible. Keep boom and arm as low 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 or working, nor downhill when working on a slope as this would decrease machine stability.

Load the bucket from the 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.

Follow also 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.

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 to the uphill side.

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 upper structure 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 ditch edge.

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 swing 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 gas mains from a standpoint more favourable than the Operator’s.

• This signal man (flag-man) must be in direct communication with the Operator and the Operator must pay undivided attention to the 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 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.

S-6

S. SAFETY 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 of signalling duties.

This person will have the responsibility of observing the machine, any part of it and/or the load approaching the electric lines from a standpoint more favourable than the Operator’s.

This signal man (flag-man) must be in direct communication with the Operator and the Operator must pay undivided attention to the 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: • Digging near previous trenches filled with material.

• Digging in bad ground conditions.

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

STOPPING 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.

Prior to leaving the operator’s seat, and after making sure that all people are clear of the machine, slowly lower the attachment until resting it safely to the ground.

Retract possible auxiliary tools to the closed safety position.

Check that all controls are in the neutral position. Move engine controls to the shut-down position. Switch off the key-start 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 appropriate flags, barriers, flares and other signals as required 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.

S-7

S. SAFETY PRECAUTIONS Sound the 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 upper structure to the tracks in order to allow to easily get on and off the operator’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 locking the machine to prevent unexpected movement.

Follow stopping instructions contained in the Operation and Maintenance Instruction Manual.

MAINTENANCE GENERALITIES 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 repair or service the machine.

Follow all recommended maintenance and service 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 operator’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.

Clean mud or grease from your shoes before climbing on the machine or driving it.

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

Keep the operator’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.

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.

S-8

S. SAFETY PRECAUTIONS 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 upper structure.

Never align holes or slots using your fingers; always use appropriate aligning tools.

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

Use only approved and effectively 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.

Use lifting eyes provided to this aim.

Pay attention to bystanders near the lifting area.

Never pour gasoline or diesel fuel into open containers.

Never use gasoline, solvents or other flammable fluids to clean parts.

Use proprietary certified non-flammable, non-toxic solvents only.

When using compressed air to clean parts, wear safety glasses with side shields. Limit pressure to maximum 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 operator’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 safety 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.

S-9

S. SAFETY PRECAUTIONS 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 as 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 range before starting or operating the machine and/or its attachments. Sound the 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 locking 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 carefully. 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.

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

Pay particular attention during transfer on inclines, both uphill and downhill.

S-10

S. SAFETY PRECAUTIONS 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 upper structure 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 upper structure 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.

ENGINE 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.

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.

ELECTRICAL SYSTEM Pay attention to connect connecting cables to correct poles (+ to +) and (- to -) at both ends. Do not short-circuit 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 SULPHURIC 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. Immediately seek medical attention.

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

S-11

S. SAFETY PRECAUTIONS 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.

HYDRAULIC SYSTEM 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 or 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.

TOOLS 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 operator’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.

Never use gases other than nitrogen to charge the accumulators.

Refer to the Operation and Maintenance Instruction Manual.

S-12

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, referring to different hazard risks.

These words are always accompanied by the safety alert symbol.

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

DANGER

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

WARNING

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

CAUTION

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

IMPORTANT

NOTE: indicates an additional explanation for information purposes.

NOTE

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

F5041

S-13

S. 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.

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.

S-14

S. SAFETY PRECAUTIONS WEAR PROTECTIVE CLOTHING Avoid wearing loose clothing, jewelry, or other items that can catch on control levers or other parts of the machine. Operating equipment safely requires the full attention of one operator. Do not wear radio or music headphones while operating machine.

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

Standard safety equipment includes: • A hard hat • Safety shoes • Safety glasses, goggles, or face shield • Heavy gloves • Hearing protection • Reflective clothing • Wet weather clothing • Respirator or filter mask.

• Do not take chances. Wear whatever is needed for the job at hand.

PROTECT AGAINST NOISE Prolonged exposure to loud noise can cause impairment or loss of hearing.

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

FASTEN SEAT BELT Should the machine overturn, the operator may become injured and/or thrown from the cab. Not only, the operator may be crushed by the overturning machine resulting in serious injury or even death.

Prior to operating the machine, thoroughly examine belt webbing, buckle, and attaching hardware. If any item is damaged or worn, replace the seat belt or component before operating the machine.

Be sure to remain seated with the seat belt securely fastened at all times when the machine is in operation to minimise injury hazard in case of accident.

After a significant accident, replace the seat belts even though they do not look damaged.

S-15

F3261

S. SAFETY PRECAUTIONS 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”.

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 OPERATOR'S 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 OPERATOR’S SEAT To start the engine 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 operator’s seat.

• NEVER start the engine while standing on a shoe or on the ground.

• Do not start the engine by short circuiting between starter motor terminals.

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

S-16

F13043

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.

Keep riders off.

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

F22015

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

• When operating near an electric line, NEVER move any part of the machine or load closer than 3 m plus twice the line insulator length (L).

• Check and comply with any local regulations that may apply.

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

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

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

To avoid back-over and swing accidents: ALWAYS LOOK AROUND BEFORE YOU BACK UP AND SWING THE MACHINE. BE SURE THAT EVERYONE IS IN THE CLEAR. F1447

Keep travel alarm in working condition (if equipped).

ALWAYS BE ALERT FOR BYSTANDERS MOVING INTO THE WORK AREA. USE HORN OR OTHER SIGNAL TO WARN BYSTANDERS BEFORE MOVING MACHINE. A PERSON COULD STAND BEHIND THE MACHINE, IN A DEAD AREA, NOT VISIBLE FROM REARVIEW MIRRORS. BEFORE BACKING UP, MAKE SURE NOBODY IS STANDING IN THAT AREA.

S-17

S. SAFETY PRECAUTIONS Use a signal person when backing up if your view is obstructed. Always keep signal person in view.

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

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

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

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

F3625

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

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, and water lines. If a fiber optic cable should be accidentally severed, do not look into the end. Doing so may result in serious eye injury.

Contact local authorities and/or the utility companies directly (electric power, gas, telephone, water, sewers, telecommunications, etc.) to obtain information about underground utility lines.

MOVE AND OPERATE MACHINE SAFELY Bystanders are in danger of being run over.

Confirm the location of bystanders before moving, swinging, 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, swinging, or operating the machine in congested areas. Coordinate hand signals before starting the machine.

F22025

S-18

S. SAFETY PRECAUTIONS 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 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 FOPS (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.

WORKS ON SLOPES • Cross-travelling on a slope can cause the machine skidding or overturning. When travelling up or down a slope, make sure the crawlers are oriented in the slope direction.

• Turning on an incline may cause the machine to tip over. If turning on an incline is absolutely unavoidable, do so at a place where the slope is gentle and the surface is firm.

F13056

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.

S-19

F22235

S. SAFETY PRECAUTIONS 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 travelling 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.

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.

PROTECTION OF 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 FOPS (Falling Object Protective Structure) to protect the cab.

F22027

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.

F22028

S-20

S. SAFETY PRECAUTIONS 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.

• Turn the auto-idle switch off.

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

• Stop the engine and remove the key from the key switch.

• Pull the safety lever (pilot control shut-off lever) to LOCK position.

• Block both tracks.

• Position the machine to prevent overturning.

• Park a reasonable distance from other machines.

F1437

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 O to stop engine. Remove key from switch.

• Pull pilot control shut-off lever to LOCK position.

F14376

• Allow engine to cool.

• Close windows, roof window, and cab door.

• Lock all access doors and compartments.

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

F14439

S-21

S. SAFETY PRECAUTIONS 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.

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.

F14381

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.

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.

F22041

S-22

S. SAFETY PRECAUTIONS AVOID UNDERCUTTING 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.

F22029

SAFETY TRANSPORTING 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 (A/I) 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.

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

WEDGES BLOCKS RAMPS F5827

S-23

S. SAFETY PRECAUTIONS • Avoid steering while driving up or down the ramp 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 flatbed is a sudden bump. Take care when travelling over it.

• Prevent possible injury from machine tipping while the upper structure is rotating.

F14383

• Keep the arm tucked under and rotate the upper structure slowly for best stability.

• Securely fasten machine frame using chains or cables.

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

F14384

PRACTICE SAFE MAINTENANCE Understand service procedures before doing work.

Keep work area clean and dry.

Never lubricate or service the machine while it is moving.

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

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

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

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.

S-24

F1458

S. SAFETY PRECAUTIONS 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

CLEAN TRASH FROM MACHINE Keep engine compartment, radiator, batteries, hydraulic lines, fuel tank, and operator’s station clean.

Temperature in engine compartment may go up immediately after engine is stopped.

BE ON GUARD FOR FIRES DURING THIS PERIOD. Open access door (s) to cool the engine faster, and clean engine compartment.

F1460

S-25

S. SAFETY PRECAUTIONS 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 (see SAFETY PLATES in this Chapter). This tag can be applied to the left-hand control lever, safety lever or cab door.

F2431

CLEAN 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.

STORE ATTACHMENTS SAFELY Stored attachments such as buckets, hydraulic hammers, 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.

S-26

S. SAFETY PRECAUTIONS 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, hollow tiles, 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 Grease in the track adjuster is under high pressure.

Failure to follow the precautions below may result in serious injury, blindness, or death.

• NEVER attempt to remove GREASE FITTING or VALVE ASSEMBLY. • As pieces may fly off, be sure to keep body and face away from valve.

Travel reduction gears are under pressure.

• As pieces may fly off, be sure to keep body and face away from air release plug to avoid injury. Reduction gear oil is hot. Wait for gear oil to cool down, then gradually loosen the air release plug to release pressure.

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 the chapter “OPERATING INSTRUCTIONS”.

The operator should be sitting in the operator’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. Mistakes in following procedures detailed for starting the engine with slave batteries may cause the batteries to explode or machine to move unexpectedly.

S-27

F3635

S. SAFETY PRECAUTIONS PROTECT AGAINST FLYING DEBRIS Guard against injury from flying pieces of metal or debris; wear goggles or safety glasses.

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

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

SUPPORT MACHINE PROPERLY Always lower the attachment or implement to the ground before you work 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, hollow tiles, or props that may crumble under continuous load.

Do not work under a machine that is supported solely by a jack. Follow the procedures in this manual.

F1468

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.

Be sure to stop the engine, and let engine and radiator cool.

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.

S-28

S. SAFETY PRECAUTIONS 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.

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.

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.

AVOID HEATING NEAR PRESSURIZED FLUID 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.

AVOID APPLYING HEAT TO 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.

S-29

S. SAFETY PRECAUTIONS AVOID HIGH PRESSURE FLUIDS Escaping fluid under pressure can penetrate the skin causing serious injury.

Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines.

Relieve the pressure by moving the control levers several times.

Tighten all connections before applying pressure.

Wear a shield or protection glasses to protect your eyes.

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.

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.

Escaping fluid under pressure can penetrate the skin causing serious injury. Do not use your bare hand to check for oil leaks.

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.

S-30

S. SAFETY PRECAUTIONS 4.

5.

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 key-start switch to the OFF position to confirm that the engine stops.

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

Check heat shields: 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 SAFELY 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.

For these products it is necessary to provide specific details about physical dangers for health, safety procedures, and emergency response techniques.

That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and use recommended equipment.

F1465

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.

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.

S-31

F1473

S. SAFETY PRECAUTIONS PREVENT ACID BURNS Sulphuric 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.

F1474

Flush your eyes with water for 10-15 minutes.

Get medical attention immediately.

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.

HANDLE FLUIDS - AVOID FIRES Handle fuel with 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.

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

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

SERVICE MACHINE SAFELY Tie long hair behind your 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

S-32

S. SAFETY PRECAUTIONS 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

DISPOSE OF FLUIDS PROPERLY Improperly disposing of fluids can harm the environment and ecology. Before draining any fluids, find out the proper way to dispose of waste from your local environmental agency.

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

DO NOT pour oil into the ground, down a drain, or into a stream, pond, or lake. Observe relevant environmental protection regulations when disposing of oil, fuel, coolant, brake fluid, filters, batteries, and other harmful waste.

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

ILLUMINATE WORK AREA SAFELY Illuminate your work area adequately but 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.

S-33

S. SAFETY PRECAUTIONS 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 only original spare parts.

EVACUATING IN CASE OF FIRE If a fire breaks out, evacuate the machine in the following way: Stop the engine by turning the key-start switch to the OFF position if there is time.

Use a fire extinguisher if there is time.

Exit the machine.

F3638

S-34

S. SAFETY PRECAUTIONS

SAFETY DECALS 1.

Decal, equipment safe area of operation.

2.

Decal, counterweight safe area of operation.

3.

Decal for engine hood warning, belts.

4.

Decal for engine hood warning, fan and pulleys.

5.

Decal for hot surfaces.

6.

Decal for pressurized fluids and lubricants.

7.

Decal for hooking point.

S-35

S. SAFETY PRECAUTIONS 8.

Track adjuster tag.

9.

Battery tag; danger warning.

10. Electrical lines tag; safety controls.

11. Window lock tag.

12. Windscreen wiper connector tag.

13. Plate, maintenance in progress.

13

F14402

S-36

S. SAFETY PRECAUTIONS 1. Decal, equipment safe area of operation Make sure that possible people standing in the operation area, are out of the machine’s reach before starting the same or to move its attachments. Sound the horn.

Background: yellow Stripe and lettering: black

F22042

2. Decal, counterweight safe area of operation Make sure that possible people standing in the operation area, are out of the machine’s reach before starting the same or to move its attachments. Sound the horn.

Background: yellow Stripe and graphics: black

F13235

3. Decal for engine hood warning, belts 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

F10391

4.

Decal for engine hood warning, fan and pulleys It indicates you have to stop the engine before opening the hood.

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

Background: transparent

F13236

Stripe and graphics: black

S-37

S. SAFETY PRECAUTIONS 5. Hot surfaces tag Located on radiator cover.

Immediately after the machine is operated, the temperature and pressure of the engine coolant, engine oil, and hydraulic oil are very high. Burns may result if caps are removed, or oil, water, or filters are changed under these conditions. Wait until the temperature goes down, before attempting to check fluids or change filters.

Background: yellow Stripe and graphics: black F13234

6. Pressurized fluids and lubricants tag Located on radiator cover.

Always release pressure from hydraulic tank, engine coolant, fuel system and all systems containing pressure before removing any caps or components. Be cautious of hot fluids and gasses from systems on machines that have just been stopped, allow sufficient time for systems to cool before performing any inspection or maintenance procedures.

F12690

Background: yellow Stripe and graphics: black 7. Decal, hooking point Indication of the eight hooking points (two on front axle, two on the back axle, two on counterweight, two on the frame) to be used for towing or lifting the machine.

Background: white Edging and graphic: black

F22045

8. Track adjuster tag It shows that obligation is made to consult the Operation and Maintenance Instruction Manual prior to acting on the track adjust valve.

Danger of severe injuries.

Background: yellow Stripe and graphics: black

F22043

S-38

S. SAFETY PRECAUTIONS 9. Battery tag; danger warning Flammable gas (hydrogen gas) is generated in the battery. Do not produce sparks near the battery, and do not put bare flame close to it to avoid the battery from catching fire and explosion.

Background: yellow Stripe and graphics: black

F14400

10. Electrical lines tag; safety controls It warns about danger in case of work near the electrical lines.

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 disconnected and any accidental equipment movement is impossible.

Background: white Stripe and graphics: black

F14404

11. Decal for window lock It indicates the danger of injury deriving from incorrect block of front windshield in open position.

Background: yellow Edging and graphics: black F14408

12. Windscreen wiper connector tag It indicates to disconnect windscreen wiper before removing lower cab window.

Background: transparent Stripe and graphics: black F22044

S-39

S. SAFETY PRECAUTIONS 13. 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 Graphic: black Edging: red

F2431

S-40

1. FEATURES

1. FEATURES

1.1

FOREWORD

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.

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

S DANGER For clarity purposes, some figures in this Manual show the machine with protection panels or covers removed.

Never operate the machine with any protection panels or covers removed.

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

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

1-3

1. FEATURES

1.2

IDENTIFICATION DATA

EXCAVATOR MARKING PLATES 1. Machine technical type

5.

Engine power in kW

2.

Product identification number

6.

Frame identification number

3.

Machine total mass

7.

4.

Machine manufacturing year

Identification decal: diesel engine type and serial number

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

1-4

1. FEATURES

1.3

NOISE LEVELS (2000/14/EC)

Sound power level Lwa = 93 dB (A) Plate (3) shows the granted sound power level, determined in compliance with 2000/14/EC European Standard.

SOUND PRESSURE LEVEL AT THE OPERATOR’S SEAT Lpa = 79 dB (A) Sound pressure level continuous, equivalent and average (A) measured in compliance with ISO 6396:1992.

VIBRATION TO THE OPERATOR The vibration level to the operator depends mainly on the conditions of the ground where the machine is being operated and on the use conditions of the machine and its equipment.

The exposition to vibrations can be remarkably reduced if the recommendations herebelow 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; • operate the equipment evenly, avoiding sudden motion or extreme shocks, if possible; • adjust speed and transfer route. Avoid very irregular routes or the impact with possible obstacles, in order to minimize 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.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

1-5

1. FEATURES

1.4

OPERATOR PROTECTIVE STRUCTURE

S WARNING Your machine may be equipped with an operator Protective Structure, such as: a Tip Over Protective Structure (TOPS) or Falling Object Protective Structure (FOPS). Refer to the identification plate attached to the cab (1) or the canopy (2) in order to understand which proective structure is installed on your unit.

The Protective Structure is a special safety component of your machine.

DO NOT attach any device to the Protective Structure for pulling purposes. DO NOT drill holes to the Protective Structure.

The Protective Structure and interconnecting components are a certified system. Any damage, fire, corrosion or modification will weaken the structure and reduce your protection. If this occurs, the Protective Structure MUST be replaced so that it will provide the same protection as a new Protective Structure. Contact your dealer for Protective Structure inspection and replacement.

After an accident, fire, tip or roll over, the following MUST be performed by a qualified technician before returning the machine to field or job site operation: • The Protective Structure MUST be replaced.

• The mounting or suspension for the Protective Structure, operator seat and suspension, seat belts and mounting components and wiring within the operator’s protective system MUST be carefully inspected for damage.

• All damaged parts MUST be replaced.

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

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

1-6

1. FEATURES

1.5

SUMMARY PLATE FOR MAINTENANCE OPERATIONS

Outside the air filter compartment, there is a summarizing plate (1) indicating the main lubrication operations and replacements to carry out periodically.

