New Holland E20.2SR E22.2SR E27.2SR Mini Excavators Operator's Manual 84287307 - PDF DOWNLOAD

E20.2SR / E22.2SR / E27.2SR Mini Excavators

CONSTRUCTION

OPERATOR’S MANUAL E20.2SR E22.2SR E27.2SR Mini Excavators

Print No. 84287307 1st Edition English 01/10 - ORIGINAL INSTRUCTIONS From serial no. NAGN00101 CONSTRUCTION

OPERATORÊS MANUAL E20.2SR E22.2SR E27.2SR Mini Excavators

Print No. 84287307 1st edition English 01/10 - ORIGINAL INSTRUCTIONS

From serial no. NAGN00101 CONSTRUCTION

INDEX FOREWORD...................................................................................................................................................... 0-1 DESIGNATED USE ........................................................................................................................................... 0-1 GENERAL INFORMATION................................................................................................................................ 0-2 PERIODIC INSPECTIONS ................................................................................................................................ 0-2 NOTE ................................................................................................................................................................. 0-2 REMARKS RELEVANT TO ORDERS ............................................................................................................... 0-3 NOISE LEVELS (2000/14/EC)........................................................................................................................... 0-4 SOUND POWER LEVEL ............................................................................................................................... 0-4 SOUND PRESSURE LEVEL AT THE OPERATOR’S SEAT ........................................................................ 0-4 LEVEL OF VIBRATIONS TRANSMITTED TO THE OPERATOR ..................................................................... 0-5 OPERATOR PROTECTIVE STRUCTURE........................................................................................................ 0-6

1. SAFETY INSTRUCTIONS 1.1 GENERAL SAFETY INFORMATION ........................................................................................................ 1-3 1.2 SAFETY INSTRUCTIONS ......................................................................................................................... 1-4 1.3 INSPECTION BEFORE TRAVELLING WITH THE MACHINE.................................................................. 1-6 1.4 SAFETY DURING OPERATION ............................................................................................................. 1-13 1.5 INSPECTION AND MAINTENANCE SAFETY ........................................................................................ 1-23 1.6 PRECAUTIONS DURING BATTERY USE.............................................................................................. 1-32 1.7 WARNING LABELS AND SAFETY DECALS .......................................................................................... 1-34 1.7.1 NOTES FOR WARNING LABELS AND SAFETY DECALS.............................................................. 1-34 1.8 FORBIDDEN USE ................................................................................................................................... 1-43 1.9 PRECAUTIONS AT THE END OF DAILY WORK ................................................................................... 1-47 1.10 TRANSPORTATION................................................................................................................................ 1-48 1.11 TOWING THE MACHINE ........................................................................................................................ 1-50

2. MACHINE FAMILIARIZATION 2.1 MACHINE FAMILIARIZATION .................................................................................................................. 2-3 2.2 GENERAL NOMENCLATURE .................................................................................................................. 2-3 2.2.1 FRONT, REAR, RIGHT AND LEFT..................................................................................................... 2-3 2.2.2 MAIN COMPONENTS ......................................................................................................................... 2-3 2.3 OPERATOR’S CAB NOMENCLATURE .................................................................................................... 2-5 2.4 INSTRUMENT AND CONTROL NOMENCLATURE ................................................................................. 2-6 2.4.1 INSTRUMENT PANEL ........................................................................................................................ 2-6 2.4.2 SWITCHES.......................................................................................................................................... 2-9 2.4.3 LEVERS AND PEDALS..................................................................................................................... 2-12 2.4.4 SEAT BELT ....................................................................................................................................... 2-17 2.4.5 CAB ................................................................................................................................................... 2-18 2.4.6 HOODS.............................................................................................................................................. 2-21 2.4.7 ESCAPE ROUTES ............................................................................................................................ 2-22 2.4.8 SEAT ADJUSTMENT ........................................................................................................................ 2-22 2.4.9 ELECTRICAL EQUIPMENT .............................................................................................................. 2-22 2.4.10STORAGE BOX AND OTHERS ........................................................................................................ 2-23

3. MACHINE OPERATION 3.1 MACHINE OPERATION ............................................................................................................................ 3-3 3.1.1 DAILY INSPECTION ........................................................................................................................... 3-3 3.1.2 CHECKS BEFORE ENGINE START-UP ............................................................................................ 3-4 3.1.3 MACHINE WARM UP........................................................................................................................ 3-10 3.1.4 STARTING THE ENGINE.................................................................................................................. 3-11

INDEX 3.1.5 CHECKS AFTER ENGINE START-UP ............................................................................................. 3-15 3.1.6 STOPPING THE ENGINE ................................................................................................................. 3-17 3.1.7 MACHINE OPERATION .................................................................................................................... 3-18 3.1.8 MACHINE PARKING ......................................................................................................................... 3-30 3.1.9 CHECKS AND VERIFICATION AFTER WORK ................................................................................ 3-31 3.1.10PRECAUTIONS AFTER OPERATION .............................................................................................. 3-31 3.1.11MEASURES AFTER AN EMERGENCY STOP OF ENGINE ............................................................ 3-32 3.1.12EMERGENCY MEASURES FOR SUDDEN FAILURE OF MACHINE .............................................. 3-33 3.1.13CAUTION WHILE USING RUBBER CRAWLERS............................................................................. 3-39 3.1.14MACHINE OPERATION WITH ADVERSE WEATHER CONDITIONS ............................................. 3-43 3.1.15PRECAUTIONS WHEN STORING THE MACHINE FOR A LONG PERIOD.................................... 3-45

4. MAINTENANCE 4.1 GENERAL SAFETY INFORMATION......................................................................................................... 4-3 4.2 GENERAL RULES AND SAFETY PRECAUTIONS .................................................................................. 4-4 4.3 LUBRICANT, FUEL AND COOLANT SPECIFICATIONS ....................................................................... 4-11 4.4 MAINTENANCE GENERAL TABLE ........................................................................................................ 4-12 4.5 TAG MAINTENANCE IN PROGRESS .................................................................................................... 4-13 4.6 TORQUE SPECIFICATIONS FOR CAPSCREWS AND NUTS .............................................................. 4-14 4.7 TORQUE SPECIFICATIONS FOR JOINTS AND HYDRAULIC HOSES ................................................ 4-15 4.8 INSTALLING FITTINGS, HYDRAULIC HOSES AND TUBES................................................................. 4-16 4.9 RELEASING INTERNAL PRESSURE FROM THE HYDRAULIC SYSTEM ........................................... 4-17 4.10 BLEEDING AIR FROM FUEL SYSTEM .................................................................................................. 4-19 4.11 REPLACEMENT OF RUBBER CRAWLER ............................................................................................. 4-20 4.11.1REMOVING OF RUBBER CRAWLER .............................................................................................. 4-21 4.11.2INSTALLING RUBBER CRAWLERS................................................................................................. 4-22 4.11.3CHECK AND ADJUSTMENT OF TENSION ON RUBBER CRAWLER ............................................ 4-23 4.12 INSPECTION AND MAINTENANCE TABLE ........................................................................................... 4-27 4.13 WHEN NECESSARY............................................................................................................................... 4-29 4.14 PRE-START (EVERY 8 HOURS) INSPECTION AND MAINTENANCE ................................................. 4-39 4.15 50-HOUR (WEEKLY) INSPECTION AND MAINTENANCE .................................................................... 4-42 4.16 250-HOUR (3-MONTH) INSPECTION AND MAINTENANCE................................................................. 4-48 4.17 500-HOUR (6-MONTH) INSPECTION AND MAINTENANCE................................................................. 4-58 4.18 1000-HOUR (12-MONTH) INSPECTION AND MAINTENANCE............................................................. 4-59 4.19 2000-HOUR SERVICE INSPECTION AND MAINTENANCE.................................................................. 4-62 4.20 INSPECTION AND MAINTENANCE TABLE ........................................................................................... 4-72 4.21 BIODEGRADABLE HYDRAULIC OIL...................................................................................................... 4-73

5. TRANSPORTATION 5.1 WHEN PREPARING TRANSPORTATION PLANS ................................................................................... 5-3 5.2 LIFTING PROCEDURES OF COMPLETE MACHINE (E20.2SR - E22.2SR)5-6 5.3 LIFTING PROCEDURES OF COMPLETE MACHINE (E27.2SR)............................................................. 5-7 5.4 LOAD SPECIFICATIONS .......................................................................................................................... 5-8

6. SPECIFICATIONS 6.1 MAINTENANCE OPERATIONS SUMMARY DECAL ................................................................................ 6-3 6.2 DIMENSIONS ............................................................................................................................................ 6-4 6.2.1 MACHINE DIMENSIONS (E20.2SR - E22.2SR) ................................................................................. 6-4 6.2.2 MACHINE DIMENSIONS (E27.2SR)................................................................................................... 6-5 6.3 GENERAL SPECIFICATIONS ................................................................................................................... 6-6 6.3.1 GENERAL SPECIFICATIONS (E20.2SR - E22.2SR) ......................................................................... 6-6 6.3.2 GENERAL SPECIFICATIONS (E27.2SR) ........................................................................................... 6-7 6.3.3 CRAWLER TYPE (E20.2SR - E22.2SR) ............................................................................................. 6-8

INDEX 6.3.4 CRAWLER TYPE (E27.2SR)............................................................................................................... 6-8 6.3.5 BUCKET TYPE (E20.2SR - E22.2SR) ................................................................................................ 6-9 6.3.6 BUCKET TYPE (E27.2SR) .................................................................................................................. 6-9 6.4 DIGGING PERFORMANCE .................................................................................................................... 6-10 6.4.1 DIGGING PERFORMANCE (E20.2SR - E22.2SR)........................................................................... 6-10 6.4.2 DIGGING PERFORMANCE (E27.2SR) ............................................................................................ 6-12 6.5 MACHINE WEIGHTS .............................................................................................................................. 6-14

7. OPTIONAL ATTACHMENT 7.1 HYDRAULIC BREAKER AND NIBBLER ATTACHMENT ......................................................................... 7-3 7.1.1 SELECTION OF HYDRAULIC BREAKER AND NIBBLER ................................................................. 7-3 7.1.2 BEFORE OPERATING HYDRAULIC BREAKER AND NIBBLER....................................................... 7-3 7.1.3 PREVENTION OF HYDRAULIC OIL CONTAMINATION.................................................................... 7-3 7.1.4 ATTACHMENT OPERATION .............................................................................................................. 7-4 7.1.5 SETTING SELECTOR VALVE ............................................................................................................ 7-6 7.1.6 SETTING THE STOP VALVE.............................................................................................................. 7-7 7.2 SAFETY INSTRUCTIONS ......................................................................................................................... 7-8 7.3 HANDLING OF HANGING LOADS ......................................................................................................... 7-12 7.3.1 LIFTABLE LOADS TABLE LOCATED IN THE CAB ......................................................................... 7-14 7.4 REGULAR INSPECTION AND MAINTENANCE..................................................................................... 7-16

8. TROUBLESHOOTING 8.1 GENERAL TROUBLESHOOTING ............................................................................................................ 8-3

9. ELECTRICAL SYSTEM 9.1 GENERALITIES......................................................................................................................................... 9-3 9.2 BATTERIES ............................................................................................................................................... 9-4 9.3 FUSE BOX................................................................................................................................................. 9-6

ATTACHMENT 1 - “EC” DECLARATION OF CONFORMITY

INDEX

FOREWORD

FOREWORD The crawler mini excavators are hydraulic machines.

They consist of two main parts: the upper frame and the lower frame.

These components are coupled by means of a slewing bearing which enables the upper frame to slew with respect to the lower frame.

The boom, tanks, radiators, counterweight, diesel engine and all hydraulic components for the operation of the excavator are fastened to the upper frame.

The lower frame is equipped with crawlers which can be made of rubber or metal and with a blade for levelling operations.

DESIGNATED USE The machine has been built in accordance with state-of-the-art standards and the recognized safety rules.

The machine must be used in accordance with its designated use, by observing the safety and precautionary rules and by strictly following the operating instructions. Any functional disorders, especially those affecting the safety of the machine, should therefore be rectified immediately.

The Excavator is intended to be used in digging and loading operation (with bucket), ground levelling (with blade) and use of hydraulic hammer to break concrete or other solid material.

NOTE: by using appropriate lubricants, the excavator can work with temperatures ranging from -20 °C to + 40 °C (-4 °F to + 104 °F).

For the correct operation of the machine in this temperature range, please refer to the table of lubricants contained in this manual.