Replacement of engine oil filters

Replacement of fuel pre-filter Lubrication

Replacement of engine coolant

Replacement of reduction gear oil, axles and gearbox

Replacement of engine oil

(*) Replacement of hydraulic system oil Replacement of air filter Replacement of hydraulic system return oil filter (*) IMPORTANT: if the machine has been refilled with biodegradable hydraulic oil (on demand), be informed this oil cannot be mixed with mineral hydraulic oil.

Replacement of fuel filters Engine valves

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

1-7

1. FEATURES

1.6

BASIC COMPONENTS OF THE MINI EXCAVATOR

(FIXED CRAWLER FRAME VERSION)

1.

Bucket

10. Counterweight

2.

Link rod

11. Hydraulic oil tank

3.

Linkage

12. Shoe slide

4.

Bucket cylinder

13. Travel motor

5.

Arm

14. Canopy

6.

Arm cylinder (penetration)

15. Lower roller

7.

Monobloc arm

16. Track adjuster

8.

Fuel tank

17. Blade

9.

Boom cylinder

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

1-8

1. FEATURES

1.7

BASIC COMPONENTS OF THE MINI EXCAVATOR

(ADJUSTABLE CRAWLER FRAME WIDTH VERSION)

1.

Bucket

10. Counterweight

2.

Link rod

11. Hydraulic oil tank

3.

Linkage

12. Shoe slide

4.

Bucket cylinder

13. Travel motor

5.

Arm

14. Cab and operator’s compartment

6.

Arm cylinder (penetration)

15. Lower roller

7.

Monobloc arm

16. Idler adjuster

8.

Fuel tank

17. Blade

9.

Boom cylinder

18. Crawler frame width adjusting cylinder

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

1-9

1. FEATURES 1.7.1

TECHNICAL SPECIFICATIONS

DIESEL ENGINE Model

YANMAR 3TNE74

Type

vertical, 4-cycles, swirl chamber, water cooled

Net power at flywheel at 2000 rpm-1 (ISO9249)

11 kW

Number of cylinders

3 in-line

Bore x Stroke

74 mm x 78 mm 1006 cm3

Total displacement ELECTRICAL SYSTEM Voltage of operation

12 V

Batteries (capacity 20 h)

45 Ah

Alternator (current)

20 A

Starter motor (Power)

1 kW

HYDRAULIC COMPONENTS with axial pistons, with variable displacement + gear pump

Pump

orbit at fixed displacement

Slewing motor Travel motor

with axial pistons, variable volume for 2 speeds

Control valve

10-spool multiple

Cylinders Boom, arm, bucket, swing, dozer, spanner

double action

SPEED AND PERFORMANCE ON GRADIENTS rubber / steel

Crawlers

9.0 rpm-1

Slewing speed Travel speed slow

2.0 km/h

fast

3.5 km/h 58%

Maximum climbable gradient SWINGING

swinging with cylinder

Type Swinging angle Right side

50°

Left side

85°

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

1-10

1. FEATURES 1.7.2

DIGGING PERFORMANCES (CANOPY)

With 0.044 m3 bucket

(Dimensions in mm) ARM

1020

1220

A

3780

3970

A’

3683

3879

B

2178

2378

C

3530

3654

D

2490

2613

E

851

654

F

1904

2099

G

1548

1579

H

2667

2667

K

1699

1970

L

1143

1065

X

210

210

Y

270

270

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

1-11

1. FEATURES 1.7.3

DIGGING PERFORMANCES (CAB)

With 0.044 m3 bucket

(Dimensions in mm) ARM

1020

1220

A

3780

3970

A’

3683

3879

B

2178

2378

C

3530

3654

D

2490

2613

E

851

654

F

1904

2099

G

1548

1579

H

2667

2667

K

1699

1970

L

1143

1065

X

210

210

Y

270

270

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

1-12

1. FEATURES 1.7.4

TRANSPORT DIMENSIONS (CANOPY)

With 0.044 m3 bucket

(Dimensions in mm) *

A

B

C

D

E

F

G

H

I

L

M

N

N’

O

O’

P

Q

R

S

T

U

1020 3620 1050 2350 440 1220 1570 1080 770 2130 250

980

760 1070 990 1300 230

505

560 1050 360

170

1220 3650 1050 2350 440 1220 1570 1080 770 2130 250

980

760 1070 990 1300 230

505

560 1050 360

170

* Versions with arm

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

1-13

1. FEATURES 1.7.5

TRANSPORT DIMENSIONS (CAB)

With 0.044 m3 bucket

(Dimensions in mm) *

A

B

C

D

E

F

G

H

I

L

M

N

N’

O

O’

P

Q

R

S

T

U

1020 3620 1050 2350 440 1220 1570 1080 770 2130 250

980

760 1070 990 1300 230

505

560 1050 360

170

1220 3650 1050 2350 440 1220 1570 1080 770 2130 250

980

760 1070 990 1300 230

505

560 1050 360

170

* Versions with arm

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

1-14

1. FEATURES 1.7.6

BUCKETS APPLICATION

BUCKET

ARM

Type

Width mm

Capacity m3 heaped (ISO 7451)

Buckets for digging

250

0.028

22.52

Buckets for digging

300

0.034

28.21

Buckets for digging

350

0.040

30.37

Buckets for digging

400

0.044

32.28

Buckets for digging

450

0.046

34.01

Buckets for digging

500

0.051

37.01

Buckets for digging

600

0.060

40.99

Buckets for digging

700

0.069

45.11

Ditch cleaning buckets

800

0.056

27.32

Ditch cleaning buckets

1000

0.072

31.75

Mass kg

Length 1020 mm

Length 1220 mm

S WARNING The buckets with this length, during left arm slewing higher than 1 m from ground, can interfere with the cabin. For your safe use, consult the Dealer and ask for left slewing limiter of the arm support. : : :

:

Width with lateral cutter Width without lateral cutter Generic digging for digging and sand loading operations, gravel, clay, earth in general, etc.

The specific weight of the material should not be higher than 1400 kg/m3.

Digging for light applications for operations of digging, sand loading/unloading of gravel, clay, earth in friable and dry state, ditch cleaning, etc.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

1-15

1. FEATURES NOTE:

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

1-16

2. OPERATING INSTRUCTIONS

2. OPERATING INSTRUCTIONS

2.1

SAFETY PRECAUTIONS FOR USING THE MACHINE

S WARNING Read this Chapter carefully before starting, operating, servicing, refuelling or carrying out any other work on the machine.

S This symbol is your safety alert sign.

It means: WARNING! BE ALERT! YOUR SAFETY IS INVOLVED! Read and observe all safety precautions headed by the key words DANGER, WARNING AND CAUTION. Do not rush on the machine. Use the grab rails and steps which should be kept clean at all times.

Keep the operator’s platform clean and clear from foreign objects.

Any tools or personal belongings not necessary on the machine should be removed or firmly secured.

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

Your safety and 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.

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

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

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

Sound the horn.

Keep people clear of the attachments when in the raised position to prevent any possible personal injury.

Never operate the machine and its attachments from any position other than from the operator’s seat.

Under all circumstances keep your head, body, limbs, hands, and feet inside the operator’s compartment to minimise the risk of exposure to external dangers.

Check the engine exhaust system for leaks.

During night work, use all lights available.

During the day, check if any lamp is burned and replace it immediately.

Never leave the machine unattended with the engine running.

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

Bring auxiliary attachments, if any, to the closed safety position.

Move all controls to the neutral position.

Move engine controls in the shutdown position.

Shift the safety control lever to LOCK position and switch off the key-start switch.

Never park the machine downhill without carefully locking it to prevent unexpected movement.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-3

2. OPERATING INSTRUCTIONS

2.2

CONTROLS AND INSTRUMENTS

1.

Left safety lever

2.

Key-start switch

3.

Travel control levers

4.

Travel speed select switch

5.

Right-hand control lever

6.

Left-hand control lever

7.

Boom swinging pedal

8.

Tool pedal (optional) (Nibbler and hydraulic hammer)

9.

Horn control

10. Blade control 11. Accelerator control 12. Crawler frame width adjusting lever (Adjustable crawler frame width version) 13. Left panel 14. Right safety lever (canopy) 15. Right panel 16. Operator’s seat

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-4

2. OPERATING INSTRUCTIONS 2.2.1

LEFT SAFETY LEVER

The pilot control shut-off lever is a safety device which locks all attachments, including the stabilizers, blade and swing function.

Use pilot control shut-off lever (1) to release catch (2), allowing the left console to be raises for easier entry/exit of operator’s seat.

S WARNING Before abandoning the working site, lay the equipment to the ground and pull safety device lever up to the lock position.

To lock safety device, pull lever (1) up. It automatically reaches the lock position.

Unlock by pulling lever (1) down until hooking it to lock device (3).

Pilot control shut-off lever operation When leaving the operator’s station, park the machine on a firm, level surface.

Lower the bucket onto the ground.

Turn the ignition key counterclockwise to pull it out.

Pull up pilot shut-off lever (1) further to release catch, so that the left console (2) can be moved upward.

2.2.2

KEY-START SWITCH

Key-start switch positions: - When engine start up is difficult due to cold climate, turn the key counterclockwise to activate the pre-heating. Hold the key in this position for about 15 seconds to ease up the engine start.

Then turn the key clockwise to start the engine.

- Engine start-up (unstable position: after being rotated the key returns automatically to the startup position).

- Turn the key counterclockwise to pull it out.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-5

2. OPERATING INSTRUCTIONS

NOTE: When placing the ignition key to start position all lamps on the monitor panel illuminate (bulbs test) for approximately 3 seconds, except the following warning lamps: • low battery charge warning light • low engine oil pressure warning light which will remain on until engine start-up.

If any light does not come on during the CHECK, the bulb may be faulty (broken filament).

2.2.3

TRAVEL CONTROL LEVERS

S WARNING Standard use, provides for the travel controls at the front and travel motors at the back. Should travel motors be positioned at the front with regard to the actual travel direction, remind relative to travel direction that controls are reversed.

Always check travel motor position before moving off.

NOTE: The words right, left, front, back, clockwise, and anticlockwise are to be referred of the operator position properly sitting in the operator’s seat.

Machine movements N - Neutral A - Tracks move forward B - Tracks move backward C - Upper frame counter-clockwise rotation D - Upper frame clockwise rotation E - F - G - H - Intermediate moving positions

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-6

2. OPERATING INSTRUCTIONS 2.2.4

TRAVEL SPEED SELECT SWITCH

Use this switch to select travel speed, HIGH

U

or

LOW T with suitable switch located on the handgrip of the right travel lever. When the starter switch is turned to the OFF position, the travel speed is automatically set to LOW. Select the desired speed before starting travelling.

S WARNING Travel the machine in LOW T speed on slopes and at loading/unloading the machine on a truck/ trailer.

Sudden change of the machine travel speed may cause the machine to roll over.

T

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

U

Set to HIGH speed (2nd speed) when travelling on flat, hard grounds. Warning light (1) switches on.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-7

2. OPERATING INSTRUCTIONS 2.2.5

RIGHT-HAND CONTROL LEVER

S WARNING Prevent possible injury from unexpected machine movement. Make sure you know the location and function of each control before operating.

Boom cylinder control N - Neutral E - Boom lift F - Boom lower Bucket cylinder control N - Neutral G - Bucket filling H - Bucket dumping

2.2.6

LEFT-HAND CONTROL LEVER

Arm cylinder control N - Neutral A - Digging arm expansion B - Digging arm retraction

Upper structure swing control N - Neutral D - Anticlockwise rotation C - Clockwise rotation

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-8

2. OPERATING INSTRUCTIONS 2.2.7

BOOM SWINGING PEDAL

This pedal allows the boom to swing.

• Unlock pedal by shifting lock to (D).

• Lock pedal by shifting lock to (E).

• Pushing pedal on (B), the left swinging is activated.

• Pushing pedal on (C), the right swinging is activated.

2.2.8 TOOL PEDAL (Optional, nibbler and hydraulic hammer)

S WARNING Lock the boom swing control pedal when this function is not operated, failure to do so may cause serious accidents.

The optional tools are activated by means of this pedal.

• Unlock pedal by bringing lock to (D).

• Lock pedal by bringing lock to (E).

Use of the nibbler (double effect system): • Bring pedal on (G) and the nibbler closes.

• Bring pedal on (F) and the nibbler opens.

Use of the hydraulic breaker (simple effect system): • Bring pedal on (G) and the hydraulic breaker rests in stand-by.

• Bring pedal on (F) and the hydraulic breaker operates.

• For a change of the single or double effect see chapter “OPTIONAL EQUIPMENT”.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-9

2. OPERATING INSTRUCTIONS 2.2.9

HORN CONTROL

The horn control button (1) is located on the top front of left control lever and allows use during working steps. Press to operate.

2.2.10 BLADE CONTROL By shifting the lever forwards (B) the blade sinks, by shifting lever backwards (A) the blade lifts up.

By means of lever (2) located under the operator’s seat, he can select two functions: blade activation and adjustment of the crawlers frame width. Normally should this lever always be located downwards (blade operation).

2.2.11 ACCELERATOR CONTROL By shifting the lever forwards (B) the engine rpm decreases, while by shifting lever (A) backwards the engine rpm increases.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-10

2. OPERATING INSTRUCTIONS 2.2.12 CRAWLER FRAME WIDTH ADJUSTMENT (ADJUSTABLE CRAWLER FRAME WIDTH VERSION)

S WARNING • Change the machine width on a flat and hard ground without any obstacles.

• Make sure to lift the machine body up to change the crawler width. Otherwise, the crawler frame and width adjusting cylinder may be damaged.

• Lift up the machine body as shown in the sketch.

• Set the crawler/dozer shifting lever to (A) position (crawler frame width side).

• Expanding Move the adjustable crawler frame width/dozer lever to (B) position (crawler frame width expansion) to expand the machine width (crawler frame width).

• Retracting Move the adjustable crawler frame width/dozer lever to (C) position (crawler frame width retracting) to contract the machine width (crawler frame width).

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-11

2. OPERATING INSTRUCTIONS CHANGING DOZER WIDTH (ADJUSTABLE CRAWLER FRAME WIDTH VERSION) If required, the width of dozer blade can be extended by setting the additional plate as follows.

• Pull the pin off, and remove the plate.

• Set the plate outside, and align the pin bores.

• Insert the pin to set it.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-12

2. OPERATING INSTRUCTIONS 2.2.13 LEFT PANEL 1.

Wiper switch

2.

Working light switch

WIPER SWITCH (CAB) The switch is used for the wiper and washer fluid (1).

WASH - Spraying washer fluid.

OFF

- Stop.

ON

- Operating wiper.

NOTE: If washer is used continuously for 20 second or more, or if washer is operated without washer fluid, the motor mounted on washer tank may have trouble.

WORKING LIGHT SWITCH The switch is used for the boom and frame working lights (2): OFF - ON.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-13

2. OPERATING INSTRUCTIONS 2.2.14 RIGHT PANEL 1.

High travel speed lamp

2.

Fuel level gauge

3.

Hour-counter

4.

Batteries insufficient load warning light

5.

Engine oil insufficient pressure warning light

6.

Engine coolant too high temperature warning light

7.

Air filter warning light.

HIGH TRAVEL SPEED LAMP This indicator will be illuminated when the travel speed is switched to high (2nd) speed U (1). The travel speed selector switch is located on the grip of the right travel lever.

The engine returns automatically to 1st speed T when ignition key is in pull out position.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-14

2. OPERATING INSTRUCTIONS FUEL LEVEL GAUGE When the fuel level gauge needle (2) reaches the letter (E) the fuel tank is almost empty. Immediately refuel the machine.

HOUR-COUNTER The hour-counter (3), records the machine working hours.

NOTE: The first digit (black digit on white field) shows hour tenths (6 minutes).

BATTERIES INSUFFICIENT LOAD WARNING LIGHT When the ignition key is turned to start, warning light (4) comes on, but it should go off as soon as the engine is running.

NOTE: Possible delayed extinction of the warning light (4) is permissible only with the engine idling.

If the warning light illuminates during machine operation, this means that the battery charge is low.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-15

2. OPERATING INSTRUCTIONS LOW ENGINE OIL PRESSURE WARNING LIGHT When the ignition key is turned to start, warning light (5) comes on, but it should go off as soon as the engine is running.

During machine operation, the warning light (5) illuminates if the engine oil pressure is too low.

ENGINE COOLANT TOO HIGH TEMPERATURE WARNING LIGHT If this warning light (6) is lit, it means that the temperature of the engine coolant is too high.

AIR FILTER WARNING LIGHT If this warning light (7) is lit, it means that the air filter is to be cleaned or replaced, see chapter MAINTENANCE.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-16

2. OPERATING INSTRUCTIONS 2.2.15 OPERATOR’S COMPARTMENT ADJUSTING THE SEAT

S WARNING 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 FRONT TO BACK ADJUSTMENT Pull the seat adjustment lever to right side (1).

Move the seat forward or backward to desired position.

Release the lever to lock the seat in position.

Weight-absorbing adjustment The seat weight-absorbing is adjusted by pulling central lever (2) and shifting the same rightwards to decrease the weight to be absorbed and leftwards to increase the weight to be absorbed.

SEAT BELT

S CAUTION Prior to operating the machine: • check the seat belt, buckle and tying points; • ensure that the belt is not twisted; • always fasten the seat belt; • have the belt replaced by a dealer if damaged or frayed.

Fasten the safety belt as follows: • insert the retaining tang (3) into the buckle (4); • check the belt is positively buckled and adjust belt length around your body.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-17

2. OPERATING INSTRUCTIONS

S CAUTION The seat belt is correctly adjusted when it perfectly adheres to the pelvis.

Unfasten the seat belt as follows: • press the button (5) on the buckle (4); • slide out the tang (3).

S WARNING Always buckle the seat belt. Working with the belt unbuckled increases the hazards for severe injuries or even death in case of accidental crash.

After an important accident, replace the seat belt even though it does not look damaged. For this operation refer to a dealer.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-18

2. OPERATING INSTRUCTIONS

2.3

CAB

2.3.1

VENTILATION AND HEATING SYSTEM

1.

Heating/ventilation control

2.

Upper directable diffuser

3.

Lateral defrost directable diffuser

S WARNING If a window glass is missing or is broken, replace it as soon as possible.

NOTE: The upper diffusers and the defroster, are directable to address the air jet and adjustable to change their capacity.

2.3.2

VENTILATION/HEATING CONTROLS

Fan speed switch.

This switch has 2 positions for the fan control, L and H. Bringing the switch on OFF the fan is switched OFF.