The manufacturer/supplier cannot be held responsible for any damage resulting from other than the designated use. The risk involved in such misuse lies entirely with the user.

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.

S DANGER Using the excavator and its attachments differently from the way described in this manual will be deemed as improper use. Please find below some examples of improper use of the excavator: - for lifting or transporting persons; - as a working platform; - for pulling slung loads; - for driving in posts, supports, sheet-piles, without the attachment being approved for this purpose.

Improper use may cause injury or life-threatening risks for the operator and for other persons.

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FOREWORD This manual may contain attachments and optional equipment not available in your area. Please contact your Dealer for any optional attachment required.

S WARNING READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS AND PROCEDURES FOUND IN THIS MANUAL BEFORE ATTEMPTING ANY OPERATION, INSPECTION, MAINTENANCE OR REPAIR OF THIS MACHINE, ATTACHMENT OR ANY OF ITS SYSTEMS. THE MANUFACTURER CANNOT ANTICIPATE EVERY POSSIBLE CIRCUMSTANCE THAT MIGHT INVOLVE A POTENTIAL HAZARD. THE WARNINGS IN THIS PUBLICATION AND ON THE PRODUCT ARE THEREFORE NOT ALL INCLUSIVE. IF A TOOL, PROCEDURE, WORK METHOD OR OPERATING TECHNIQUE NOT SPECIFICALLY RECOMMENDED BY MANUFACTURER IS USED, YOU MUST SATISFY YOURSELF THAT IT IS SAFE FOR YOU AND OTHERS. YOU SHOULD ALSO ENSURE THAT THE PRODUCT WILL NOT BE DAMAGED OR MADE UNSAFE BY THE OPERATION, LUBRICATION, MAINTENANCE AND/OR REPAIR PROCEDURES YOU CHOOSE.

We expressly stress the fact that this manual is written on the presupposition that only genuine Manufacturer’s parts are to be used. Not including cases where parts locally procured were used and/or the machine was arbitrarily modified by the user locally.

Materials and specifications are subject to change without notice.

PERIODIC INSPECTIONS After delivery of a machine, the Dealer will make periodic service inspections. Contact your Dealer for any service related to issues not explained in this manual.

NOTE

GENERAL INFORMATION

The contents of this manual may not reflect the specifications of the machine delivered. Contact your Dealer to obtain detailed information about specifications for machines provided with optional equipment not described in this manual.

This manual contains procedures to aid the operator gain peak performance through effective, economical machine operation and maintenance for the Hydraulic Excavators.

Owing to the policy of continual improvement, changes may be made by Manufacturer to any of its products without any obligation on the part of Manufacturer.

Before operating the machine, operators must thoroughly read and understand all safety, Operation and Maintenance instructions found in this manual.

Failure to follow the instructions given in this manual, may lead to serious injuries to persons and or to equipment failure.

Operators and persons working with this machine should continually study this manual until proper Safety, Operation and Maintenance procedures are completely understood.

This manual describes the basic operating techniques. Skill is gained as the operator utilizes these techniques and perfects them with an actual machine.

Some illustrated pictures may differ from the real version of your machine. As technical updating and improvement of products is continuous. The manuals are constantly updated to reflect these changes.

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FOREWORD

REMARKS RELEVANT TO ORDERS To order spare parts or call for service, inform your Dealer of your machine’s serial number and engine serial number, as well as of the hourmeter reading.

These numbers are reported on the plates shown in the illustration below. For future and quick reference, record these numbers in the appropriate spaces in the plates on your machine: MACHINE No. ENGINE No. MACHINE No.

ENGINE No.

HOUR COUNTER

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FOREWORD

NOISE LEVELS (2000/14/EC) SOUND POWER LEVEL Lwa = 93 dB (A) Plate (1) shows the guaranteed 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 weighted, measured at the driver’s seat inside the cab with door and windows closed and with the heater/air conditioner blower operating at 2nd speed, measured on an identical machine, in compliance with standard ISO 6396:2008.

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FOREWORD

LEVEL OF VIBRATIONS TRANSMITTED TO THE OPERATOR The weighted average acceleration value to which the operator’s arms are subjected does not exceed 2.5 m/s2 (8.20 ft/s2).

The vibration level transmitted to the operator depends mainly on the conditions of the soil where the machine is being operated and on the use conditions of the machine and its equipment.

The weighted average acceleration value to which the operator’s body is subjected does not exceed 0.5 m/s2 (1.64 ft/s2).

The exposition to vibrations can be remarkably reduced if the recommendations here below are followed:

These results have been obtained by using an acceleration gauge during the excavation works.

- use equipment suitable for the machine and the type of work to be carried out;

NOTE: the Whole-body exposure value is determined under particular operating and terrain conditions and therefore may not be representative of all the possible operating conditions within the intended use of the machine. Consequently this single vibration emission value is not intended to determine the whole-body vibration exposure as required

by European Directive 2002/44/EC. For this purpose it is recommended to conduct actual working condition measurement. If this is not feasible use of information provided in the table below, from ISO/ TR 25398:2006 (*), is suggested.

- adjust and lock the seat in the correct position; regularly check the seat suspensions, if provided, and carry out adjustments or maintenance as required; - carry out regularly the ordinary maintenance of the machine at scheduled intervals; - operate the attachment evenly, avoiding sudden motion or extreme shocks, if possible; - as far as possible, avoid travelling on particularly uneven soils or the impact with possible obstacles, such as large rocks.

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

Basic emission value Operating conditions

Standard deviation

1.4*aw,eqx m/s2 (ft/s2)

1.4*aw,eqy m/s2 (ft/s2)

aw,eqz m/s2 (ft/s2)

1.4*Sx m/s2 (ft/s2)

1.4*Sy m/s2 (ft/s2)

Sz m/s (ft/s2)

Digging

0.33 (1.08)

0.21 (0.69)

0.19 (0.62)

0.19 (0.62)

0.12 (0.39)

0.10 (0.32)

Use of the hydraulic hammer

0.49 (1.60)

0.28 (0.92)

0.36 (1.18)

0.20 (0.65)

0.13 (0.42)

0.17 (0.56)

Transfer movement

0.45 (1.47)

0.39 (1.27)

0.62 (2.03)

0.17 (0.56)

0.18 (0.59)

0.28 (0.92)

(*) ISO/TR 25398:2006 Mechanical vibration Guideline for the assessment of exposure to wholebody vibration of ride on operated earth-moving machines - Using harmonized data measured by international institutes, organizations and manufacturers.

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2

FOREWORD

OPERATOR PROTECTIVE STRUCTURE S WARNING THE MANUFACTURER HAS PROVIDED THE MACHINE WITH OPERATOR PROTECTIVE STRUCTURES, SUCH AS: A SIDE TIP OVER PROTECTIVE STRUCTURE (TOPS) AND A FALLING OBJECT PROTECTIVE STRUCTURE (FOPS). REFER TO THE IDENTIFICATION PLATE IN THE CAB (1) OR ON THE CANOPY (2) IN ORDER TO IDENTIFY THE CHARACTERISTICS OF THE PROTECTIVE STRUCTURES. The protective structure and interconnecting components are a certified system.

Never attach towing devices to the protective structure. Do not drill holes on 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 or replacement.

After an accident, fire or roll over, the following must be performed by a qualified technician before returning the machine to field or job site operation: • Check the protective structures and, if necessary, replace them.

• The mounting or suspension of the protective structure, operator’s seat, safety belts, mounting components and cables 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.

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1. SAFETY INSTRUCTIONS

1-1

1. SAFETY INSTRUCTIONS

1-2

1. SAFETY INSTRUCTIONS

1.1

GENERAL SAFETY INFORMATION

S WARNING Safety messages appear in this manual and on the machine. All safety messages are identified by the words “DANGER”, “WARNING” and “CAUTION”.

DO NOT OPERATE OR PERFORM ANY MAINTENANCE ON THIS MACHINE UNTIL ALL INSTRUCTIONS FOUND IN THIS MANUAL HAVE BEEN THOROUGHLY READ AND UNDERSTOOD.

Indicates an imminently hazardous situation which, if not prevented, will result in death or serious injury.

IMPROPER OPERATION OR MAINTENANCE OF THIS MACHINE MAY CAUSE ACCIDENTS AND COULD RESULT IN SERIOUS INJURY OR DEATH.

S DANGER Indicates a potentially hazardous situation which, if not prevented, will result in death or serious injury.

ALWAYS KEEP THIS MANUAL IN THE OPERATOR’S SEAT POCKET. IF PARTS ARE MISSING OR DAMAGED, CONTACT YOUR DEALER TO HAVE THEM REPLACED.

S WARNING Indicates a potentially hazardous situation that, if not prevented, will result in minor or moderate injury. It may also be used to alert against possible damage to the machine and its components.

IF YOU HAVE ANY QUESTIONS, PLEASE CONSULT YOUR DEALER. Most accidents occurring during operation are due to negligence of precautionary measures and safety instructions. Sufficient care should be taken to prevent these accidents. Incorrect operation, lubrication or maintenance are very dangerous and may cause injury or death of the personnel. Therefore all precautionary measures, NOTES, DANGERS, WARNINGS and CAUTIONS contained in this manual and on the machine should be read and understood by all personnel before starting any work with or on the machine.

S CAUTION It is very difficult to forecast every danger that may occur during operation. However, safety can be guaranteed by fully understanding the operating procedures for this machine according to the methods recommended by the Manufacturer.

While operating the machine, be sure to perform work with great care, so as not to damage the machine, or allow accidents to occur.

Continue studying this manual until all Safety, Operation and Maintenance procedures are completely understood by all persons working with the machine.

Operation, inspection and maintenance should be carefully carried out, and safety must be given the first priority. Safety messages are indicated with marks. The safety information contained in this manual is intended only for supplement of safety codes, insurance requirements, local laws, rules and regulations.

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1. SAFETY INSTRUCTIONS

1.2

SAFETY INSTRUCTIONS If possible, make all repairs with the machine parked on a level and firm surface. Block the machine so it does not roll while working on or under the machine. Hang a “Maintenance in progress” tag in the operator’s compartment.

S WARNING THE PROPER AND SAFE LUBRICATION AND MAINTENANCE FOR THIS MACHINE, RECOMMENDED BY MANUFACTURER, IS OUTLINED IN THE OPERATOR’S MANUAL FOR THIS MACHINE. IMPROPER PERFORMANCE OF LUBRICATION OR MAINTENANCE PROCEDURES ARE DANGEROUS AND COULD RESULT IN INJURY OR DEATH. READ AND UNDERSTAND THE OPERATOR’S MANUAL BEFORE PERFORMING ANY LUBRICATION OR MAINTENANCE.

Do not work on any machine that is supported only by lift, jacks or a hoist. Always use blocks or stops for the jack before carrying out any disassembly operation.

S WARNING DO NOT OPERATE THIS MACHINE UNLESS YOU HAVE READ AND UNDERSTOOD THE INSTRUCTIONS IN THE OPERATOR’S MANUAL. IMPROPER MACHINE OPERATION IS DANGEROUS AND COULD RESULT IN INJURY OR DEATH.

The operator or serviceman may be unfamiliar with many of the systems in this machine. This makes a careful use of the systems very important when performing maintenance operations. Getting familiar with the system or its components is very important before removing or disassembling any of them.

Relieve all pressure in air, oil or water systems before any lines, fittings or related devices are disconnected or removed. Always make sure all raised components are blocked correctly and be alert for possible pressure when disconnecting any device from a system that utilizes pressure.

Because of the size of some of the machine’s components, the operator or serviceman should check the weights noted in this manual. Use proper lifting procedures when removing any components.

The following is a list of basic precautions that must always be observed.

Lower the bucket, dozer or other attachments to the ground before performing any operation on the machine. If this cannot be done, make sure the bucket, dozer or other attachment is blocked correctly to prevent it from dropping unexpectedly.

Read and understand all warning labels and safety decals before operating, servicing or repairing this machine.

Always wear protective glasses and protective shoes when working around machines.

In particular, wear safety goggles when using hammers, punches or drifts on any part or attachment of the machine. Use welders gloves, hood/goggles, apron and the protective clothing appropriate to the welding job being performed. Do not wear loose fitting or torn clothing. Remove all rings from fingers, loose jewellery, confine long hair and loose clothing before working on this machinery.

Use the steps and the grab handles when mounting or dismounting a machine. Remove any debris or mud from steps, walkways or work platforms before using them.

Always face the machine when using steps, ladders and walkways. When it is not possible to use the designed access system, provide ladders, scaffolds, or work, platforms to perform safe repair operations.