2.3.3

STORAGE AND OTHERS

STORING PLACE FOR MANUAL Store the manual in the storage box provided on the back of seat.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-19

2. OPERATING INSTRUCTIONS 2.3.4

DOOR

NOTE: the key supplied is used for starting and for the following: • open/close door; • open/close the air filter compartment door; • open/close radiator bay door; • open/close fuel tank and hydraulic oil compartment; • open/close engine hood.

OPENING THE DOOR FROM THE OUTSIDE With lock unlocked, press key (1) towards the inside.

CLOSING THE DOOR FROM THE OUTSIDE Close the door and turn the key in the lock.

OPENING THE DOOR FROM THE INSIDE Press opening lever (2) towards the outside.

RELEASING THE DOOR FROM THE INSIDE NOTE: To keep the door wide open during machine operation, open it until it securely locks into the latch on the cab side.

Pull lever (3) downwards to unlock open door.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-20

2. OPERATING INSTRUCTIONS 2.3.5

FRONT WINDSCREENS AND WINDOWS

SLIDING THE FRONT WINDSCREEN OPEN/ CLOSED

S WARNING Ensure to move the machine to the level ground when opening/closing the front windshield, and lock it.

Especially, unlocking windscreen at forward-inclined posture of the machine causes falling down of front windshield.

It is possible to glide the upper windscreen on the deck and to lock it in this position.

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

• Pull down the levers (4) provided on the left/right sides of upper portion to unlock the front windshield.

• Grasp the handle on windshield, hold it up and slide into backside ceiling.

• Ensure to lock the front windscreen housed into ceiling by means of pushing up the lever (4).

• Lower the upper windscreen following the opposite proceeding.

S WARNING When closing the upper front windshield, slowly get down it paying attention not to be caught fingers, etc.

Machine operation with insufficient locking is quite dangerous. Make sure to lock it.

FRONT LOWER WINDSCREEN REMOVAL/ INSTALLATION • The lower windscreen can be removed, by slipping it off its seat.

It can be fixed in a safe way in the back support of the cabin.

• Insert the windscreen in the supports, in the lower part and lock it with preposed clamps (5).

S WARNING Do not start working with the front windscreen dismantled.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-21

2. OPERATING INSTRUCTIONS LATERAL RIGHT WINDOWS Press lock (6) and let glass glide.

2.3.6

INNER CEILING LIGHT

Press relevant switch (7) located under the ceiling light: ON:

to switch on the ceiling light and the courtesy light.

OFF: to switch the light off.

2.3.7

EMERGENCY EXIT

If the cab door cannot be opened (due to an accident occurred while working), recommended escape routes are the following: • by opening the front sliding windscreen.

In case the opening of the front windscreen is not possible, a hammer (8) is included to break the front or rear glass.

S WARNING Always wear safety gloves and glasses prior to shattering the window pane, if necessary. Danger of bodily injuries.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-22

2. OPERATING INSTRUCTIONS 2.3.8

WINDSCREEN WIPER

Blade replacement.

Replace the windscreen wiper blade as follows: • pull the wiping arm outwards; • rotate the blade until it is square to the wiping arm (90° angle); • press the support tang and remove the blade to be replaced.

2.3.9

WINDSCREEN WASHER

Cleaning the spraying holes.

If the spraying pattern is not satisfactory, clean the spraying holes using a needle.

IMPORTANT: Do not hold down the windscreen washer control button longer than 20 seconds. Do not press the button if there no detergent in the tank. Damage to the windscreen washer motor may ensue. Check detergent level in the bottle and top up as necessary.

WINDSCREEN WASHER AND TANK They are inside of the cabin. Check and eventually top-up the level of the washing liquid.

NOTE: In winter, use an all season washer fluid.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-23

2. OPERATING INSTRUCTIONS

2.4

USING THE MACHINE

Prior to starting the machine carefully read all procedures and precautions contained in this Operation and Maintenance Instruction Manual.

S DANGER Do not run the engine in closed spaces without proper ventilation and/or an adequate system capable to removal lethal exhaust gases.

S WARNING Before starting the machine or operating its attachments, ensure that all bystanders are clear of the machine operating range. Walk all around the machine before mounting. Sound the horn.

Before starting the machine, adjust and lock the operator’s seat for maximum riding comfort and control accessibility.

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

Before leaving the operator’s seat and after ensuring no-one is near the machine, slowly lower the attachment until it rests safely onto the ground. Move possible supplementary tools in the safe retracted position.

Always stop the engine before leaving the operator’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 pulled fully vertical to the LOCK position.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-24

2. OPERATING INSTRUCTIONS 2.4.1

REFUELLING

S WARNING Fuel is flammable. Do not puncture or burn containers.

Strictly observe the Manufacturer’s instructions as regards storage and distribution.

Following the presence of highly flammable vapours, extinguish all smoking materials and open flames or sparks before checking fuel level or refuelling, replacing the filters or opening the condensation drain plug.

Do not refuel with the engine running.

Do not use matches, cigar lighters or torches as light sources on the machine.

NOTE: Refuel using decanted fuel.

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 tank as this would cause air to enter the fuel system. The fuel system should then be bled from air.

• Turn ignition key (1) to start, so that the warning lights of the monitor panel light up.

• Check the fuel gauge (2), and remove filler cap (3) to refuel if needed.

• Fill the tank with fuel.

• Fuel tank capacity: 19.7 litres.

• After refuelling, install fuel cap (3) and tighten securely.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-25

2. OPERATING INSTRUCTIONS 2.4.2

CHECKS BEFORE ENGINE STARTUP

CONTROL CHECKS Ensure that the safety lever (1) is on the LOCK position (see paragraph “INSTRUMENTS AND CONTROLS” in this Chapter).

Ensure that all controls (control levers and pedal/ lever assemblies) are in the neutral position.

Make sure that the control lever (2) of the manual accelerator, is set on minimum revolutions/number of engine.

INSTRUMENT CHECK When setting the ignition key on start position the warning lights turn on, according to the key position, as shown in the table: Start key position

Pre-heating

Before start-up

Immediately after start-up

3 Load checking light

OFF

ON

OFF

4 Engine oil pressure light

OFF

ON

OFF

5 Coolant temperature warning light

OFF

OFF

OFF

6 Air filter clogging warning light

OFF

OFF

OFF

7 Fast speed warning light

OFF

OFF

OFF

Warning lights

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-26

2. OPERATING INSTRUCTIONS 2.4.3

MACHINE WARM-UP

Perform correct engine warm-up as follows: • start the engine by turning the engine speed hand control (1) to slow idle, as shown; • let the engine idle until the yellow indicator light goes off.

Perform correct warm-up of the hydraulic system components as follows: • after correct engine preheating as detailed below, move the engine speed hand control (1) to the intermediate position.

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 longer than 15 seconds (by holding the control lever). This is to avoid excess heating of hydraulic oil in the operating section only. After each operating cycle, wait 5 to 10 seconds at least.

• Move control levers slowly to operate the boom, arm, and bucket cylinders to stroke end. Repeat this operation several times.

• Slowly move the upper structure swing control in both directions, one after the other. Repeat this operation several times.

• Move travel control pedals/levers, by covering first short distances.

2.4.4

KEY-START SWITCH

Key-start switch positions: - When engine start up is difficult due to cold climate, turn the key counterclockwise to activate the pre-heating. Hold the key in this position for about 15 seconds to ease up the engine start.

Then turn the key clockwise to start the engine.

- Engine start-up (unstable position: after being rotated the key returns automatically to the startup position).

- Turn the key counterclockwise to pull it out.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-27

2. OPERATING INSTRUCTIONS 2.4.5 STARTING THE ENGINE (cold, with thermostarter)

S WARNING The engine must be started exclusively from the operator’s seat. Before starting the engine, make sure that he safety lever is in the vertical LOCK position.

After completing the checks before start-up as detailed in the previous paragraph, proceed as follows: • bring accelerator control lever (1) in one position slightly higher than the engine idle run;

• Turn ignition key (2) counterclockwise activating the pre-heating and keep it in this position for 15 seconds; • Turn ignition key clockwise to operate the start; • Let the ignition key (2) return to rest position as soon as the engine starts; • If the engine does not run within 15 seconds, repeat start-up procedure (2) and hold it in position for 10 seconds.

IMPORTANT: Do not crank the engine for long.

After a fail start of the engine, replace the key in pull out position and wait at least 30 seconds before repeating the starting procedure.

NOTE: When the ignition key is turned to pre-heat position, it is normal that also low oil pressure, alternator and light warning lights are on, in addition to preheating warning light.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-28

2. OPERATING INSTRUCTIONS 2.4.6

CHECKS AFTER ENGINE START-UP

Check that: • the low battery charge warning light (3) is off. A slightly delayed extinction is permissible only with the engine idling.

• The low engine oil pressure warning light (4) is off.

• Engine noise and exhaust gases are normal.

IMPORTANT: If the warning lights do not go off after start-up, immediately stop the engine and investigate the causes.

2.4.7

STARTING THE ENGINE AFTER PROLONGED STORAGE

If the machine has been inoperative for a long time, it is necessary to bleed air from the fuel system, as follows: • loosen the bleed screw (5) to allow air to escape; • repeatedly press the button (6) located on the primer to circulate the fuel into the system; • continue priming the fuel system until a minimum amount of fuel comes out of the loose bleed screw (5) connection. Tighten the screw; • start the engine.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-29

2. OPERATING INSTRUCTIONS 2.4.8

COLD WEATHER WARM-UP

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 hold it over relief for several seconds (no more than 30 seconds) at the stroke end.

Retract the bucket cylinder and hold it over relief for several seconds (no more than 30 seconds) at the stroke end.

Slowly operate the arm and boom cylinder a few times.

Operate travel and swing functions slowly, initially moving only short distances.

Repeat the above procedures until the bucket cycle time is normal. In extremely cold conditions, extend the warming-up period, running the engine at medium speed.

Even after completing thorough warm-up operation, travel function may respond slowly for a while because lubricants in axles and transmission remain cold, not because of machine trouble.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-30

2. OPERATING INSTRUCTIONS 2.4.9

STARTING THE ENGINE USING BOOSTER BATTERIES

S WARNING 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 well ventilated place. Park the machine on a dry firm, surface.

Do not park on metal surfaces.

Take care to make correct connections: never connect a positive terminal (+) to a negative terminal (-).

F1464

IMPORTANT: The machine electrical system is 24 V with negative (-) ground. Use only booster batteries with same voltage.

CONNECTING BOOSTER BATTERIES Proceed 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); • start the engine.

Booster battery

Machine battery Machines frame groundings

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.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-31

2. OPERATING INSTRUCTIONS 2.4.10 STOPPING THE ENGINE

S WARNING Park the machine on firm and possibly level ground.

Always rest the bucket safely onto the ground before stopping the engine.

S WARNING Never leave the machine unattended with the engine running. Attachment and tools may be lowered to ground by hand lever either under power or not.

• Park the machine on a firm and possibly level ground.

• Rest the bucket safely onto the ground.

• Make sure that lever (1) of manual accelerator control, is set on minimum engine revolutions number.

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

NOTE: Refer to the paragraph “EMERGENCY BOOM LOWERING PROCEDURE” in this Chapter to lower the boom and rest the bucket onto the ground in case of emergency when the engine stalls and cannot be restarted.

• Bring then the ignition key to start (2) in pull out position.

• Remove the ignition key from the key-start switch.

• Move the safety lever (3) in the vertical LOCK position.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-32

2. OPERATING INSTRUCTIONS

2.5

OPERATION NORMS

2.5.1

EMERGENCY BOOM LOWERING PROCEDURE

S WARNING Ensure that no one is under or near the front attachment before starting the procedure to lower the boom.

If the engine stops and cannot be restarted, lower the lifting arm to lay the bucket to the ground in the following way: • Turn the ignition key (1) to start; • to lower the equipment, shift the right hand control lever forwards.

If the arm does not lower down to bucket-to-theground position when acting as above, carry out the following.

MACHINE WITHOUT ANTIDROP VALVES • Take off the cover outer left side under the cabin.

• Locate main control valve section (2) controlling lifting (second section).

• Remove hose (3).

• Remove fitting (4).

• Tighten screw (5) supplied with the machine.

• When tightening, the arm lowers and lowering speed increases the more screw (5) is tight.

• For this operation two open spanners are required one 16 mm spanner for hose (3) and one 19 mm spanner for the connection and screw (5) supplied with the machine.

• Proceed in reverse to reset control valve operation.

Fitting (4) • Tightening torque: 25 Nm Hose (3) • Tightening torque: 30 Nm Handle and dispose of hydraulic oil according to current regulations. Use only authorised disposal procedure. If in doubt, contact authorities concerned.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-33

2. OPERATING INSTRUCTIONS MACHINE WITH ANTIDROP VALVES The antidrop valve is fitted to the lifting cylinder.

• Remove plug (6) with a 8 mm hexagonal wrench supplied with the machine.

• Fit shim (7) supplied with the machine and reinstall plug (6).

• Carry out all the operations in sequence as described on paragraph “MACHINE WITHOUT ANTIDROP VALVES”.

• Proceed in reverse to reset antidrop valve function.

Plug (6) • Tightening torque: 25 N

S WARNING Have antidrop valve and control efficiency checked at an authorized after-sales centre.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-34

2. OPERATING INSTRUCTIONS 2.5.2

EXCAVATOR REMOVAL

S CAUTION It is forbidden to tow the machine on roads.

The machine can be removed by hooking up to the back hook (1) and possibly by hooking points of blade and arm.

For removal with Diesel engine running, follow general safety rules and operate only with skilled personnel and a signal person for operation coordination.

NOTE: The machine is braked with diesel engine off.

Do not remove the machine WITH BRAKE CONNECTED. When the machine becomes unable to travel due to any troubles on the travel motor, etc., it is possible to temporarily move the machine by means of releasing lock on the travel engine with removing the spool in the counter balance valve of the travel motor.

S WARNING When dis/re-assembling the travel motor, pay special attention not to allow invasion of foreign particles and dust into the travel motor.

• Disassemble rubber track by slightly opening the grease gun of the track idler of one complete turn.

• Apply safety blocks under the lower frames of left and right (travel engine side), and get down the machine which has been lifted up, then stop the engine.

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

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

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

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-35

2. OPERATING INSTRUCTIONS • Remove the socket capscrews (4) with a wrench to remove the travel engine from the lower frame.

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

Socket capscrew (4): M10x20.

• Remove the plug (5) with a wrench.

Plug (5): 27 mm of hex. size.

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

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

• Reinstall the travel engine in the lower frame.

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

• Reassembly the crawlers.

• As the case is disassembled the travel engine is not locked.

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

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

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-36

2. OPERATING INSTRUCTIONS 2.5.3

SAFETY LEVER

The safety lever (1) is used to disable swing controls and the attachment movements.

It has two positions: • when in the lock position 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; • when in the unlock position, the safety lever enables operation of all controls. Therefore, to control and operate the machine, the lever should be moved to this position.

S WARNING Before starting the engine, ensure that the safety lever in the lock position (vertical).

S WARNING When the machine is parked or upon leaving it for whatever reason, always ensure that the safety lever in the lock position (vertical).

BEFORE START-UP Before starting the engine, ensure that the safety lever (1) is at end of travel in the lock position.

AFTER START-UP 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.

S WARNING If attachment movement is detected when the safety lever is released with the control levers still in the neutral position, proceed as follows: • pull the safety lever to stroke end in the lock position (vertical); • stop the engine; • Contact the nearest Dealer.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-37

2. OPERATING INSTRUCTIONS 2.5.4

CONTROL LEVERS

NOTE: The following descriptions concerning use of the controls are to be intended with the travel motors at the rear relative to the travel direction. The words right, left, front, back, clockwise, and anticlockwise are to be referred to the Operator’s position properly sitting in the operator’s seat.

S CAUTION Prior to any digging operation, get acquainted with location and function of each control lever as detailed below.

S DANGER It is forbidden to expose limbs or any part of the body outside the cab windows during work: Danger of severe injuries and even death.

NOTE: The machine is fitted with a plate showing all functions of control levers and pedals.

MAIN CONTROLS 1. Arm roll-out (forward) 2.

Arm roll-in (reverse)

3.

Swing right

4.

Swing left

5.

Boom lower

6.

Boom raise

7.

Bucket roll-in

8.

Bucket roll-out

When a control lever is released, it returns automatically to the neutral position and the associated work function stops.

S CAUTION If the machine is fitted with the following options: triple articulation, clamshell bucket or breaker, see descriptions of the associated controls at the paragraph “INSTRUMENTS AND CONTROLS” in this Chapter.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-38

2. OPERATING INSTRUCTIONS 2.5.5

ENGINE SPEED HAND CONTROL

The accelerator control lever (1) allows to increase or to reduce the engine rpm.

By moving the lever forwards, the engine rpm is decreased, while by moving the lever backwards the engine rpm is increased.

2.5.6

TRAVEL SPEED SWITCH

S WARNING Should slopes be faced with a gradient equal or higher than 6%, the reduced speed function should be activated, by selecting the low travel switch T. Use this switch to select travel speed, HIGH U (2nd speed) or LOW T (1st speed). When the ignition key shifts from start-up to pull out position, the travel speed is automatically set to LOW T. Select the desired speed before starting travelling.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-39

2. OPERATING INSTRUCTIONS TRAVEL BY LEVERS OR PEDALS

S WARNING In the standard travel position, travel controls are at the front and travel motors (1) at the rear of the machine. Remember that travel controls are reversed when, travel motors (1) are positioned at the front relative to the travel direction.

Be always aware of travel motors (1) location prior to moving off.

NOTE: The words right, left, front, back, clockwise, and anticlockwise are referred to the operator’s position properly sitting in the operator’s seat.

Forward travel Push both levers (1) forward simultaneously.

Reverse travel Pull both levers (3) backward simultaneously.

Neutral position When both levers are in the neutral position (2), automatic brake operation will stop machine travel.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-40

2. OPERATING INSTRUCTIONS Right turn Push the left-hand lever (1) forward.

This action will cause only one track to turn and the machine will steer by pivoting on the stationary track.

Left turn Push the right-hand lever (1) forward.

This action will cause only one track to turn and the machine will steer by pivoting on the stationary track.

Clockwise spin Push the left-hand lever (1) forward and at the same time pull the right-hand lever (3) backward.

This action will cause the tracks to turn opposite to one another at the same time. As a consequence, the machine will rotate by pivoting on its centreline.

Counterclockwise spin Push the right-hand lever (1) forward and at the same time pull the left-hand lever (3) backward.