Refer to paragraph “MOUNTING ON OR DISMOUNTING FROM THE MACHINE, 1-9”.

Disconnect the battery and hang a “Maintenance in progress” tag in the operator’s compartment.

Remove the starter key.

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1. SAFETY INSTRUCTIONS To prevent back injury, use a hoist when lifting components which weigh 20 kg (44 lb) or more. Make sure all chains, hooks, slings, etc., are in good condition and have the correct capacity. Be sure hooks are positioned correctly. Lifting eyes are not to be side loaded during a lifting operation.

Make sure all protective devices including the operator’s protective devices are properly installed and functioning correctly before starting a repair operation. If a guard or shield must be removed to perform the repair work, use extra caution and replace the guard or shield after repair is complete.

In order to prevent burns, be careful not to touch hot machine parts and hot liquids in systems, tubes and sections.

Performing maintenance and repair operations while the bucket is lifted is dangerous, because there is the possibility of a device falling. Do not fail to lower such device and place the bucket to the ground before starting the operation.

Be careful when removing cover plates. Gradually back off the last two capscrews or nuts located at opposite ends of the cover or device and carefully pry the cover loose to relieve any spring or other pressure before removing the last two capscrews or nuts completely.

Loose or dirty fuel, lubrication and hydraulic systems, pipes and hoses may cause fires. Do not bend or strike high-pressure lines, nor install bent or damaged lines. Inspect lines, tubes and hoses carefully. Do not check for leaks with your hands. Very small leaks from holes can result in a high-velocity oil jets that will be invisible close to the hose. This oil can penetrate the skin and cause personal injury.

Use cardboard or paper to locate hole leaks.

Be careful when removing filler caps, breathers and plugs on the machine. Hold a rag over the cap or plug to prevent being sprayed or splashed by liquids under pressure. Danger is even greater if the machine has just been stopped, as liquids might be boiling hot.

Tighten the connections to the correct torque. Make sure that all protections against burns, the clamps and the operator’s protective devices are correctly installed in order to prevent excessive heat, vibrations or rubbing against other parts during operation. The protections against oil leaks from hot hoses or damaged seals must be correctly installed.

Always use proper tools that are in good condition and that are suited for the job at hand. Be sure you understand how to use them before performing any service work.

Reinstall all clamps with the same spare part number. Do not use clamps of inferior quality if replacement is necessary.

Do not operate a machine if any rotating part is damaged or contacts any other part during operation. Any high speed rotating component that has been damaged or altered should be checked for balance before reusing.

Repairs which require welding should be performed only with the benefit of the appropriate reference information and by personnel adequately trained and skilled in welding procedures. Determine the type of metal being welded and select the correct welding procedure and electrodes, rods or wires to provide a metal weld strength at least equivalent to that of the parent metal. Make sure to disconnect the battery before any welding operation is performed.

Block the machine to prevent it from moving when adjusting or replacing the crawlers.

Do not damage the cables during removal operations. Reinstall the cables so that they are not damaged during machine operation, by contacting the machine’s sharp corners or by rubbing against objects or hot surfaces. Do not connect the cables to a system containing liquids.

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1. SAFETY INSTRUCTIONS

1.3

INSPECTION BEFORE TRAVELLING WITH THE MACHINE

Many failures that occur during machine operation or servicing result from neglecting fundamental safety precautions. The following safety precautions are given to prevent such failures, but they are only a part of what you must follow.

Before operating the machine, carefully read and observe all precautionary measures given in this manual.

OBSERVE SAFETY INSTRUCTIONS Follow all safety instructions, precautions and operating procedures. If there are other persons or flagmen working near the machine, have them observe the conventional signs.

WEAR PROTECTIVE CLOTHING Wear well fitting safety shoes, hard hat, and working equipment, and put on protective glasses, face shield, ear protection and gloves. When necessary, wear reflective vest.

S WARNING DO NOT WEAR WORKING CLOTHES CONTAMINATED WITH OIL, SINCE IT IS WILL EASILY CATCH FIRE.

READ AND UNDERSTAND THE OPERATOR’S MANUAL Before operating the machine, read and understand this manual thoroughly in order to use the machine effectively and safely.

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1. SAFETY INSTRUCTIONS KEEP THE OPERATOR’S MANUAL Keep this manual in the specified storage compartment for quick reference. Should the operator’s manual become lost or damaged, contact your Dealer to order a new copy.

DO NOT OPERATE MACHINE WHEN YOU ARE TIRED OR UNDER THE INFLUENCE OF DRUGS A poor physical condition causes improper reactions. Voluntarily refrain from operating the machine when feeling excessively tired, and never operate the machine under the influence of drugs.

PREPARE FOR EMERGENCIES Have a fire extinguisher and first aid kit ready for emergencies. Know how to operate the fire extinguisher and know where the First Aid Kit is located for easy access in case of emergency.

Prepare beforehand the communication means to be used in case of any emergency, and take note of telephone numbers for emergency contact.

1-7

1. SAFETY INSTRUCTIONS ENSURE SAFETY AT THE WORK SITE Know the work area! Before operating the machine, carefully survey and record the land and work site features to prevent the machine from falling or the soil from caving in.

ENGAGE THE SAFETY LOCK LEVER(S) BEFORE LEAVING THE MACHINE In models provided with cab, there is only one lever on the left side, while the models with canopy are provided with two levers, one on each side; by setting just one lever to the LOCKED position, the controls will be blocked.

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

Before leaving the machine, lower the bucket to the ground, set the safety lock levers to the LOCKED (up) position, stop the engine and remove the starter key.

SIGNS, SIGNALS AND FLAGMEN Install signs on soft shoulders and ground areas.

Have a flagman direct the operation if necessary.

The operator should note marks and follow signals from the flagman. All personnel should know the meaning of the signs, marks, and signals. Only one flagman should give the signs and signals.

1-8

1. SAFETY INSTRUCTIONS KEEP FIRE AWAY FROM FUEL AND OIL Oil, antifreeze, and especially fuel are highly flammable. Keep the machine away from fire sources.

Securely tighten all fuel and oil caps. Keep fuel and oil in the designated storage areas. Immediately clean the areas where fuel and oil residues are found and dispose of waste in compliance with the relevant regulations.

MOUNTING ON OR DISMOUNTING FROM THE MACHINE When getting on and off the machine, always maintain three point contact by using the handrails and step. Inspect and clean handrails, step, and mounting parts. Remove slippery materials, such as lubricants, and mud. Always place the cab entrance door parallel to the crawlers before stopping the engine to dismount.