This action will cause the tracks to turn opposite to one another at the same time. As a consequence, the machine will rotate by pivoting on its centreline.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-41

2. OPERATING INSTRUCTIONS

2.6

OPERATING THE MACHINE

S WARNING Keep the attachment down or in any case in a suitable position to guarantee maximum visibility and control of the machine.

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

Should the machine be accidentally placed under voltage (for ex., after pulling out an electric line), absolutely do not touch machine metal structure while getting off.

Spot an adjacent area not very rough and jump directly over it from the cab.

Working near electric lines can be very dangerous, therefore some special precautions must be observed.

By “work near electric lines” we mean when the attachment or load raised by the machine (in any position) may reach the minimum safety distance according to local or international Safety Regulations.

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

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 by looking up their 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 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 standpoint more favourable than the Operator’s.

This signal-man must be in direct communication with the Operator and the Operator must pay undivided attention to the 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 the line is question is out of work and visibly connected to the ground.

Working on slopes is dangerous.

Do not travel with a full bucket or a load from uphill downhill.

Do not work with the bucket turned to the uphill side.

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°.

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.

Prior to 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 Distributing 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 cave-in hazards.

Pay the utmost attention when working near overhang walls.

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: • digging near previous trenches filled with materials; • digging in bad ground conditions; • digging trenches subject to vibration 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 (auxiliary equipment) when raised to prevent possible injuries.

Only highly experienced personnel should be allowed to work on difficult virgin soil.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-42

2. OPERATING INSTRUCTIONS 2.6.1

MAJOR OPERATING NORMS

KEEP THE BUCKET DOWN Always move with the bucket down, namely on slopes or during transfers. The bucket, however, should be sufficiently raised from the ground to overcome possible obstacles. Do not use the bucket as a man lift or to carry riders.

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 crawlers pay attention not to cause the machine to overturn. With a full bucket, pay the utmost attention and care while swinging or lifting the attachment.

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 existence and location of electrical lines, gas ducts, water pipes or other public utilities installations. If in doubt, contact local authorities and/ or the distributing companies (Electric Power, Gas, Telephone, Water, Telecommunications, etc.).

F22028

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-43

2. OPERATING INSTRUCTIONS

S WARNING Should optical fibre cables be damaged, do not look into the cable ends to avoid eye injuries.

Never dig under the machine. In case of emergency, should the engine stall and not be possibly restarted, it is possible to lower the boom and rest the bucket safely onto the ground following the “EMERGENCY BOOM LOWERING PROCEDURE” detailed in this chapter.

AVOID ELECTRIC LINES

S WARNING 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 less than 3 meters plus twice the length of line insulators.

Check and behave in compliance with any applicable local regulation. Ground dampness increases the area on which people might be affected by electric shocks. Keep all people and/or assistants away from the working area.

CHECK THE WORKING AREA Always make sure that the work site has sufficient strength to firmly support machine weight.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-44

2. OPERATING INSTRUCTIONS RAISING ONE SIDE OF CHASSIS WITH BOOM AND ARM Keep the angle between boom and arm 90° to 110° when lifting the machine using the thrust from the front attachment. Rest the outer (round) side of the bucket onto the ground and use it as the origin of force, as shown.

AVOID EXCESS DIGGING EFFORT Never travel with the bucket teeth deep into the ground, nor try to dig using the excavator weight as additional digging force.

• Both operations cause excessive stress on the machine.

OPERATING IN MUD OR WATER The machine can wade or work into a river, providing that: • the terrain is firm enough to prevent the machine from sinking excessively; • the water level does not overflow the guiding plates of the crawlers; • the stream is not excessive.

When operating under these conditions, check frequently the positioning of the machine. Re-position it, as required.

Avoid dipping the bullgear, the swing engine reduction unit and the centre joint below the water level.

In the event they are accidentally submerged, please contact a Dealer.

The non compliance with these due precautions could cause a premature wear of some components of the machine.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-45

2. OPERATING INSTRUCTIONS HAMMERING OR PILING Never use the bucket as a hammer. Improper use would damage the bucket and other parts of the front attachment.

DO NOT USE AS A CRANE Avoid this use in particular as the machine is specifically designed for digging works.

S WARNING The machine has been specially designed for digging/loading works. Overhead load handling after finishing digging/loading cycles is allowed if the machine is equipped with the suitable option supplied by the Dealer on demand. Handle overhead loads strictly following the national rules on this subject, as well as the rules mentioned in this chapter and those described on the SAFETY RULES chapter.

DIGGING HINTS • 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 with the digging direction, and use full-stroke bucket wrist action to effectively fill the bucket.

• When digging a trench, 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 with some distance remaining before stroke ends.

NOTE: Do not stop the boom abruptly during lowering as this may cause harmful kick-backs to the machine. When using the arm, do not fully extend the arm cylinder.

Should it be necessary to dig with the upper structure not aligned with the tracks, prevent bucket teeth from hitting the tracks. If the trench is deep, also avoid that the drive cylinder tubes hit the ground.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-46

2. OPERATING INSTRUCTIONS GRADING OPERATION IMPORTANT: Do not pull or push dirt with the bucket when traveling.

Position the arm slightly forward of the vertical position with bucket rolled-back, 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 to maintain a smooth surface.

Grading operation can be more precisely done by operating the boom, arm and bucket simultaneously.

Swing force Do not use the swing force (rotation) to move huge stones, pull down walls, etc.

This use may damage the front attachment and swing motor.

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 thrust into ground.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-47

2. OPERATING INSTRUCTIONS 2.6.2

PRECAUTIONS DURING OPERATION

S WARNING Carefully inspect the work site before digging. If there is the possibility of falling objects, install overhead cab guards for safety purposes. If the ground where 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., when operating the machine.

• 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 counterweight against such obstacles while swinging.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-48

2. OPERATING INSTRUCTIONS 2.6.3

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 the paragraph “USING THE MACHINE” in this Chapter.

Bring then the ignition key to start in pull out position and remove the ignition key.

Pull the safety lever upwards and ensure it has reached end of travel to the vertical lock position.

Close all windows.

Lock the cab door and the following panels: • tanks compartment door; • radiator compartment door; • engine hood door.

IMPORTANT: Inside the slewing engine, is located the negative brake, consequently with engine off, it is impossible to turn the upper structure.

S CAUTION Do not park the machine on slopes whenever possible.

Should parking the machine on a slope be unavoidable, perform that detailed before and observe the following: • thrust the bucket teeth into the ground; • lock suitably (with wedges) both crawlers, as shown in the picture.

IMPORTANT: Always protect cab electrical components from bad weather taking care to close all windows, roof window, and access door.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-49

2. OPERATING INSTRUCTIONS 2.6.4

PRECAUTIONS FOR TRAVELING ON SLOPES

S WARNING Should it be necessary to operate the machine on slopes, carefully observe the following precautions.

This is to prevent bodily injuries due to accidental machine overturn.

S WARNING Always stop the machine before selecting the other travel speed. Do not change speed during travel.

Avoid especially to select fast travel on slopes: it might be dangerous.

• Never attempt to enter or exit the machine when on 30° (~ 58%) slopes or steeper.

• Ensure the seat belt is properly fastened.

• Avoid travelling across the slope as much as possible.

• Never attempt to travel across 15° slopes or steeper.

• Keep the bucket in 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.

• 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 swing the upper structure on slopes.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-50

2. OPERATING INSTRUCTIONS • Never attempt to swing the upper structure downhill as the machine may overturn. If swinging uphill is unavoidable, operate very carefully by moving very slowly the upper structure swing and lift control.

RIGHT

• Never turn loads downhill. Keep the bucket to the uphill side and reduce rotation speed at minimum.

• If the engine stalls on a slope, immediately lower the bucket to the ground and move control levers back to the neutral position. Then restart the engine.

• Be sure the machine has completely warmed up before ascending a steep slope. If hydraulic oil has not warmed up correctly, sufficient performance may not be obtained.

WRONG

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-51

2. OPERATING INSTRUCTIONS

2.7

HANDLING OF OVERHEAD LOADS

S WARNING The machine has been specially designed for digging/loading operations. The handling of hanging loads when the digging and/or the loading operation is ended, is allowed under the condition that the machine is efficient and handled by proper personnel. When handling overhead loads, strictly follow national regulations with respect of safety, the rules listed herebelow and those described on chapter SAFETY RULES. (EN474-5/4.1.7.5).

For overhead loads handling, act as follows:

S WARNING To avoid accidents, do not exceed machine load rated capacity. If the machine is not on a level ground, load capacities are reduced. Operate with care.

• Lay the load to any position you wish but make sure it is firm and suitable for the load weight.

2.7.1

READING KEY FOR THE LIFTABLE LOAD CHART LOCATED IN THE CAB

1.

Boom length.

5.

Counterweight weight.

2.

Digging arm length (LD), alternatively.

6.

3.

Load distance from pivot point.

Main relief valve/hydraulic safety valves pressure setting.

4.

Maximum liftable load in kg to roll-over limit as per ISO 10567 Standards.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-52

2. OPERATING INSTRUCTIONS 2.7.2

LIFTABLE LOADS TABLE AT THE BUCKET CONNECTION PIN

NOTE: The lifting loads are as per ISO 10567 norm (75% stability, 87% hydraulic system). Loads at hook without bucket at 360°. For weights and capacities see, “BUCKETS APPLICATION”.

NOTE: If it is necessary to lift a load with a machine equipped with some or all above mentioned components (buckets, hooks, etc.), their weight should be detracted from the weights indicated in the table. This to work out the lifting capacity.

Cab Version

Arm 1.02 m Boom 1.75 m Arm 1.22 m

Canopy Version

Arm 1.02 m Boom 1.75 m Arm 1.22 m

m

1

1.5

2

2.5

3

Z2

-

-

-

220

-

Z1

480

520

290

240

190

Z3

670

420

280

-

-

Z2

-

-

-

-

200

Z1

450

500

320

220

180

Z3

890

510

330

-

-

m

1

1.5

2

2.5

3

Z2

-

-

-

220

-

Z1

480

460

290

210

160

Z3

670

420

280

-

-

Z2

-

-

-

-

180

Z1

450

440

280

200

150

Z3

890

460

290

-

-

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-53

2. OPERATING INSTRUCTIONS

2.8

BUCKET INSTALLATION

Install the bucket as follows: • Clean each pin and pin hole and grease sufficiently.

• Move the bucket cylinder to match the pin bores of the bucket (6) and bucket link (8) with each other; then insert the pin (4) installing the shims (10).

• Raise the boom up to lift the bucket slightly from the ground.

• Move the arm (7) to match the pin bores of the bucket (6) and arm (7) with each other; then insert the pin (5) installing the shims (10).

• Insert the lock pin (3) into pin (4) and (5), and attach the spring lock rings (2).

• Fit the O-ring (1) into the normal position as shown in the right Figure.

• Apply grease to the bucket link from the grease nipples sufficiently.

NOTE: Replace the O-ring (1) showing cracks or losing elasticity with a new one.

S WARNING Always use suitable tools to align holes. DO NOT USE HANDS OR FINGERS. Bucket play adjustment (optional) • Lower the bucket to the soil.

If the bucket leans too heavily on the soil, some adjustment problem might be encountered.

NOTE: Bucket play (G) should be 0.1 to 0.5 mm.

• Roll the O-ring (1) from its normal position to the bucket boss to avoid damage.

• Measure the total clearance (G) between the arm and bucket boss. The clearance is the existing total clearance. Exact clearance is gotten easily by using a thickness gauge.

• Decrease the play, if the measured value is equal or higher than 0.5 mm, by inserting shims.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-54

2. OPERATING INSTRUCTIONS 2.8.1

BUCKET TEETH

• Ensure the machine is parked on a level surface.

• Rest the bucket to the ground.

• Move the accelerator control lever to idle position, switch off engine, pull out ignition key and set safety lever in LOCK position.

REPLACING THE TOOTH POINTS Replace the bucket tooth in the following cases: • When little holes appear on the tooth point.

• When the edge lines of the tooth point are worn.

S WARNING Wear, goggles, safety shoes, hard hat, work clothes and work gloves to perform inspection and maintenance on this machine.

• Using a hammer and punching tool, hammer out the locking pin. Be careful not to damage the rubber lock pin (3).

• Inspect the locking pin (4) and rubber lock pin (3).

Replace them if the locking pin (4) is too short or the rubber lock pin (3) is in poor condition.

• Clean the surface of the adapter nose (1) with a putty knife to remove the adhered soil.

• Fit the tooth point (2) onto the adapter nose (1).

• Push the rubber lock pin (3) in the hole of the adapter nose (1).

• Drive the locking pin (4) until it is aligned with the point face.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-55

2. OPERATING INSTRUCTIONS REPLACING THE SIDE CUTTERS

S WARNING Wear, goggles, safety shoes, hard hat, work clothes and work gloves to perform inspection and maintenance on this machine.

• Completely remove all sand and soil adhering around the capscrews. Use an acetylene torch to cut off the capscrews, then remove the side cutter.

• Clean the mounting face and install a new side cutter. When replacing the side cutter, replace the capscrews and nuts with new ones.

• Tightening torque: 115 ± 12 Nm. • After tightening the nuts, spot-weld them.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-56

2. OPERATING INSTRUCTIONS 2.8.2

LOWER ROLLER EXCHANGE

S WARNING When the kind of crawler shoe is changed, it is necessary to exchange the assembly position of the lower rollers.

The disassembly, assembly and oil drain are described herewith: • Release the crawler shoe tension.

• Unscrew lightly the fastening screws (1) of the lower roller (of about one turn).

• Start the engine. Lower the bucket to the ground and lift the machine by means of the brackets.

• Support the machine with stands. Then stop the engine.

• Remove the crawler.

• Remove the screws (1) and the washers (2) by means of which the lower roller is fastened to the frame inside and outside. Then remove the lower roller (3).

• If necessary replace oil in the suggested quantity (75 cm3), through the filler.

• Exchange the roller position.

• Apply Loctite 262 on the screws thread (1) and assembly momentarily lower roller (3) on the frame of crawler shoe group.

• Assembly crawler.

• Remove stands to lower the machine to the ground.

Tighten screws (1).

• Tightening torque: 115 ± 2 Nm • Lift the machine again to adjust the crawler shoe tension.

NOTE: The collars (4) suit to the kind of crawler, modifying the assembly direction.

A. Rubber crawler shoe B. Steel crawler shoe

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-57

2. OPERATING INSTRUCTIONS

2.9

ROAD TRANSPORT

2.9.1

NORMS FOR TRANSPORT

• When transporting the machine on a trailer on public roads, you must know and observe all the Norms of the Highway Law as well as all provisions released by the different Agencies owning the roads (Municipality, Province, Region, State).

• 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 vary dependent upon the type of crawlers and/or front attachment installed.

• Investigate beforehand the conditions of the road you are going to travel, weight and size limits, and special local traffic regulations.

2.9.2

NORMS FOR LOADING/UNLOADING THE MACHINE ON A TRAILER

Always load/unload the machine on a firm level surface.

Thoroughly clean the flatbed 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°.

S WARNING Always select the slow travel speed mode (T) and 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 it meets the flatbed, is a sudden bump. Travel over the bump with extreme care and increase machine stability using the front attachment.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-58

2. OPERATING INSTRUCTIONS 2.9.3

LOADING THE MACHINE ON A TRAILER

Observe the following when loading the machine on a trailer.

NOTE: In cold weather, the machine should be properly warmed up before loading.

• Loading procedure may vary dependent upon whether the front attachment is installed or not.

With the front attachment installed: • Travel forward along the ramp with the front attachment at the front.

• Once at the ramp end and before the machine starts falling forward onto the flatbed (shifting the position of its centre of gravity), rest the bucket flat side onto the flatbed (boom to arm angle to be 90° to 110°).

• Slowly move forward until the crawlers are correctly positioned on the trailer platform.

• Slightly raise the bucket from the flatbed, retract the arm and keeping it tucked under, slowly swing the upper structure by 180°.

• Roll in the bucket and rest it on blocks of suitable matter and strength (for ex. wooden blocks).

With the front attachment removed: 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 ignition key from the start switch.

• Cycle the control levers to relieve any residual hydraulic pressure from the boom and arm drive cylinders.

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

• Close all windows, front windscreens, roof window, and cab door. Cover the exhaust pipe to prevent ingress of water or dirt.

• 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.

- Place wedges under the crawlers ends.

- Lock the front attachment (if fitted) to the flatbed using chains or metal cables of suitable size.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-59

2. OPERATING INSTRUCTIONS 2.9.4

UNLOADING THE MACHINE FROM A TRAILER

The following precautions should be observed while unloading the machine from a trailer: • unloading procedure may vary dependent upon whether the front attachment is installed or not.

With the front attachment installed: • travel slowly in reverse along the 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 to be 90° to 110°); • drive slowly forward while retracting the boom, extending the arm and repositioning the bucket resting onto the ground until the entire machine is unloaded.

With the front attachment removed: • travel forward down the ramp.

S WARNING Never change the travel speed mode while travelling downhill as it will create a very dangerous situation.

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 not violently hit the ground.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-60

2. OPERATING INSTRUCTIONS

2.10 SEA TRANSPORT 2.10.1 CRANING THE MACHINE FOR SEA TRANSPORT

S DANGER Metal cables or chains may break causing severe injuries.

Carefully inspect metal cables and/or chains prior to use and check for damages or wear. Always wear suitable protection gloves when handling metal cables or chains.

Use metal cables or chains of appropriate size according to the load to be raised.

Arrange the lifting sling with the utmost care to avoid any possible movement of the machine while it is being raised.

Crane the machine very slowly.

Ensure no one is under or near the machine while this is being raised: danger of death.

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 safety lever to end of travel to the LOCK position.

• Stop the engine and remove the ignition key from the start switch.

• Arrange the sling around the machine.

Take care to place protections (such as, rubber, crawler pieces, wooden blocks) to prevent any damage during craning, as shown in the figure.

• Check that the sling is correctly attached to the crane hook prior to start lifting.

• Ensure that no one is near.

Slowly raise the machine and check that it is correctly balanced when it is taken off the ground.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-61

2. OPERATING INSTRUCTIONS

2.11 PRECAUTIONS IN COLD WEATHER The antifreeze fluid is recommended for all climates: 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. If not, replace the radiator coolant with this mixture.

Flush the cooling system prior to filling with the antifreeze mixture (refer to the chapter “MAINTENANCE”).

S CAUTION Fluid under pressure. Turn cap or cover slowly before removing to relieve pressure.

We recommend to use AGRIFLU antifreeze fluid.