PAY ATTENTION TO WORKING MACHINE Do not approach a working machine. Make sure to make visual contact with the operator before approaching a working machine.

1-9

1. SAFETY INSTRUCTIONS USE SUITABLE OPTIONAL ATTACHMENTS Only use optional attachments approved by the Manufacturer. Read all the instructions in this manual regarding the optional attachments and make sure to understand and observe them. The use of any unsuitable or non-approved optional attachment can cause severe injury, damage the machine or its components or shorten the machine’s life. Consult your Dealer for the optional attachments available for the machine.

PREVENT FIRES Leaking or spilled fuel, lubricants and hydraulic oil can cause fire and serious injuries. Clean and properly dispose of spills as they occur. Repair or replace all leaking components to prevent fires. Also, clean the machine regularly removing all debris to help prevent fires. Pay particular attention to removal of leaves, sticks, paper etc.

Keep a fire extinguisher in an accessible area and know how to use it in case of fire.

CHECK OPERATING LEVERS PATTERN Check the operating levers pattern before working on the machine.

The figure shows the standard configuration of operating levers according to ISO.

1-10

1. SAFETY INSTRUCTIONS KEEP CLEAN CAB FLOOR AND OPERATOR’S SEAT Do not place any parts and tools in the operator’s cabin to prevent injury due to slipping and stumbling.

Remove any debris from the cab floor, control levers, handrails, etc.

Make sure that all control levers are always clean.

HOW TO HANDLE LIFE HAMMER-CAB ONLY A life hammer is provided on the right side of cab. In case of emergency, take the life hammer (1), break the cab glass, and escape from the cab. In addition, the life hammer (1) is equipped with a cutter (2) on the lever side to cut the seat belt, etc.

COMMISSIONING INSPECTION Walk around the machine before commissioning it, perform a pre-start inspection of the same and make note of any fault. If any problems are found, repair or replace defective components immediately. Do not start the machine until all faults have been solved.

Always keep the windshield, the work lights and the rearview mirrors clean for a good visibility.

1-11

1. SAFETY INSTRUCTIONS APPLY NOTICE OF MAINTENANCE IN PROGRESS Before performing any inspection or maintenance procedures to the machine, apply to the controls a “Maintenance in progress” tag, to warn persons not to start the machine.

Be sure to inform the supervisor and all operator that the machine is under inspection or maintenance and they will be informed when the machine is ready for normal operation.

USE CAUTION NEAR NOISE If noise is high during operation the loss of hearing can result. Approved hearing protection should be used if personnel will be exposed to high noise levels for a long period of time.

AVOID HOT SURFACES AND AREAS Immediately after the machine is operated, the temperature and pressure of the engine coolant, engine oil, and hydraulic oil are very high. Burns may result if caps are removed, or oil, water, or filters are changed under these conditions. Let the components cool down first.

1-12

1. SAFETY INSTRUCTIONS

1.4

SAFETY DURING OPERATION

PASSENGERS This equipment is not intended or designed for the transportation of persons. Nobody is allowed on the machine except for the driver. Serious injury or death can result from allowing passengers on or in the machine.

ENGINE START-UP Start engine from the operator’s seat. Do not shortcircuit the starter with the battery to start. This may cause serious injury or damage to the electrical system.

SOUND THE HORN WHEN THE ENGINE IS STARTED Sound the horn before starting the engine to alert people the machine is being started. Make sure no one is near the machine.

S CAUTION Do not start the engine if a “maintenance in progress” tag has been hung.

1-13

1. SAFETY INSTRUCTIONS CHECK AFTER THE ENGINE START Be sure to check machine for proper operation after the engine start. Slowly cycle attachments, swing, and travel functions in an area with sufficient space, without obstacles, and personnel. Failure to do so could result in injury or machine damage. Make note of any abnormalities and repair as needed.

WARM UP MACHINE BEFORE OPERATION Take sufficient time to warm up the machine, especially in the cold season, otherwise the response of machine to the operation of operating levers is delayed. Which may cause injury and/or machine damage.

CHECK OPERATING LEVERS PATTERN Check the operating levers pattern before working on the machine.

The figure shows the standard configuration of operating levers according to ISO.

1-14

1. SAFETY INSTRUCTIONS CHECK THE TRAVEL DIRECTION Before activating the control pedals/levers ensure the position of the travel motors.

If the travel motors (1) are on the front side of the machine, the travel control levers must be shifted in the opposite direction (2).

Sound horn before moving the machine to inform any personnel around the machine that the machine is now in operation.

DO NOT HIT THE CAB WITH THE ATTACHMENT Check clearance between bucket and machine before operation. Exercise care when operating a bucket near machine.

SLEWING Make sure that nobody stays in the slewing range of the machine. Make sure that the area around, above and underneath the machine is clear of persons or objects, before operating it. Before moving the machine sound the horn or send an acoustic signal, so that nobody can approach the dangerous area.

Have a flagman signal operator during operation to help prevent injury to persons or damage to obstacles and equipment.

1-15

1. SAFETY INSTRUCTIONS TRAVELLING ON SLOPES When travelling on slopes, the machine could turn over or slide.

Keep the bucket at a height of 30 ÷ 40 cm (0.10÷0.13 ft) from the ground and always keep the safety belt fastened.

Never make a change of direction on a slope.

FROZEN OR SNOW-COVERED WORK SITES Use extreme caution when operating the machine on frozen or snow-covered work sites. Operate the machine controls slowly and carefully to avoid sudden movements which could cause the machine to slip or move out of control. Even on the slightest slope, when snow is present or work area is frozen, the machine may unexpectedly move. Snow on shoulders or snow drifts can be much deeper than expected. The machine can easily sink under such conditions. Use extreme caution while operating the machine around or in snow.

Be careful for frozen ground that becomes soft along with the increase of temperature.

TRAVEL Before start-up position the attachment as shown in the illustration. On rough terrain move the machine at slow speeds, and do not turn suddenly. Avoid travelling over obstacles. If this cannot be avoided, keep the attachment close to the ground and travel at extremely slow speed.