Refer to the below for mixing percentage according to outer temperature: Outer temperature (up to ...)

AGRIFLU

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” in the MAINTENANCE chapter.

NOTE: Do not use the machine immediately after first startup of the day or after prolonged inoperative time.

Always warm up hydraulic, engine and cylinder oil as detailed in the previous paragraphs.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-62

2. OPERATING INSTRUCTIONS

2.12 PROLONGED MACHINE INACTIVITY • Before operating the machine, check coolant level (or refill the system if drained) and lubrication conditions.

S DANGER Do not run the engine in confined spaces without proper ventilation and/or a suitable system capable of removing poisonous exhausts.

• Check battery charge each month and recharge, if necessary.

S WARNING Explosive gas is produced while batteries are being charged. Keep open flames and/or sparks away from the battery charging area. Remove cell plugs during recharging. Take care to make correct connections: Never connect a positive terminal (+) to a negative terminal (-).

• Inspect the machine. Repair damaged or worn parts. Install new parts, if necessary.

• Clean the air filter.

• Fully retract all cylinders, if possible. If not, coat the exposed cylinder rods with grease.

• Lubricate all grease points.

• Park the tracks on long stable blocks.

• Wash the machine.

• Remove the batteries and store in a dry protected place after charging fully. 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, crank the engine several turns (using the starter motor) to spread a protective coat of oil over cylinder walls. Reinstall injectors.

• Paint parts needing it to prevent rust formation.

• Store the machine in a dry protected place. If the machine is parked outside, cover it with a tarpaulin arranged as to consent ventilation. If not, humidity harmful to the machine may result.

• If the machine is to be stored for a prolonged period of time, operate travel, swing and digging hydraulic systems at least once per month to guarantee proper lubrication.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-63

2. OPERATING INSTRUCTIONS

2.13 USING THE MACHINE AFTER PROLONGED STORAGE

S DANGER Do not run the engine in confined spaces without proper ventilation and/or a suitable system capable to remove harmful 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 fluid.

• 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.

NOTE: After prolonged machine storage, perform all the operations detailed above and the following checks: a.

Check condition of all hoses and connections.

b.

Warm up the engine.

c.

Stop the engine.

d.

Install new fuel filters. Replace engine oil filters and top up engine oil.

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.

2.14 DECOMMISSIONING OF THE MACHINE

S WARNING • The decommissioning of the machine must be carried out exclusively by trained personnel, qualified and authorised to perform such operation.

• Start the removal of hydraulic components only after the same, the hydraulic oil and lubricants are completely cooled-off and after releasing residual pressures, as described by the Workshop Manual.

• Before proceeding with removal/disassembly operations, comply with the GENERAL SAFETY RULES and drain all components of the machine filled with fluids both in tanks and the relevant systems.

To demolish the machine, it is necessary to have access to specific equipment (hoist, hydraulic presses, containers for liquids, ect.) 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.

The machine contains: • Fluids under pressure (hydraulic system, cooling system, etc.).

• Gases (air conditioning system and accumulators, as applicable).

• Acid (batteries).

• Heavy components (booms, buckets, etc.).

Handle and dispose of fluids according to current regulations. Use only authorised disposal procedure. If in doubt, contact authorities concerned.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

2-64

3. OPTIONS AND VARIANTS

3. OPTIONS AND VARIANTS

3.1

HYDRAULIC BREAKER

3.1.1

HYDRAULIC BREAKER SELECTION AND INSTALLATION

If it is required to install a hydraulic breaker to the excavator, select a breaker model that meets the requirements of stability, pressure and oil quantity of the excavator hydraulic system.

S CAUTION Ask your dealer for the choice of the hydraulic breaker most suitable for your machine and also for the possible regulations of the feed capacity and of the working pressures needed by the choosen tool.

3.1.2

PRECAUTIONS WHEN USING THE HYDRAULIC BREAKER

S WARNING 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 (see LIFTABLE LOADS TABLE in the chapter OPERATING INSTRUCTION).

Avoid hitting objects with breaker. The breaker is heavier than the bucket and lowers faster. This may cause damages to the breaker, attachment, and upper structure.

WRONG

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 swing function to push objects as damages to the attachment may result.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

3-3

3. OPTIONS AND VARIANTS Do not operate the breaker with the excavator cylinders fully extended or retracted to avoid attachment and/or cylinder damage.

WRONG

Stop working if hydraulic hoses look abnormally bent.

Contact your authorised Dealer.

WRONG

Do not operate the hydraulic breaker in water. Doing so will cause rust and seal damage, resulting in damage to the hydraulic system components.

WRONG

Do not use the hydraulic breaker to move objects.

The excavator might overturn and/or the hydraulic breaker may be damaged.

WRONG

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

3-4

3. OPTIONS AND VARIANTS Do not operate the breaker to the side of the machine.

The machine may become unstable and undercarriage component life may be reduced.

WRONG

RIGHT RIGHT

WRONG

Operate the excavator carefully to avoid hitting the boom with the hydraulic breaker.

WRONG

Do not operate the breaker with the arm positioned vertically. Excessive vibration to the arm cylinder may cause oil leakage.

WRONG

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

3-5

3. OPTIONS AND VARIANTS Press the breaker so that the chisel point thrust is square (perpendicular) to the object to be broken.

RIGHT

WRONG

Do not operate the hydraulic breaker continuously longer than one minute. Excessive chisel wear will result. If an object could not be broken within one minute, apply chisel to other locations, less than one minute for each location.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

3-6

3. OPTIONS AND VARIANTS 3.1.3

HYDRAULIC BREAKER CONTROL

The hydraulic activation for the use of the hydraulic breaker is obtained with pedal (4) located on the left side of the steering column.

• Connect the hammer with suitable piping for quick connection tools (3) of the arm.

• Verify that selector (1) is in a position connecting the return from the hammer to the hydraulic tank. In the event the selector is not in such position, proceed as follows: - turn selector (1) into the position return of the hammer to the hydraulic tank, using a 24 mm wrench.

• Free hydraulic hammer pedal (4) moving pedal lock device (2) outward.

• To operate the hydraulic breaker, press pedal (4) on the right.

• To cut-off the operation of the hydraulic hammer, release pedal (4).

• The engine must be operated at 85% of rated speed while the work for breaker or nibbler.

• From time to time, stop the work for a while, and make the engine speed at idling to cool the hydraulic oil.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

3-7

3. OPTIONS AND VARIANTS

3.2

NIBBLER

3.2.1

NIBBLER SELECTION AND INSTALLATION

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.

Contact your authorised Dealer to select a type of nibbler suitable for this machine.

NOTE: For operations with nibbler, refer to the relevant Instruction Manual provided by the Manufacturer.

3.2.2

PRECAUTIONS TO BE OBSERVED WHEN USING THE NIBBLER

S WARNING 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 (see LIFTABLE LOADS TABLE in the chapter OPERATING INSTRUCTION).

1.

Do not allow the machine weight to be supported by prying with the nibbler and cylinders fully extended or retracted. Doing so may damage the front attachment. In particular, avoid doing so with the nibbler cylinder fully extended as the front attachment will be more easily damaged.

2.

Do not perform crushing on either side of the machine, always do so at front or rear, parallel with tracks. Otherwise, the machine may overturn.

WRONG

WRONG

S WARNING Works for the demolition of buildings and general structures present a high level of intrinsic risks. In the event a building must be demolished, using an excavator simply equipped with arms and bucket, the maximum working height must not exceed those allowed by local and national regulations.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

3-8

3. OPTIONS AND VARIANTS 3.

When operating the nibbler up high with the boom fully raised, be careful of falling objects.

4.

When operating the nibbler on a floor in a building, first confirm that the floor has sufficient strength to support the load caused by crushing in addition to machine weight.

5.

Always operate the nibbler on a firm level surface, not on a slope or crushed scraps.

6.

Do not use the nibbler to haul or move crushed scraps.

7.

Always remove the nibbler from the 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.

WRONG

WRONG

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

3-9

3. OPTIONS AND VARIANTS 3.2.3

NIBBLER CONTROL

To operate the nibbler, proceed as follows: • Connect nibbler with suitable pipings for quick connections (3) installed on the arm.

• Verify that selector (1) is in a position connecting the return from the nibbler to the hydraulic tank (see the position of the arrows indicated on the selector).

In the event the selector is not in such position, proceed as follows: - turn selector (1) into the position return of the nibbler to the hydraulic tank, using a 24 mm wrench.

• Free demolition nibbler pedal (4) moving pedal lock device (2) outward.

• Then press pedal (4) to carry out opening/closing operation of the nibbler.

• To cut-off the operation of the nibbler, release pedal (4).

2

4 1

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

3-10

3. OPTIONS AND VARIANTS 3.2.4

HYDRAULIC OIL AND FILTER ELEMENT SERVICE INTERVAL

When the hydraulic breaker is used, the excavator is subjected to working conditions more critical than usual, that speed up hydraulic oil deterioration and contamination.

To prevent damages to the excavator hydraulic system, breaker, carefully respect service intervals detailed in this Manual.

In particular, replace hydraulic oil and filter element according to the instructions below: Change interval (hours) Component to be replaced

Machine equipped with hydraulic breaker

Machine installed with bucket

Hydraulic oil

600 (*)

2500

Filter element

100 (*)

500

IMPORTANT: Change intervals shown should be applied if the machine is used 100% of the time equipped with the hydraulic breaker. In case of lower time percentage of breaker use, hydraulic oil and filter element change intervals may vary accordingly to the following diagram.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

3-11

3. OPTIONS AND VARIANTS NOTE:

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

3-12

4. MAINTENANCE

4. MAINTENANCE

4.1

SAFETY PRECAUTIONS DURING MAINTENANCE

S WARNING Do not allow unauthorised persons to maintain or repair this machine. Read carefully this Manual before starting, operating, maintaining, fuelling or servicing the machine.

Do not lubricate, repair or adjust a machine with the engine running, unless this is expressly required by the Operation and Maintenance Manual, to avoid being caught by moving parts or crushed by the machine.

Stop the machine in accordance with the procedure prescribed by the Operation and Maintenance Manual, prior to lubricating or performing any intervention.

Every time groups of the machine must be removed or installed, being lifted by jacks, ensure that the supports under the jack and between jack and machine are appropriate for the load to be supported.

Transfer immediately the load on appropriate supports and stands.

Do not loosen the connections of the hydraulic system located on the front equipment, unless the equipment has not first being lowered to the ground, totally flat and after discharging residual pressures.

In the event of a sudden cutting-off of the engine, lower the equipment to the ground as possible then, prior to operating on the hydraulic system, consult a Dealer.

Do not work on or under the machine or on its components if they are supported only by jacks or lifting devices, in accordance with local and national safety rules.

Do not work under or near the equipment of a machine or components which are not adequately supported or blocked.

Always shift the safety lever into the LOCK position prior to cleaning, repairing or intervening on the machine and after parking it, so that personal injuries are prevented.

Never use petrol, solvents or any other flammable solvent for cleaning operations. Use approved, non toxic non flammable commercial solvents.

Never use your hands to identify pressure leakages.

Leakages of fluids under pressure could have enough force to penetrate the skin. Press the pressure relief button, located on the hydraulic oil tank, before performing servicing on hydraulic system.

When servicing or maintenance require access to areas that cannot be reached from the ground, use a ladder or step platform that meet local and national regulations, to reach the service point. If such ladder or platform are not available, use the machine hand holds and steps as provided. Perform all service or maintenance carefully.

To reduce the risk of electrocution, use only grounded auxiliary devices, such as heaters, battery charges, pumps or similar equipment.

Prior to starting the engine, warn all persons performing operations or working around the machine.

When performing maintenance operations involving the handling of lubricant fluids, grease or coolant liquids, make sure that proper protective clothing and rubber gloves are worn to prevent contacts with eyes and skin.

A prolonged contact with such fluids with the skin can cause irritation and dermatitis.

In the event an accidental contact occurs, wash with plenty of water and seek medical attention, if required.

Keep hands and face away form loosen pipe connections, when efficiency and tightness tests for injectors and systems are performed. Also, wear protective glasses with side shields.

Do not work under or near a linkage of the equipment or other components of the machine which are not adequately supported and blocked.

Always shift the safety lever to lock position.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-3

4. MAINTENANCE

S 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.

Always use suitable tools to align holes. DO NOT USE HANDS OR FINGERS. 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.

4.2

GENERALITIES

To operate the machine correctly means to prolong its working life. Adhere to instructions to inspect and correctly 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.

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 from water and dampness.

• Never remove electrical components such as the main electronic central unit, sensors, etc. as they may be irreversibly damaged.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-4

4. MAINTENANCE 4.2.1

CHECKING THE HOUR-COUNTER 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.

4.2.2

SERVICE REMINDER PLATE

A plate (2) is located inside the toolbox showing main lubrication and cleaning operations and replacements to be carried out periodically.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-5

4. MAINTENANCE 4.2.3

PREPARING 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.

• Make sure that accelerator control lever is positioned on idle run.

• Bring then the ignition key to start in pull out position and remove the ignition key. (If maintenance is to be performed with the engine running, do not leave the machine unattended).

• Pull the safety lever (1) to the LOCK position.

• Before performing any maintenance work on the machine, maintenance men 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 left 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 matter 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.

S CAUTION 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.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-6

4. MAINTENANCE 4.2.4

HOOD AND ACCESS COVERS

S WARNING 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 • Open engine hood.

• Insert the key in the lock.

• Release cylinder lock and open the hood.

• Keep the hood open by means of provided holder.

Tanks compartment door (machine left side) • Insert key in the lock.

• Release cylinder lock and open the hood.

Radiator case cover (machine right side) • Insert key in the lock.

• Release cylinder lock and open the cover.

Air filter compartment door (under the operator’s seat) • Insert key in the lock.

• Release cylinder lock and open the door.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-7

4. MAINTENANCE

4.3

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.

Crawler shoe rollers and tensioners: oil leaks.

1.

Oil leakage from the hydraulic system; dirt buildup on the hydraulic cylinders and leaks.

2.

Loose bolts, nuts, and/or straps; worn or damaged parts.

3.

Failed or inoperative gauges.

12. Dirt build-up in air filter intake.

4.

Dirt build-up in the radiator grid.

13. Attachment conditions.

5.

Oil and water leaks in the engine.

6.

Roller lateral reduction gears: oil leaks.

7.

Dirt build-up in the crawler shoe carriages.

8.

Retaining hardware and general condition of crawler shoes.

9.

10. Chain tension, grease leaking from the crawler shoe.

11. Instable electric contacts.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-8

4. MAINTENANCE

4.4

CHECKS BEFORE STARTING DAILY WORK ITEM TO BE CHECKED

Replace

Lubricate

Clean

Check

Engine oil Engine cooling system Hydraulic system oil Fuel tank Windscreen washer tank Fuel pre-filter

4.4.1

ENGINE OIL

(Visual inspection and topping-up)

S DANGER Do not run machine engine in confined spaces without proper ventilation and/or suitable system capable to remove harmful exhaust gases.

S WARNING Always ensure that the engine hood, once in the open position, is securely locked by means of the locking rod: danger of personal injury.

S CAUTION Remember that engine and engine oil can reach very high operating temperatures. It is essential, during this operation with the engine still hot, to protect your body using suitable clothing and protections as there is the danger of burns and personal injury.

IMPORTANT: Check oil level with the engine cold and stopped.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-9

4. MAINTENANCE In the event the check is made at the end of the work shift, comply with the following: • Ensure that the machine is positioned on a flat surface.

• Rest the bucket on the ground.

• Shift accelerator lever to idle run, switch off engine, pull out ignition key and place safety lever on LOCK. • Wait until the machine is cold.

• Open engine hood described in the Paragraph “ENGINE HOOD AND ACCESS DOORS”.

• Pull out the dipstick (1), wipe it clean using a clean cloth and insert it again into its seat. Pull it out again and check the level. The level should be between the MIN and MAX marks indicated on the dipstick.

NOTE: Insert the dipstick into its seat slowly to prevent that pressure may alter the level check.

• If a low engine oil level is indicated, remove the plug (2) and restore correct level by adding oil through the filler neck.

• Close the engine hood.

IMPORTANT: Do not add oil with different characteristics from the oil already in the engine (see “FILLING CHART” in this chapter).

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-10

4. MAINTENANCE 4.4.2

ENGINE COOLING SYSTEM

(Visual inspection of engine coolant level and topping-up)

S CAUTION When the engine is hot, do not remove the plug from the expansion tank or from the radiator: danger of burns.

In the event the check is made at the end of the work shift, comply with the following: • Ensure that the machine is positioned on a flat surface.

• Rest the bucket on the ground.

• Shift accelerator lever to idle run, switch off engine, pull out ignition key and place safety lever on LOCK. • Wait until the machine is cold.

• Open the engine hood and hold it open.

• The coolant level must be checked with cold engine and it must be between the FULL and LOW reference marks visible on expansion tank (1).

• In case the level is insufficient, remove cap (2) and top-up the level, through the filler neck, until it reaches the FULL mark.

• Re-install cap (2) and close the doors.

IMPORTANT: when topping up, keep the water and antifreeze percentage existing in the system. Use clean water and free from chlorinated compounds whenever possible (see “FILLING CHART” in this chapter).

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-11

4. MAINTENANCE 4.4.3

HYDRAULIC SYSTEM OIL

(Visual inspection and topping up)

S CAUTION During work components and lines composing the hydraulic system can reach high temperatures. Shut off the machine and let it cool down before starting any inspection or maintenance: danger of burns.

In the event the check is made at the end of the work shift, comply with the following: • Position the equipment as illustrated in the figure.

• Shift accelerator lever to idle run, switch off engine, pull out ignition key and place safety lever on LOCK. • Open the tanks compartment door, check on visual indicator (1), located on the hydraulic oil tank, the oil level should be visible from the visual check.

• In the event a low level of the hydraulic oil is found, proceed wit its topping-up, operating as indicated in the 2500 WORK HOURS MAINTENANCE paragraph “HYDRAULIC SYSTEM OIL”.

• Close the tanks compartment door.

IMPORTANT: Do not top up using oil with different specifications from the oil already in the hydraulic oil tank (see “FILLING CHART” in this chapter).

IMPORTANT: If the machine was filled with biodegradable hydraulic oil (option), take note that this oil cannot be mixed with mineral hydraulic oil.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-12

4. MAINTENANCE 4.4.4

FUEL TANK

(Visual inspection of fuel level and refuelling)

S WARNING 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 with the engine running. Do not use matches, cigar lighters or torches as light source on the machine.

In the event the check is made at the end of the work shift, comply with the following: • Ensure that the machine is positioned on a flat surface.

• Rest the bucket on the ground.

• Shift accelerator lever to idle run, switch off engine, pull out ignition key and place safety lever on LOCK. NOTE: For refuelling use decanted fuel. 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 tank as this would cause air to enter the fuel system. The fuel system should then be bled from air.

• Open the filler neck (2) using the key supplied and refuel.

• Then check indicator (1) to determine the level of fuel reached.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-13

4. MAINTENANCE 4.4.5

WINDSCREEN WASHER TANK

(Checking the level and topping up)

S WARNING The pure detergent liquid catches fire easily when in touch with comburent substances or in presence of incendive sources (sparks, open flames,). Avoid smoking during windscreen washer liquid refuelling.

This operation should be carried out consistently with how frequently the windscreen washer is used.

• Remove the plug (1) located on the tank (2) and add water and glass detergent in the tank. During the cold weather, use a glass detergent for all seasons.

4.4.6

FUEL PRE-FILTER

(Visual inspection and possible water discharge) Draining the water Proceed to water drain present inside the fuel prefilter (1) as follows: • Open the engine hood and lock it open.

• After cooling down each portion, push the handle (2) of the water separator upward to the “CLOSE” position.

• Loosen the ring (3) to remove the case (4), and drain the water out.

NOTE: Pay attention not to loose the red float (5) and spring (6).

• Check the water drained for its contamination. And when it is dirty, clean up the element (7) and inside of the case (4).

• Remove the element (7), and clean it with diesel fuel.

• Replace the O-ring (8) with a new one.

• Install the element (7) to the water separator body.

• Set the O-ring (8) to the case (4), then tighten it up with ring (3).

• Push the handle downward to set at “OPEN” position.

• After draining water, make sure to bleed out the air releasing for the fuel system.

NOTE: Do not clean up the element with gasoline.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-14

4. MAINTENANCE

4.5

MACHINE LUBRICATION AND MAINTENANCE GENERAL CHART

SERVICE INTERVALS (HOURS) 50 250 500 1000 2000

0.33 l

3.5 l

DESCRIPTION OF SERVICE Bucket links

4-16

Slewing ring bearing

4-17

Boom and arms

4-18

Arm swinging cylinder

4-19

Tracks

4-20

Hydraulic oil tank

4-25

Travel reduction gears oil

4-26/4-55

Air cleaner (*)

4-27/4-46

Hardware tightening torques

4-28

Hoses, lines and connections

4-34

Fuel hoses

4-37

Travel motor pinion, slewing ring teeth

4-38

Engine oil and filter

4-39

Fuel filter

4-41

Engine cooling system

3.7 l

22 l

PAGES

4-43/4-52

Hydraulic system return oil filter

4-44

Fuel pre-filter

4-48

Alternator - fan belt

4-50

Hydraulic system oil (**)

4-57 Replace

(**) IMPORTANT: if the machine has been refilled with biodegradable hydraulic oil (on demand), be informed this oil cannot be mixed with mineral hydraulic oil.

Lubricate Clean

( * ) Service to be carried out when the relative warning light comes on.

Check

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-15

4. MAINTENANCE

4.6

AFTER 50 HOURS OF OPERATION ITEM TO BE CHECKED

Replace

Lubricate

Clean

Check

Bucket links Slewing ring bearing Boom and arms Arm swinging cylinder

4.6.1

BUCKET LINKS

(Lubrication) • Ensure the machine is parked on a level surface.

• Rest the bucket to the ground.

• Shift accelerator lever to idle run, switch off engine, pull out ignition key and place safety lever on 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.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-16

4. MAINTENANCE 4.6.2

SLEWING RING BEARING

(Lubrication)

S WARNING The lubrication of the slewing ring, of the gear and the upper structure swing 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: • Park the machine on a level surface.

• Rest the bucket to the ground.

• Shift accelerator lever to idle run, switch off engine, pull out ignition key and place safety lever on LOCK. • With upper frame stopped, inject grease of the prescribed type (see “TABLE OF REFILLINGS” in this chapter) by grease gun (1).

• Start the engine, raise the bucket approximately 20 cm from the ground and swing the upper structure by 45° (1/8 of a turn).

• Lower the bucket to the ground.

• Repeat the procedure above three times. Always observe safety precautions supplied at the beginning of the paragraph.

• Grease should be injected until it is seen coming out of the seals. Do not inject excess grease.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-17

4. MAINTENANCE 4.6.3

BOOM AND ARMS

(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 safety ladders during lubrication.

• Shift accelerator lever to idle run, switch off engine, pull out ignition key and place safety lever on LOCK. By means of a greasing pump, inject grease of the prescribed type (see “TABLE OF REFILLINGS” in this chapter) in the greasing guns of the joints, showed with the arrows, until grease comes out.

F22061

F22062

F22063

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-18

4. MAINTENANCE 4.6.4

ARM SWINGING CYLINDER

(Lubrication) • Position the machine on a flat surface.

• Lay the bucket on the ground and position the arm in such a way that all indicated greasing point are easily accessible.

• Shift accelerator lever to idle run, switch off engine, pull out ignition key and place safety lever on LOCK. By means of a greasing pump, inject grease of the prescribed type (see “TABLE OF REFILLINGS” in this chapter) in the greasing guns of the joints, showed with the arrows, until grease comes out.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-19

4. MAINTENANCE

4.7

AFTER 250 HOURS OF OPERATION TRACKS ITEM TO BE CHECKED

Replace

Lubricate

Clean

Check

Tracks Hydraulic oil tank Travel reduction gear oil Air cleaner (*) Hardware tightening torques Hoses, lines and connections Fuel hoses Travel motor pinion, slewing ring teeth Engine oil and filter

4.7.1

3.5 l

TRACKS

(Adjusting tension)

S WARNING Fluid under pressure. Proceed as detailed in this paragraph to reduce or increase crawler shoe tension.

The crawler shoe adjust wheel return spring is installed on the machine with a high compression load. Follow the procedure detailed in the “WORKSHOP MANUAL” for assembling/disassembling it.

Carry out this maintenance work paying the utmost attention to the safety precautions for personal safety.

In case of doubt, even minimum, contact your Dealer: do not act on your own initiative as this may prove dangerous.

This work should be carried out by two persons. The operator should move the machine in accordance with the signals by the ground assistant. If the tracks are to be inspected visually while in motion, always keep at a safe distance and outside the machine operating range.

All services to the tracks should be carried out with the machine controls in the following positions: • accelerator lever on idle run; • engine off; • ignition key removed; • safety lever in the locked position (LOCK).

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-20

4. MAINTENANCE Checking crawler shoe sag NOTE: Check crawler shoe sag after thoroughly removing dirt stuck on the crawler shoe by pressure-washing.

• Turn the upper structure 90° and lower the bucket to raise one crawler shoe off the ground as shown.

• Keep the angle between boom and arm 90° to 110° and rest the bucket round side (outer) onto the ground.

• Place blocks under the frame to support the machine.

• Rotate the raised crawler shoe in reverse two full rotations, then forward two full rotations.

• Measure the distance (A) between lower part of crawler shoe and upper part of crawler shoe in the middle of the crawler shoes frame.

Correct value (tension) (A): - rubber crawler shoe: 35 - 45 mm - steel crawler shoe: 75 - 80 mm IMPORTANT: In case the machine is employed mainly on gravelly, muddy or with rocky bumps soils, we recommend to carry out the crawler tension check daily.

• If crawler shoe sag is not within specification, loosen or tighten the crawler shoe following the procedures detailed below.

Loosening the crawler shoe

S WARNING Do not loosen the valve (1) quickly or too much as grease pressure inside the cylinder might dangerously eject it off its seat. Loosen the valve with care, keeping the body parts and face away from the valve (1).

IMPORTANT: Remove any matter such as mud or gravel possibly stuck between sprockets and crawler shoe links before loosening.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-21

4. MAINTENANCE • To loosen the crawler shoe chain, turn slowly valve (1) anticlockwise.

Then, the grease shall start getting out the base of the valve.

• 1 to 1.5 turns of the valve (1) are sufficient to loosen the track.

• If grease does not come out evenly, slowly rotate the raised track.

• When proper crawler shoe sag is obtained, turn valve (1) clockwise and tighten.

Tightening torque: 59 ± 10 Nm.

Tightening the crawler shoe

S WARNING It is abnormal if the crawler shoe remains tight after turning valve (1) anticlockwise or if the crawler shoe is still loose after charging grease through the grease fitting (1). In such cases NEVER ATTEMPT TO DISASSEMBLE the crawler shoe or the crawler shoe adjuster due to dangerous high-pressure grease inside the crawler shoe adjuster. Contact your Dealer immediately.

• To tighten the crawler shoe, inject grease from a grease gun into fitting (1) until sag is within specification.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-22

4. MAINTENANCE Check of the crawler shoe Repair or replace the rubber crawler shoe under following conditions.

Ask and authorized Dealer for repairs or replacement of the rubber crawler shoe.

• Lugs height - When the lugs (5) wear, the traction decreases.

Replace the rubber crawler shoe (2) if dimension (A) is lower than 5 mm.

- Replace rubber crawler shoe (2) if the lug (5) is so worn out that the steel frame is visible on two links.

• Breaking of the steel frame - Replace the rubber crawler shoe (2) if the steel frame of the crawler shoe (1) is broken beyond the half of a row.

• Crack of the rubber crawler shoe - Repair the rubber crawler shoe if you notice a crack with length equal or bigger than 60 mm between the rubber crawler shoe and the lug: (8): necessary repair (6): necessary repair with crack length of 60 mm or more.

- If anyway, because of a short/little crack, the frame is visible, the crawler should be repaired immediately.

(7): repair not yet necessary.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-23

4. MAINTENANCE • Detachment of the metal core - According to the rubber crawler shoe stress (2), the metal core (3) can detach from the inner face (1) because it comes in contact (10) with the lower rollers (4) and the track idler/sprocket or according to the rubbing, even though from the lug side (outer face) outer damages are not visible or rubbing wear.

NOTE: • The metal core can detach easily if the rubber crawler shoe is not used correctly.

• No warranty is valid if the rubber crawler shoes are used under not corresponding or if their tension is inadequate.

- Replace rubber crawler shoe on which the metal core (3) detaches, even only in one point.

- Replace the rubber crawler shoe torn on which the metal core (3) is naked.

- The repair is not necessary in case of a crack (9) on the contact surface between the metal core and the roller.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-24

4. MAINTENANCE 4.7.2

HYDRAULIC OIL TANK

(Condensation discharge)

S WARNING The hydraulic oil tank is pressurized. Release filling plug slowly before carrying out maintenance.

Danger of damages to people.

• Park the machine on a level surface and turn the upper structure 90° to obtain easy access.

• Rest the bucket to the ground.

• Shift accelerator lever to idle run, switch off engine, pull out ignition key and place safety lever on LOCK. • Wait until machine cools down.

• Loosen plug (1) located on the tank to release pressure inside.

S CAUTION Do not release the drain plug until oil has properly cooled down. Contact with hydraulic oil at working temperature may cause burns and personal injuries.

• When oil is cold, release the drain plug (2) and 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.

• After draining, fully tighten the plug (2).

Handle and dispose of water mixed to hydraulic oil according to current regulations. Use only authorised disposal procedure. If in doubt, contact authorities concerned.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-25

4. MAINTENANCE 4.7.3

TRAVEL REDUCTION GEAR OIL

(Check)

S WARNING Travel reduction gears and oil therein can reach high operating temperatures. Therefore, the body must be protected with suitable clothing, glasses and protections to avoid burns and personal injuries.

Slowly loosen the filler/drain/level threaded plug from the reduction units. This is to slowly relieve the pressure which builds up inside the reduction gears.

When checking oil level, stay at the side of the reduction units for protection and wear safety glasses. Filler/drain/level plug alignment procedure, which is described below, is to be carried out with the help of a ground assistant. The assistant must stay clear of the machine operating range. Never service or inspect travel motor circuits when on slope. They are under high pressure due to machine weight.

• Park the machine on a level surface. The side reduction gears should be positioned as to have the plugs (1) and (2) as shown. Observance of this position is essential to proper servicing.

• Rest the bucket to the ground.

• Shift accelerator lever to idle run, switch off engine, pull out ignition key and place safety lever on LOCK. • Wait until the machine is cold.

• Slowly release the threaded plug (1) gradually relieving pressure from inside the reduction unit.

After relieving pressure, fully remove the plug (1) from its seat.

• Check oil level inside the travel reduction gears through the plug (1) seat. Oil level should be flush with the hole. If oil is low, top up through the hole of plug (1) until oil comes out of the hole of plug (1).

• Reinstall the threaded plugs (1).

The above operation should be carried out on both travel side reduction units.

IMPORTANT: Do not top up using oil with different specifications than the one already contained in the travel side reduction units (see “FILLING CHART” in this chapter).

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-26

4. MAINTENANCE 4.7.4

AIR CLEANER

(Check) IMPORTANT: operation to be performed also in the case of activation of the relevant indicator light on the display of the monitor.

S CAUTION Always wear safety glasses with side shields when using compressed air to clean parts to reduce the risk of personal injuries due to projected particles. Limit pressure to 0.2 MPa (2 kg/cm2).

Proceed with air cleaner outer element cleaning as follows: • Position the machine on a flat surface.

• Rest the bucket to the ground.

• Shift accelerator lever to idle run, switch off engine, pull out ignition key and place safety lever on LOCK. • Open air filter compartment door. Press on the tang.

• Turn the cover (1) counter-clockwise and remove it.

• Clean the element (2) with compressed air. Direct the air jet from the inside of the filter towards the outside.

• Check that there are no holes or cuts in the filter placing a light inside the filter. The light shows holes or cuts in the filter. In this case replace it.

• Insert the element (2), making sure that it seats properly, assembly the cover (1) and turn it clockwise.

• Close the air filter compartment door.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-27

4. MAINTENANCE 4.7.5

HARDWARE TIGHTENING TORQUES

(Check) • Position the machine on a flat surface so as to facilitate the check of the tightening torque of the fastening screws.

• Rest the bucket to the ground.

• Shift accelerator lever to idle run, switch off engine, pull out ignition key and place safety lever on LOCK. • Tightening torques should be checked using a suitably pre-set torque wrench.

Engine mounting bolts

S WARNING Always ensure 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 silent blocks retaining bolts: - Nut: - Torque: - Bush:

M10 34 ± 3.4 Nm 17 mm

B) Engine bracket retaining bolts: - Bolt: - Torque: - Bush:

M10 x 20 46.1 ± 4.9 Nm 17 mm

• Close engine hood and lock it using the two catches.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-28

4. MAINTENANCE Fuel tank retaining bolts • Open the door of the tank compartment • Check tightening torques of the following bolts: - Bolt: - Torque: - Bush:

M10 x 25 46.1 ± 4.9 Nm 17 mm

• Reinstall protection panel and associated retaining bolts.

Hydraulic oil tank retaining bolts • From under the machine, loosen the protection panel retaining bolts at the hydraulic oil tank and remove panel.

• Check tightening torques of the following bolts: - Bolt: - Torque: - Bush:

M10 x 25 46.1 ± 4.9 Nm 17 mm

Hydraulic hose connections • Check hydraulic hose connection tightening torque as follows: - Wrench: - Torque:

19 mm and 17 mm 45 ± 0.5 Nm

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-29

4. MAINTENANCE Retaining bolts engine hydraulic pump • Open the tanks compartment door and the engine hood and keep them widely open by means of the safety device.

• Proceed with check of tightening torque, hereunder indicated, of the hydraulic pump retaining bolts: - Bolts TCE: - Torque: - Bush:

M12 x 40 103.9 ± 10.4 Nm 10 mm

• After checking, close the cover.

Control valve to bracket retaining bolts • Check control valve to bracket retaining bolt torque as follows: - Bolt: - Torque: - Bush:

M8 x 60 33.3 ± 3.4 Nm 13 mm

Control valve bracket to frame retaining bolts • Check control valve bracket to frame retaining bolt torque as follows: - Bolt: - Torque: - Bush:

M8 x 20 33.3 ± 3.4 Nm 13 mm

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-30

4. MAINTENANCE Swing reduction gears retaining bolts • Check torque of the swing reduction gears retaining bolts as follows: - Bolt TCE: - Torque: - Bush:

M12 x 40 114.7 ± 11 Nm 10 mm

Canopy mounting bolts • Raise the rubber mat covering the cab floor to gain access to the cab to machine frame mounting nuts.

• Check cab mounting nut torque as follows: - Screws: - Torque: - Bush:

M16 x 55 191 ± 20 Nm 24 mm

Swing bearing retaining bolts • Check torque of the swing bearing to carriage bolts (A) and swing bearing to upper structure bolts (B) as follows: Swing bearing to carriage bolts (A): - Bolt: - Torque: - Bush:

M12 x 50 115 ± 12 Nm 19 mm

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-31

4. MAINTENANCE Swing bearing to upper structure bolts (B): - Bolt: - Torque: - Bush:

M12 x 45 115 ± 12 Nm 19 mm

Travel reduction gears retaining bolts • Check torque of the travel reduction gears to carriage bolts (A) and ring gear to reduction gears bolts (B) as follows: • Loosen the bolts retaining the reduction gears inner protection and remove protection.

Travel reduction gears to carriage bolts (A): - Bolt TCE: - Torque: - Bush:

M10 x 25 54.9 ± 5.5 Nm 61 mm

• After checking, reinstall the reduction gears inner protection and associated retaining bolts.

Ring gear to reduction gears bolts (B): - Bolt TCE: - Torque: - Bush:

M10 x 25 54.9 ± 5.5 Nm 61 mm

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-32

4. MAINTENANCE Supporting pads retaining bolts • Proceed with check of tightening torque, hereunder indicated, of supporting pads retaining bolts: - Bolt TCE: - Torque: - Bush:

M10 x 20 54.9 ± 3 Nm 6 mm

Lower roller retaining bolts • Check lower roller retaining bolt torque as follows: - Bolt: - Torque: - Bush:

M12 x 25 115 ± 2 Nm 19 mm

Counterweight retaining bolts • Proceed with check of the tightening torque, hereunder indicated, of the counterweight retaining bolts: - Bolt: - Torque: - Bush:

M16 x 40 279 ± 29 Nm 24 mm

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-33

4. MAINTENANCE 4.7.6

HOSES, LINES AND CONNECTIONS

(Check and assembly instructions)

S CAUTION Always ensure that engine hood is correctly locked in the open position. Danger of personal injuries.

Bring safety lever in LOCK position.