1-16

1. SAFETY INSTRUCTIONS COVERED OR UNSTABLE WORK SITES Make sure that the work site is stable and capable of supporting the machine weight during its movements. Do not operate the attachment too close to the machine. Operation of the machine on shoulders or filled areas could cause the machine to become unstable presenting accident hazard. Position the crawler at right angle to shoulder and the travel motors to the rear of the machine, allowing for quick reversal, should the work area become unstable.

OPERATING ON SLOPES When operating on a slope the machine risks to become unstable or unbalanced. Work up and down inclines or slopes, never across. Never slew or turn machine on slopes. Prepare a level and safe platform for the machine operation. Operate controls carefully to prevent sudden movements that may cause the machine to slip or tip over.

WORKING AROUND ELECTRIC POWER LINES If it is suspected that utility lines such as telephone or electrical power lines are in the work area, contact the local utility authority for line location BEFORE beginning work in the area. Use extreme caution around electrical power lines. Keep a sufficient distance away from electrical lines during operation.

See chart below for minimum distances.

Line voltage

Minimum distance - metres (ft)

0 ÷ 50000

≥ 3 (9.84)

50000 ÷ 200000

≥ 4.5 (14.76)

200000 ÷ 350000

≥ 6 (19.68)

350000 ÷ 500000

≥ 7.5 (24.60)

500000 ÷ 750000

≥ 10.5 (34.45)

750000 ÷ 1000000

≥ 13.5 (44.29)

1-17

NO

OK

1. SAFETY INSTRUCTIONS LIFTING This machine is an excavator. Use extreme caution when lifting or moving heavy loads. Use proper lifting equipment rated at a capacity to handle the load.

Never use the bucket teeth to lift or move heavy loads.

WORKING AROUND UTILITY LINES UNDERGROUND When working in the presumed area of power, water or gas lines under the ground, ask the organization concerned for the actual location and carry out a trial digging. Once located the lines, proceed with your work carefully.

PARKING THE MACHINE Always park the machine on a firm, level surface.

If no level and firm surface is available, block the crawlers with wedges (1) and lower the bucket (2) and the dozer (3) to the ground to prevent an unexpected machine movement.

Should the machine be parked on a roadway, move the machine to the shoulder to allow passing of traffic. Also warn other drivers by placing warning signals and lights. To protect the work site, observe the local regulations in force.

1-18

1. SAFETY INSTRUCTIONS RESTRICTED WORK AREAS In work sites with limited height and rotation areas such as tunnels, bridges, around electrical power lines, other utilities, or inside structures, use extreme caution in keeping the machine and its attachment a safe distance away to prevent personal injury and/or equipment or structure damage.

Use a flagman to direct the operator.

DO NOT DIG UNDER PRECIPICES Do not dig under a precipice. Rocks could fall or the ground could slide down and this could cause personal injury or machine damage.

WORK WITH SUFFICIENT LIGHTING When working in dark places, turn on the work lights. If required, provide additional lighting facilities to ensure a good visibility.

When a sufficient lighting is impossible due to fog, snow or rain, stop working.

1-19

1. SAFETY INSTRUCTIONS SET LIMITS TO WORKING AREAS Set limits around the working area to avoid collision or personal injury. Before starting to work, check for the presence of personnel or obstacles in the area around the machine. Use a flagman to guide the operator whenever necessary.

CAUTION FOR WORK IN URBAN AREAS It is dangerous to allow people to access the work site.

Make the work site off-limits to other people by installing warning plates.

Make sure to provide a flagman in working areas with heavy traffic to avoid accidents.

DO NOT USE NON-SERVICED MACHINE The use of non-serviced machine may cause an unexpected accident or breakdown.

Stop operation of a faulty machine. Make sure to repair any abnormalities before resuming operation.

1-20

1. SAFETY INSTRUCTIONS SLIPPERY GROUND Use caution when operating machine on boards or steel plates. Wet wood or steel ramps become slippery.

Pay special attention when working on ramps.

Provide protective devices against slipping and continue working with extreme care. Also dead leaves and branches may cause slips.

STRENGTHEN MUDDY GROUNDS When working on a soft ground or marshy area, the machine may sink.

To prevent this risk, provide logs or lumber to pave horizontally to reinforce the ground.

Frozen ground becomes soft along with the increase of temperature. Always check the ground conditions, so as to prevent possible accidents.

LOOSENED GROUND AFTER RAIN After rain, there is a possibility of the machine being exposed to the danger of tumbling down or falling down of the machine under the vibration and weight of the machine, due to the loosened shoulder of the road.

Pay attention to non-protected precipices or unstable road shoulders and approach such places with extreme care.

1-21

1. SAFETY INSTRUCTIONS LOOSE GROUND AFTER EARTHQUAKE OR DYNAMITING Pay attention to loose precipices or shoulders of roads, and falling rocks. Also pay attention to the unexploded dynamite.

BOOM, ARM AND ATTACHMENTS Give the work you are doing your undivided attention. Make certain the attachment being used is suited for the job at hand. Make certain of obstacles in the work area and operate the machine within those limits. If necessary have a flagman signal the operator to prevent injury to persons or damage to the machine or obstacles in the work area.

Before leaving the operator’s seat, lower the attachment to the ground and set the safety lock lever to the LOCKED (up) position.

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

1-22

1. SAFETY INSTRUCTIONS

1.5

INSPECTION AND MAINTENANCE SAFETY

UNDERSTAND INSPECTION/MAINTENANCE PROCEDURES Incorrect maintenance may cause not only damages on the machine, but also injury.

Before performing any maintenance operation, it is necessary that you read and understand the instructions given in the operator’s manual.

MEETING PRIOR TO WORK To prevent any accidents or injury due to errors, have a meeting before start working. When a flagman is provided, make sure that all signals are understood accordingly.

ORGANIZE AND CLEAN UP WORKING AREA Organize and clean up the working area. Remove any obstacles and also remove any grease, oil, paint, broken pieces, etc., from the working area to avoid injury.

1-23

1. SAFETY INSTRUCTIONS APPLY NOTICE OF MAINTENANCE IN PROGRESS Before performing any inspection or maintenance procedures to the machine, apply to the controls a “Maintenance in progress” tag, to warn persons not to start the machine. Inform the supervisor and all other drivers that the machine is under inspection or maintenance and that they will be informed when the machine is ready for operation.

SUITABLE TOOLS AND ATTACHMENTS Always use tools that are designed for the task at hand. Know the correct use of the tools and material before starting any maintenance or inspection procedure.