• Escaping fluid under pressure can penetrate the skin causing severe injuries. Use a piece of cardboard when checking for leaks.

• Protect hands and body from high pressure fluids.

In case of accidents, seek immediate medical care specialised for this type of injuries. Any fluid penetrated under the skin should be surgically removed within few hours as gangrene may result.

• Hydraulic oil and lubricant leakage may start 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 and be a cause for possible personal injuries.

• Keep body parts and face far from plugs and bolts during removal.

• Hydraulic components can be under pressure even after cooling down.

• Never service or inspect travel or swing motor circuits when on slope. 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, press the pressure discharge button located on the hydraulic tank prior to starting any maintenance work.

• Hydraulic components can become very hot during operation. Wait until the machine has cooled down before starting inspection or maintenance.

F3636

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-34

4. MAINTENANCE • Ensure that the machine is positioned on a flat surface.

• Rest the bucket on the ground.

• Shift accelerator lever to idle run, switch off engine, pull out ignition key and place safety lever on LOCK. • Wait until the machine cools down.

• Open the engine hood, the tanks compartment door, the air filter compartment doors and radiator locking them in open position, as described in the paragraph “ENGINE HOOD AND ACCESS DOORS”.

Hoses and lines check • Check for missing or loose clamps, kinked hoses, line-to-hose rubbing. Check oil cooler for damages.

Check proper tightening of the oil cooler flange bolts.

This check will also exhibit possible leaks.

• Check the hoses, lines and oil cooler at the check points listed below to assess possible damages which may be the cause for future leaks. 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 the following precautions: - wash pipes and hoses both, inside and outside, with washing fluid and thoroughly dry them before reconnecting; - use exclusively O-Ring seals without damages or faults. Pay attention not to damage seals during assembly; - do not kink high pressure hoses when connecting them. Duration of kinked hoses is drastically reduced; - carefully tighten the low pressure hose clamps to the torque of 0.6 ÷ 0.7 da Nm. Do not overtighten.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-35

4. MAINTENANCE TIGHTENING TORQUE FOR FITTINGS AND HYDRAULIC HOSES O-ring connection for Jis seat Nominal dimension

Wrench (mm)

Tightening torque daNm

1/8

14

0.17 ± 0.2

1/4

19

0.37 ± 0.2

3/8

22

0.75 ± 0.5

1/2

27

1.10 ± 1.0

3/4

36

1.65 ± 1.0

1

41

2.60 ± 1.0

Hydraulic hoses with BSP seal at 60° Nominal dimension

Wrench (mm)

Tightening torque daNm

1/8

14

0.15 ± 0.2

1/4

19

0.30 ± 0.5

3/8

22

0.50 ± 0.5

1/2

27

0.80 ± 0.5

3/4

36

1.20 ± 1.0

1

41

1.40 ± 1.5

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-36

4. MAINTENANCE 4.7.7

FUEL HOSES

(Check)

S WARNING Never use gasoline, solvents or other flammable fluids to wash components. Use approved, non flammable, non toxic commercial solvents only. Always make sure that the engine hood, once opened, has the locking device securely engaged; there is a danger for personal injuries.

S CAUTION You are reminded that the engine can reach a high temperature during operation. Protect body and limbs with appropriate clothing and protections, since there is a danger for burns and personal injuries.

• Place the machine on a flat surface.

• Rest the bucket on the ground.

• Shift accelerator lever to idle run, switch off engine, pull out ignition key and place safety lever on LOCK. • Wait for the machine to cool-off.

• Open the engine hood, the tanks compartment door, as described in the paragraph “ENGINE HOOD AND ACCESS DOORS”.

• 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.

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.

• Close the engine hood.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-37

4. MAINTENANCE 4.7.8

TRAVEL MOTOR PINION, SLEWING RING TEETH

(Lubricate) • 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.

• Shift accelerator lever to idle run, switch off engine, pull out ignition key and place safety lever on LOCK. By means of a greasing pump, inject grease of the prescribed type (see TABLE OF REFILLINGS in this chapter) in the grease gun of the arrow spotted joint.

Insert 2 cm3 of grease.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-38

4. MAINTENANCE 4.7.9

ENGINE OIL AND FILTER

(Replace)

S DANGER Do not run the engine in closed spaces without proper ventilation and/or an adequate system capable to remove noxious exhaust gases.

S WARNING Always ensure that engine hood is correctly locked in the open position. Danger of personal injuries.

Remember that engine and oil can reach high working temperatures. Therefore, while carrying out this operation when the engine is still hot, the body must be protected with suitable clothing and protections to avoid burns and personal injuries.

S CAUTION Avoid prolonged repeated skin contact with exhaust engine oil as skin diseases or other syndromes may result. If this happens, thoroughly wash the area of contact.

• Park the machine on a level surface.

• Rest the bucket to the ground.

• Shift accelerator lever to idle run, switch off engine, pull out ignition key and place safety lever on LOCK. • Wait until the machine has cooled down.

• Open engine hood and lock it in the raised position as detailed in the paragraph “HOOD AND ACCESS COVERS”.

• Remove plug (2) and extract dipstick (1). These two operations provide a faster draining of the oil contained by the sump.

• Get under the turret, loosen the screws securing guard (3) and remove it from its seat.

• Unscrew plug (4), this will allow old oil to flow into a proper container.

• Once this drain operation is completed reassemble plug (4) and guard (3).

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-39

4. MAINTENANCE Replace filter (5) proceeding in the following manner: • clean the contact area and around the filter; • loosen filter (5) using a general tool; • lubricate the gasket of the new filter with engine oil.

• hand tighten the filter until the gasket touches support; • tighten the filter further 3/4 turn using a general tool.

Handle and dispose of exhausted engine oil and filters, in accordance with current regulations. Use only authorised disposal procedure and, in case of doubt, contact the appropriate authorities.

Proceed with the filling of oil of the type, gradation and quantity prescribed (see “FILLING CHART” in this chapter) as follows: • pour oil into the engine through filler neck (2) until the maximum level indicated on dipstick (1) is reached; • then, tighten plug (2) and insert dipstick (1); • start the engine, let it run a few minutes then cut it off; • use dipstick (1) to check again the level and top-up in the event it has changed with respect to the previous check.

NOTE: Insert the dipstick slowly into its seat so as to prevent that pressure alters the reading of the level.

• Close the engine hood.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-40

4. MAINTENANCE

4.8

AFTER 500 HOURS OF OPERATION DESCRIPTION OF SERVICE

Replace

Lubricate

Clean

Check

Fuel filter Engine cooling system Hydraulic system return oil filter

4.8.1

FUEL FILTER

(Replace)

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

Always ensure that engine hood is correctly locked in the open position. Danger of personal injuries.

S CAUTION Remember that engine and oil can reach high working temperatures. Therefore, while carrying out this operation when the engine is still hot, the body must be protected with suitable clothing and protections to avoid burns and personal injuries.

S WARNING Pay attention, during the removal phase, to avoid spilling the fuel inside the filter: there is a danger of fires.

• Park the machine on a level surface.

• Rest the bucket to the ground.

• Shift accelerator lever to idle run, switch off engine, pull out ignition key and place safety lever on LOCK. • Wait until the machine has cooled down.

• Open engine hood and lock it in the raised position as detailed in the paragraph “HOOD AND ACCESS COVERS”.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-41

4. MAINTENANCE Replace the filter proceeding as follows: • clean the area around the filter (1) and support (2); • set the handle (3) of fuel filter at “CLOSE” position.

And remove the retaining ring (4), and take the element (5) out of the cup case (6). At this time, care must be exercised not to miss the spring which is placed in the cup case.

For the sake of safety and in order not to make the ground dirty, make sure to discharge the fuel into the container and make the around clean; • replace element (6) and O-ring (7) with new ones; • reassembly following the opposite sequence of the described procedure.

Bleeding air • Bleed air which entered the fuel system during filter replacement as follows: - loosen the bleed screw (8) to allow air to bleed; - repeatedly press the button (9) located on the priming pump to circulate fuel inside the fuel system; - continue priming until a minimum amount of fuel free of bubble comes out of the loosened bleed screw (8). Close the screw; - start the engine.

• Close the engine hood.

Handle and dispose of used fuel filters according to current regulations. Use only authorised disposal procedures.

If in doubt, contact authorities concerned.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-42

4. MAINTENANCE 4.8.2

ENGINE COOLING SYSTEM

(Radiators cleaning)

S WARNING Always ensure that engine hood is correctly locked in the open position. Danger of personal injuries.

S CAUTION Compressed air or pressure water jets will be used to perform this operation. Therefore, suitable clothing must be used to protect the body. In particular, wear glasses with side shields. Keep people not involved in the maintenance work outside the working area.

• Ensure that the machine is positioned on a flat surface.

• Rest the bucket on the ground.

• Shift accelerator lever to idle run, switch off engine, pull out ignition key and place safety lever on (LOCK).

• Open the radiator compartment panel and the engine hood and secure them in open position as described in paragraph “HOODS AND ACCESS PANELS”.

• Using compressed air or a jet of water, clean accurately, directing the jet from the upper part of the radiators toward the bottom.

• Once the cleaning operation is complete, close the engine hood and the radiator door.

IMPORTANT: Use compressed air or pressure water not exceeding 0.2 MPa (2 kg/cm2) to avoid damaging radiator fins and coils.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-43

4. MAINTENANCE 4.8.3

HYDRAULIC SYSTEM RETURN OIL FILTER

(Replace)

S WARNING The components and pipes of the hydraulic system can reach high temperatures. Thus it is recommended to cut-off the machine and let it cool-off prior to performing any inspection or maintenance operation. Danger of burns. The hydraulic oil tank is pressurised. Press the button on the tank to bleed the pressure prior to performing maintenance operations. Danger of personal injuries.

• Stop the machine on a flat surface and lay the tool as shown in the figure.

• Shift accelerator lever to idle run, switch off engine, pull out ignition key and place safety lever on (LOCK).

• Wait until the machine has cooled down.

• Loosen the cap (1) located on the tank so as to release the pressure inside of the tank.

S WARNING Under the cover (2) there is a loaded spring (5).

Loosen the bolts (3) slowly to avoid sudden spring release.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-44

4. MAINTENANCE • Loosen the bolts (3) which retain the cover (2) as follows: - loosen two of the four bolts (3); - hold the cover (2) down and loosen the last two bolts (3). This is to avoid sudden release of the spring (5); - remove cover (2); • Remove spring (5) and filtering element (6).

• Replace the filter element (6) and the O Ring seal (4).

• Insert in the tank housing the new filtering element (6) and the spring (5).

• Install cover (2) with a new O-Ring seal (4).

• Install the six cover retaining bolts (3) and tighten to 23.5 daNm. Handle and dispose of hydraulic system return oil filter according to current regulations. Use only authorised disposal procedure. If in doubt, contact authorities concerned.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-45

4. MAINTENANCE

4.9

AFTER 1000 HOURS OF OPERATION DESCRIPTION OF SERVICE

Replace

Lubricate

Clean

Check

Air cleaner Fuel pre-filter Alternator - fan belt Hydraulic system oil

4.9.1

3.7 l

AIR CLEANER

(Air cleaner replacement) IMPORTANT: The normal maintenance interval prescribes the replacement of the outer element of the air cleaner any 1000 hours. Under particular ambient conditions (very dusty areas) it is recommended to reduce the replacement interval at least 50%.

Proceed with replacement of the air cleaner as follows: • Stop the machine on a flat surface.

• Rest the bucket on the ground.

• Shift accelerator lever to idle run, switch off engine, pull out ignition key and place safety lever on (LOCK).

• Open the door of the air cleaner compartment, as described under paragraph “ENGINE HOOD AND ACCESS DOORS”.

• Turn the cover (1) counterclockwise and remove it.

• Check that dust ejection valve (2) is clean.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-46

4. MAINTENANCE • Insert inside the housing the new air cleaner (3) make sure it seats properly.

• Assembly the cover (1) and turn it clockwise.

• Close the air filter compartment door.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-47

4. MAINTENANCE 4.9.2

FUEL PRE-FILTER

(Replacement)

S WARNING Pay attention, during the disassembly phase, not to spill the fuel in the filter; there is a danger of fires.

Proceed with the replacement of the fuel pre-filter (1), operating as follows: • Ensure that the machine is positioned on a flat surface.

• Rest the bucket on the ground.

• Shift accelerator lever to idle run, switch off engine, pull out ignition key and place safety lever on (LOCK).

• Wait until the machine has cooled down.

• Open engine hood and lock it in the raised position as detailed in the paragraph “HOOD AND ACCESS COVERS”.

• After cooling down each portion, push the handle (2) of the water separator upward to the “CLOSE” position.

• Loosen the ring (3) to remove the case (4), and drain the water out.

NOTE: Pay attention not to loose the red float (5) and spring (6).

• Replace pre-filter (7) and inside of cup (4).

• Replace the O-ring (8) with a new one.

• Install the element (7) to the water separator body.

• Set the O-ring (8) to the case (4), then tighten it up with ring (3).

• Push the handle downward to set at “OPEN” position.

• Bleed the air of the supply system.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-48

4. MAINTENANCE Bleeding air • Proceed with the bleeding of the air that, during the replacement of the pre-filter, was introduced into the fuel system.

Perform this operation as follows: - loosen the bleed screw (9) to allow air to bleed; - repeatedly press the button (10) located on the priming pump to circulate fuel inside the fuel system; - continue priming until a minimum amount of fuel free of bubble comes out of the loosened bleed screw (9). Close the screw; - start the engine.

• Close the door of the engine pumps compartment.

Handle and dispose of used fuel filters according to current regulations. Use only authorised disposal procedures.

If in doubt, contact authorities concerned.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-49

4. MAINTENANCE 4.9.3

ALTERNATOR - FAN BELT

(Replace)

S WARNING Always make sure that the engine hood, once opened, has the locking device securely engaged; there is a danger for personal injuries. Never place any part of the body near belts or rotating blades. Be particularly aware near fans (alternator and radiator fan).

S CAUTION 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 belt (4) operating as follows: • Ensure that the machine is positioned on a flat surface.

• Rest the bucket on the ground.

• Shift accelerator lever to idle run, switch off engine, pull out ignition key and place safety lever on (LOCK).

• Wait until the machine is cold.

• Open engine hood and lock it in the raised position as detailed in the paragraph “HOOD AND ACCESS COVERS”.

• Loosen adjusting screws (2) and fastening bolt (3) of the alternator (1).

• Remove belt (4) and replace it ensuring that it is placed as shown in the picture.

• Adjust the belt.

• Apply the lever between the alternator (1) and the cylinder block, and fix it on the alternator. At that time, insert a wooden piece between the alternator and the lever to avoid damaging the alternator.

Select the wooden piece of suitable thickness for the clearance between the alternator (1) and the lever.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-50

4. MAINTENANCE • Apply the lever to the wooden piece, and pulling it with hands to give tension on the belt, tighten the fixing capscrew (3).

• Tighten the adjusting capscrew (2).

• After adjustment, start the engine and operate it at low idling for around 5 minutes, then stop the engine to confirm the belt tension.

An insufficient tension can cause the battery unloading, engine overheating or belt wears out abnormally.

An excessive tension of the belt can damage the bearings or the belt itself.

To check the tension, press with your thumb in the middle of the belt with a pressure like 10 kg and measure the bending.

The table hereunder indicates the normal value.

Bending Belt

8 - 10 mm

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-51

4. MAINTENANCE 4.9.4

ENGINE COOLING SYSTEM

(Engine coolant replacement and system flushing)

S DANGER Do not run the engine in closed spaces without proper ventilation and/or an adequate system capable to remove noxious exhaust gases.

S WARNING Always ensure that engine hood is correctly locked in the open position. Danger of personal injuries.

S CAUTION Pressure fluid. Turn the 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.

• Ensure that the machine is positioned on a flat surface.

• Rest the bucket on the ground.

• Shift accelerator lever to idle run, switch off engine, pull out ignition key and place safety lever on (LOCK).

• Wait until the machine has cooled down.

• Open the radiator compartment panel and the engine hood and secure them in open position as described in paragraph “HOODS AND ACCESS PANELS”.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-52

4. MAINTENANCE Draining of coolant Drain the coolant operating as follows: • with cool engine remove plug (1) of radiator and plug (2) of level cup (3); • remove the plug (4) and let the coolant drain into a container of appropriate capacity. Once the operation is over, retighten the plug; • inspect carefully the sleeves checking that they are trouble free and tight (replace them if required) and tighten the securing band if slacken. Check the there are no leakages from the radiator, damages or accumulation of dirt.

Flushing the cooling system Proceed with the flushing of the cooling system operating as follows: • Refill system, through filler plug (1), with water and a detergent for inner cleaning, up to radiator complete filling.

• Complete the filling through the level cup (2).

• Assembly plug (1) of radiator and complete the filling of the expansion container (3).

• Assembly the plug (1) and the level cup plug (2).

• Start the engine and let it run slightly higher than idle run for about 10 minutes.

• Cut-off the engine and let it cool-off.

• Drain the water and detergent following the procedure described here above.

• Then refill the cooling system with fresh water only and flush the system again. Repeat this operation until the water drained is clean.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-53

4. MAINTENANCE Filling the cooling system Proceed with the filling of the cooling system operating as follows: • make sure that plug (4) is fitted; • fill the system, through plug (1), with coolant (see “FILLING CHART” in this chapter) up to complete filling of the radiator.

NOTE: When the coolant is topped-up, proceed slowly to prevent the formation of air bubbles in the system.

• Reinstall plug (1).

• Start the engine and let it operate several minutes.

• Cut-off the engine, let it cool-off and check the coolant level in level tank (3).

• The coolant level must be between the marks FULL and LOW. In the event the coolant is insufficient, remove cap (2) and top up.

• Close the engine hood and the radiator compartment door.

Handle and dispose of coolant in accordance with current regulations.

Use only approved procedures for the disposal and, in case of doubts, consult with the appropriate Authorities.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-54

4. MAINTENANCE

4.10 AFTER 2000 HOURS OF OPERATION DESCRIPTION OF SERVICE Travel reduction gears oil

Replace

Lubricate

Clean

Check

0.33 l

Hydraulic system oil (*)

22 l

(*) IMPORTANT: If the machine has been refilled with biodegradable hydraulic oil (on demand), be informed this oil cannot be mixed with mineral hydraulic oil.

4.10.1 TRAVEL REDUCTION GEARS OIL (Replacement)

S WARNING You are reminded that the travel reduction units and their oil can reach, during operation, high temperatures, thus it is indispensable to protect body and limbs with appropriate clothing, glasses and protections, since there is a danger of burns and personal injuries.

Loosen slowly the threaded plugs for the inspection of the oil level in the reduction units.

This is to allow a slow bleeding of the pressure created inside the final drives.

When changing the oil, stand in a out-of-line position with respect to the side of the reduction units and always wear protective glasses.

The operation for the alignment of the reduction units filling and level check plugs, described here below, must be made with an assistant on the ground. However, this assistant must always stand away from the field of action of the machine.

Never perform maintenance or inspection operations on the circuits of the travel motors on gradients. They are strongly pressurised due to the effect of the weight of the machine.

• Park the machine on a level surface. The reduction units should be positioned as to have the plugs (1), (2) as shown.

Observance of this position is essential to proper servicing.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-55

4. MAINTENANCE • After positioning the reduction unit for either discharge or filling, set the machine controls as follows: - rest the bucket to the ground; - shift accelerator lever to idle run, switch off engine, pull out ignition key and place safety lever on (LOCK). The machine should be positioned as shown.

Oil discharge • Position the reduction unit as shown and slowly release the threaded plug (1) gradually relieving pressure from inside the reduction unit. After relieving pressure, fully remove the plug (1) from its seat.

Loosen plug (2) and take it out of its seat. Allow oil to drain in a suitable container.

Oil refilling • Tighten plug (2) and refill through the hole of plug (1) with the prescribed oil (see “FILLING CHART” in this chapter) until it flows out the plug itself. Oil flowing out indicates that the correct level is reached.

• Reinstall plug (1).

The above operation should be carried out on both travel side reduction units.

Handle and dispose of travel side reduction unit oil according to current regulations. Use only authorised disposal procedure. If in doubt, contact authorities concerned.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-56

4. MAINTENANCE 4.10.2 HYDRAULIC SYSTEM OIL (Replace)

S DANGER Never operate the engine of this machine in enclosed areas and without systems for the evacuation of fumes, since exhaust fumes are toxic.

S WARNING The components and pipes of the hydraulic system can reach high temperatures. Thus it is recommended to cut-off the machine and let it cool-off prior to performing any inspection or maintenance operation. Danger of burns. The hydraulic oil tank is pressurised. Press the button on the tank to bleed the pressure prior to performing maintenance operations. Danger of personal injuries.

• Position the machine on a flat surface with the turret swung 90° to facilitate the access.

• Position the front attachment as indicated in the figure.

• Shift accelerator lever to idle run, switch off engine, pull out ignition key and place safety lever on (LOCK).

• Wait for the machine to cool-off.

• Clean the upper side of the hydraulic oil tank to prevent dirt to contaminate the hydraulic system.

• Loosen the plug (1) on the tank, releasing the pressure inside the tank.

• Suck the oil from the tank using an appropriate pump.

• Unscrew the four retaining bolts (3) using a 13 mm key and remove the cover (4).

• Remove draining plug (2) allowing old oil to flow into a container.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-57

4. MAINTENANCE • Remove suction filter assembly (5) and O-Ring (6).

• Remove the hydraulic system return oil filter inside cover (7) as described in the 500 HOUR WORK MAINTENANCE paragraph “HYDRAULIC SYSTEM RETURN OIL FILTER”.

• Replace the hydraulic system return oil filter as described in 500 HOUR WORK MAINTENANCE paragraph “HYDRAULIC SYSTEM RETURN OIL FILTER”.

• Clean suction filter (5). If necessary assembly a new one.

• Assembly a new O-ring seal (6), the complete suction filter (5) and the cover (4), make sure that the complete suction filter is seated properly.

• Introduce through plug (1) oil of the type, gradation and quantity prescribed (see “FILLING CHART” in this chapter) until the level is visible on the level visual check (8).

Handle and dispose of hydraulic oil and filters according to current regulations. Use only authorised disposal procedure. If in doubt, contact authorities concerned.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-58

4. MAINTENANCE 4.10.3 BIODEGRADABLE HYDRAULIC OIL Specifications • Recommended oil PANOLIN AG - HLP SYNTH 46.

Operating range • Ambient temperature: -20 °C to 40 °C. • Oil temperature in the tank -20 °C to 95 °C. Instructions for use IMPORTANT: Biodegradable hydraulic oil must not be mixed with mineral hydraulic oil.

Oil change

Oil sampling for analysis

Every 2000 hours

Every 500 hours

• Oil samples to be analysed should be taken every 500 hours of operation using the sampling kit and related instructions supplied by the Dealer.

• The samples should be sent by the Customer to PANOLIN AG - HLP SYNTH 46, that will carry out necessary analyses. The Dealer will then inform the Customer when oil characteristics are no longer suitable for use.

IMPORTANT: If special equipments (hydraulic breaker, etc.) are used, oil sampling for analysis should be done every 250 hours.

IMPORTANT: Oil should be changed if the Dealer informs the Customer that oil is outside operating limits. Failure to observe this measure will invalidate the warranty and may cause damages to the machine.

• To change the biodegradable hydraulic oil, please proceed as indicated in the preceding pages.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-59

4. MAINTENANCE Replacing mineral hydraulic oil with biodegradable hydraulic oil.

IMPORTANT: If the machine was bought filled with mineral hydraulic oil and you want to change to biodegradable hydraulic oil (option), this operation must be carried out by the Dealers personnel. In fact, it is necessary to thoroughly drain mineral oil and flush the entire hydraulic system. Remember that mineral hydraulic oil must not be mixed with biodegradable hydraulic oil.

SERVICE REMINDER PLATE Outside the air cleaner compartment is located a summarizing plate (1) indicating the main lubrication and replacements to be carried out periodically.

This decal differs from the one normally applied to the machine, since it lists the maintenance sequences related to biodegradable hydraulic oil.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-60

4. MAINTENANCE

Replacement of fuel pre-filter

Engine valves

Lubrication

Replacement of engine oil filters

Replacement of reduction gear oil, axles and gearbox

Replacement of engine coolant

(*) Replacement of hydraulic system oil

Replacement of engine oil

Replacement of hydraulic system return oil filter

Replacement of air filter

Oil sampling for analysis

Replacement of fuel filters

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

4-61

4. MAINTENANCE

4.11 FILLING CHART RECOMMENDED FLUIDS AND LUBRICANTS COMPONENT TO BE FILLED

QUANTITY Litres

MANUFACTURER'S SPECIFICATIONS

Engine cooling system

3.7

AGRIFLU

NH 900 A

Fuel tank

19.7

-

-

Engine

3.5

Travel reduction gear (each)

0.33

Attachment hydraulic system (**)

22

Pressure grease fittings

-

Swing joint teeth

8.3 (*)

Windscreen washer

NOTES Protective fluid to be mixed with water at 50%. This mix has anticorrosive, antiscaling, and antifoaming properties; does not freeze down to -35 °C.

ASTM fuel N. 2-D type TT

-

SUPER GOLD HSP

QFK 586 EN

API CH-4 ACEA E5

Multigrade oil for aspirated or turbocharged diesel engine of every types and powers.

TUTELA W140/M-DA

NH 520 A

API GL5 MIL-L-2105 D

Gear oil with Extreme Pressure (E.P.) performance.

-

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 antifreezing properties until -22 °C.

QFK 583/ HD

IDRAULICAR AP 46

QFK 585/GR

MG2

1.5

INTERNATIONAL SPECIFICATIONS

TUTELA PROFESSIONAL SC35

-

Oil quantities shown are necessary for periodical changes following discharging and filling procedures detailed for each assembly.

(**) IMPORTANT: if the machine has been refilled with biodegradable hydraulic oil (on demand), be informed this oil cannot be mixed with mineral hydraulic oil.

(*) First filling only. ì

LUBRICANT TYPE TO BE FILLED

OPERATING RANGE (AMBIENT TEMPERATURE °C) VISCOSITY

SUPERGOLD HSP

SAE 15W - 40 SAE 10W - 30

Travel reduction gear

TUTELA W140/M-DA

SAE 80W - 90

Hydraulic system

IDRAULICAR AP 46

ISO VG 46

Engine

-30

-20

-10

0

10

20

30

40

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

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50

5. TROUBLESHOOTING

5. TROUBLESHOOTING

5.1

OPERATING

Problem

Probable cause

Possible remedy

All operating speeds are slow or power is lost

Low hydraulic oil level.

Fill oil to specified level.

Air leaking into the suction pipe.

Tighten suction pipe hose clamp or replace hose.

Hydraulic pump is damaged.

Repair or replace.

Pilot gear pump is damaged.

Repair or replace.

Main relief valve is not adjusted correctly.

Adjust or replace.

Pilot relief valve is not adjusted correctly.

Adjust or replace.

A specific cylinder functions Cylinder seal is damaged. improperly or loses power

Repair or replace.

Control valve or overload valve Repair or replace/Remove air from functions incorrectly or there are signs cylinder. of air in the cylinder.

Pilot valve is damaged.

Repair or replace.

Pilot valve piping is loose.

Retighten.

Cylinder seal is scored.

The cylinder position will not hold with operating lever in neutral

Machine does not slew

Slewing speed is slow

Slewing speed is slow

Repair or replace.

Control valve or overload valve is damaged.

Repair or replace.

Overload valve is not operating.

Repair or replace.

Pilot valve is damaged.

Repair or replace.

Hydraulic motor (slewing) is not Repair or replace. working or slewing gear is damaged.

Slewing bearing is damaged.

Repair or replace.

Pilot valve is not working.

Repair or replace.

Slewing reduction unit is damaged.

Repair or replace.

Solenoid valve is not working.

Repair or replace.

Control valve is not working.

Repair or replace.

Lever lock Sol.V. is not working.

Repair or replace.

Control valve is not working.

Repair or replace.

Hydraulic motor (slewing) is not working.

Repair or replace.

Hydraulic pump is not working.

Repair or replace.

Pilot valve is not working.

Repair or replace.

Insufficient lubrication of slewing gear Grease. and bearings.

Pilot valve is not working.

Repair or replace.

Control valve is not working.

Repair or replace.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

5-3

5. TROUBLESHOOTING

5.2

TRAVEL

N

Problem

Probable cause

Possible remedy

Machine does not travel smoothly

Too much crawler tension.

Adjuster crawler tension.

Dirty or clogged crawler shoes.

Clean crawlers.

Brake valve is not working.

Repair or replace.

Travel reduction unit is damaged.

Repair or replace.

Control valve is not working.

Repair or replace.

Travel motor damaged.

Repair or replace.

Main relief valve pressure is set incorrectly

Adjust or replace.

Swivel joint is damaged.

Repair or replace.

Hydraulic pump is damaged.

Repair or replace.

Poor engine performance.

Repair or replace.

Main relief valve pressure is set incorrectly.

Repair or replace.

Low hydraulic oil level.

Adjust or replace.

Traveling power is insufficient

Hydraulic motor (travel) is not working. Fill to proper level.

Brake valve is not working.

Repair or replace.

Seal in swivel joint is scored or oil is leaking.

Repair or replace.

Machine does not travel in a Unequal tensions on crawlers. straight line

Adjust tension.

Set pressures of main relief valves unbalanced.

Adjust tension.

Performances of hydraulic travel motor has deteriorated.

Adjust.

Unbalanced flow from control valve.

Repair or replace.

Unbalanced discharge from hydraulic Repair or replace. pump.

Unbalanced flow from brake valve.

Repair or replace.

Unbalanced flow between RH swivel Repair or replace. joints.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

5-4

5. TROUBLESHOOTING

5.3

HYDRAULIC

N

Problem

Probable cause

Possible remedy

Temperature rise in the hydraulic oil temp

Oil cooler core clogged.

Clean.

Engine fan belt slipping.

Adjust or replace.

Low hydraulic oil level.

Refill to specified level.

Wrong type hydraulic oil used.

Replace with correct, new oil.

Hydraulic pump is not working.

Repair or replace.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

5-5

5. TROUBLESHOOTING

5.4

GAUGE CLUSTER DISPLAY

N

Problem

Probable cause

Possible remedy

Engine oil pressure is too low

Engine oil level low.

Fill to specified level.

Oil leaking.

Repair and fill to proper level.

Wrong oil viscosity.

Replace with proper oil.

Abnormal rise in the coolant Low coolant. temperature

Battery charge

Fill to proper level.

Coolant leaking.

Repair and fill to proper level.

Loose radiator cap.

Tighten.

Radiator core clogged.

Clean cooling system.

V-belt loose or damaged.

Tighten to proper tension.

Rust or scale in coolant.

Flush system/fill to level.

Faulty thermostat.

Replace.

Battery terminals disconnected, loose, or corroded.

Clean and connect.

Low battery electrolyte.

Replenish.

Slipping of V-belt or damaged.

Adjust or replace.

Battery service life has run down.

Replace.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

5-6

5. TROUBLESHOOTING

5.5

ENGINE

N

Problem

Probable cause

Possible remedy

Starter does not turn or Battery disconnected. turns slowly which does not start the engine

Starter turns but engine does not start

Engine tends to stop at low speed

No power

Engine overheats

Engine exhaust is black Poor fuel consumption

Excessive oil consumption

Connect.

Battery discharged.

Charge.

Battery terminals disconnected, loose, or corroded.

Clean and connect.

Ground cable disconnected.

Connect.

Engine oil viscosity too thick (Cold Weather).

Change to proper oil.

Insufficient fuel.

Refuel.

Improper starting procedure.

Refer to section “BASIC MACHINE OPERATION”.

Air in fuel line.

Remove.

Clogged fuel filter.

Replace element.

Clogged air cleaner.

Replace elements.

Air heater circuit malfunctioning.

Check circuit.

Low idling RPM.

Contact authorized workshop/Dealer.

Fuel filter clogged.

Replace element.

Air cleaner clogged.

Replace elements.

Improper valve clearance.

Contact authorized workshop/Dealer.

Fuel filter clogged.

Replace element.

Air cleaner clogged.

Replace element.

Improper valve clearance.

Contact authorized workshop/Dealer.

Loose clamps on the air inlet hose.

Tighten clamps.

Cracked air inlet hose.

Replace hose.

Insufficient coolant.

Refill coolant.

Clogged radiator.

Clean cooling components.

V-belt to loose or damaged.

Adjust or replace belt.

Faulty thermostat.

Replace.

Air cleaner clogged.

Replace elements.

Improper valve clearance.

Contact authorized workshop/Dealer.

Fuel leak.

Contact authorized workshop/Dealer.

Air cleaner clogged.

Replace elements.

Loose clamps on suction hose.

Tighten clamps.

Cracked suction hose.

Replace w/new hose.

Engine oil level is too high.

Reduce to specified level.

Improper oil.

Replace with correct oil.

Oil leak.

Contact authorized workshop/Dealer.

Improper oil replacement intervals.

Change at correct interval.

Improper warming-up operation.

Refer to the section III “STARTING AND STOPPING MACHINE ENGINE”.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

5-7

5. TROUBLESHOOTING Engine oil pressure does not rise

Battery dies often

Low oil volume.

Fill to specified level.

Oil leak.

Contact authorized workshop/Dealer.

Improper oil viscosity.

Replace with proper oil.

Battery terminals disconnected loose, Clean and tighten terminals. or corroded.

Low battery electrolyte.

Fill cells w/distilled water.

V-belt loose or damaged.

Adjust or replace belt.

Defective battery.

Replace battery.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

5-8

6. ELECTRICAL SYSTEM

6. ELECTRICAL SYSTEM

6.1

GENERALITIES

S WARNING • Use exclusively grounded sources of power for heaters, battery-chargers, pumps and similar to minimise electrical shock hazard.

• Be sure to connect cables to the correct poles (+ to + and - to -) at both ends.

• Do not short-circuit the terminals.

• If the batteries are to be recharged or starting using booster batteries, remove battery cell plugs.

• FLAMMABLE VAPOURS. Extinguish all smoking materials and open flames before checking, filling or charging the batteries.

• Do not test batteries by causing sparks.

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.

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 the alternator threaded terminal disconnected.

• If the batteries have been recharged using an external equipment, they should then be reinstalled onto the machine paying attention to match terminals of same sign (+ to + and - to -).

• 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.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

6-3

6. ELECTRICAL SYSTEM 6.1.1

BATTERIES

(Check)

S WARNING • Battery gas 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.

F1474

- When starting the machine with booster batteries, observe the procedures detailed in the chapter OPERATING NORMS, in the 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.

• The battery fitted on this machine needs no maintenance, and therefore does not need to be toppedup with distilled water. In exceptional cases, however, it is possible to restore the electrolyte level by removing cell plugs and adding distilled water. Electrolyte level should be between the maximum and minimum marks on the battery. Charge the battery after topping up.

F1464

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.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

6-4

6. ELECTRICAL SYSTEM

S CAUTION Always disconnect the negative (-) ground terminal first and reconnect it last.

• Open the radiator compartment door.

• Check the radiator compartment for electrolyte leaks. If no leaks are present, thoroughly clean the compartment to prevent metal part corrosion.

• Keep the terminals and plugs located on top of the battery clean at all times to prevent battery from discharging. Check battery terminals: clamps should not be loose and should not show signs of rust or oxidation. Apply petroleum jelly to the terminals to prevent corrosion.

• It is better not to 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.

• Close the radiator compartment door.

Handle and dispose of batteries according to current regulations. Use only authorised disposal procedure. If in doubt, contact authorities concerned.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

6-5

6. ELECTRICAL SYSTEM 6.1.2

FUSES

• 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.

• There are also fuses at high amperage in the same compartment.

• Replace the faulty fuse after checking the associated circuit.

IMPORTANT: Always install fuses of correct rating to avoid overcharge damage to the electrical system.

FUSES IN THE CONTROL UNIT Fuse No.

PROTECTED CIRCUIT Rating (A)

1

Heating

15

2

Solenoid valve

7.5

3

Working lights

15

4

Horn Cab light

7.5

5

Engine stop

3

6

Instrument panel

3

7

Current limiter

3

8

Radio, windshield wiper

7.5

9

Engine stop

30

10

Optional

3

11

Optional

7.5

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

6-6

6. ELECTRICAL SYSTEM

FUSES IN THE BATTERY BAY Fuse No. 1

PROTECTED CIRCUIT Rating (A) Starter protection

50

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

6-7

6. ELECTRICAL SYSTEM NOTE:

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

6-8

COPYRIGHT BY NEW HOLLAND KOBELCO CONSTRUCTION MACHINERY S.p.A. Strada di Settimo, 323 - 10099 S. MAURO T.SE ( TO ) ITALY

Reproduction of text or illustrations, in whole or in part, is strictly prohibited

Print No. 604.21.412.01 - VII - 2006