POSITION THE WORKING ATTACHMENT PROPERLY Before starting any inspection or maintenance procedure, park the machine on a level and firm ground in the hydraulic oil check position and lower the attachment to the ground. If this is not possible, secure the boom, arm and attachment to help prevent sudden movements.

Before leaving the operator’s seat, lower the attachment to the ground and set the safety lock lever to the LOCKED (up) position.

1-24

1. SAFETY INSTRUCTIONS CLEAN THE MACHINE Keep the machine clean and free of debris, excess or spilled lubricants, fuel and fluids. Use approved solvents, detergents and water to clean the machine and its components on a regular basis. Be careful not to allow water to reach electrical components.

Serious damage can occur to the electrical system by allowing water to reach the electrical components. Never clean inside of cab, or electrical components with pressurized water or steam.

STOP THE ENGINE Before starting any inspection or maintenance operation on the machine, make sure that the engine has been stopped and set the safety lock lever(s) to the LOCKED (up) position. Failure to stop engine could result in serious bodily injury or death.

REFUELLING Move the machine to a well ventilated area for refuelling. Use only specified fuel as described in the MAINTENANCE section of this operator’s manual.

Immediately clean up all spilled fuel and dispose of waste properly. After refuelling is complete, securely tighten fuel cap.

Never use the fuel for cleaning.

1-25

1. SAFETY INSTRUCTIONS SUPPORT THE MACHINE If it is necessary to raise the machine for inspection or maintenance operations, always support the same by positioning it as shown in the illustration and use safety supports (1) with sufficient capacity or safety wedges (2) under the crawlers or wooden boards.

Never inspect or perform maintenance procedures under a raised machine that is not sufficiently supported.

HYDRAULIC PRESSURE Under normal conditions, all circuits of the hydraulic system are under extreme pressure. When inspecting for leaks, use a small piece of cardboard, wood or metal to locate leaks. Also small (pinhole) leaks can be dangerous if hydraulic oil comes into contact with skin or eyes.

Wear approved safety goggles or face shields, gloves, a hard hat, safety shoes and work clothes during all inspection and maintenance procedures.

Seek for immediate medical assistance if injury occurs.

PRESSURIZED FLUIDS AND LUBRICANTS Always release pressure from hydraulic tank, engine coolant, fuel system and all systems containing pressure before removing any caps or components.

Escaping fluid under pressure can penetrate the skin causing serious injury.

Be cautious of hot fluids and gases from engines that have just been stopped. Carry out inspection and maintenance operations only after the systems have cooled down.

1-26

1. SAFETY INSTRUCTIONS CARE FOR PROPER VENTILATION Maintenance for the machine indoor or in a place with poor ventilation, may cause poisoning by gas.

Pay special attention to ventilate any exhaust gas, fuel, cleaning oil, paint or similar articles.

Ensure proper ventilation in the working area when the machine is operated indoors. Provide a fan for ventilation, if required.

PREVENTIVE MEASURES AGAINST FIRE During maintenance, it is unavoidable to handle flammable materials such as batteries, fuel, lubricating oil, etc.

To prevent fire: • use a nonflammable cleaning oil; • extinguish any naked flame capable of causing fires; • provide appropriate fire fighting equipment such as a fire extinguishers; • refrain from smoking during maintenance work; • keep away all flammable materials during grinding or welding.

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

1-27

1. SAFETY INSTRUCTIONS DO NOT HEAT HYDRAULIC EQUIPMENT OR PIPING Hot hydraulic components or piping will cause gas expansion, which can easily catch fire.

Dangerous works like welding, brazing, torch heating, etc. on components or ducts of the hydraulic system, or in the vicinity of it are not allowed.

WORKING ON HIGH PLACES To work on high places can generate danger of falls.

Be careful not to approach edges.

• Make sure to use the appropriate equipment, such as: ladders, man lifts etc.

• In addition, strap yourself to the proper equipment accordingly.

• Avoid spillage of any oil or grease.

• Do not leave any tools around the working area.

• Use extreme caution to avoid slipping while walking.

• Never jump into or from climbing equipment. Use a step-ladder or handrail and securely maintain a three point contact while mounting or dismounting at all times.

• Make sure to read the man lift equipment operator’s manual before using.

• Comply with climbing equipment weight ratings.

DO NOT DROP TOOLS AND PARTS Dropping of any tools and parts in the working area may cause injury or faulty machine operation.

Do not leave tools or articles in the working area or component compartments. Be sure to store all tools properly when the work is completed.

1-28

1. SAFETY INSTRUCTIONS ELECTRIC SYSTEM Before performing any inspection work or maintenance on the electrical system, or performing any welding procedures, disconnect the negative (-) cables from the battery terminals. Not disconnecting the negative (-) cable could cause extensive damage to the electrical system.

CAUTION WITH MODIFICATIONS We will not be liable for any injury or damages due to equipment modification without approval.

When any modification is intended, consult your Dealer.

AFTER COMPLETION OF MAINTENANCE WORK Always, be sure to check the machine for proper functioning when any maintenance work is completed: • once maintenance operations are completed, let the engine idle and check for leaks or anomalies; • slowly operate each machine control to confirm proper operation; • increase the engine speed gradually, and again check for leakages and abnormalities; • operate each control lever normally to confirm correct operation.

1-29

1. SAFETY INSTRUCTIONS GENERAL GUIDELINES FOR WELDING Welding work must be performed by a certified welder with sufficient experience. In addition, safety practices must be followed by any personnel involved in such work. Identify all cracks or areas to be welded by thoroughly cleaning the suspected surface, remove paint and check with dye penetrant or magnetic particle tester. The life expectancy of the welded area depends on the work quality and the attention given to details during welding.

• Avoid welding structures with surface temperatures below 16 °C (61 °F).

If needed, preheat surface with a hand torch. In cases where the machine components are extremely cold, we recommend to bring the components inside and to allow them to warm up to 16 ÷ 20 °C (61 ÷ 68 °F) for at least 12 hours prior to welding.

• Remove paint from any surface to be heated or welded. Painted surfaces produce unhealthy gases when heated or welded. Use mask and proper skin protection when removing paint from any surface. When removing paint sanding, do not breath the generated dust. Be sure to use plenty of soap and water to rinse the surface to be welded, since chemicals will generate unhealthy gases when heated and/or welded.

S WARNING HAVE A FIRE EXTINGUISHER ON HAND AT ALL TIMES WHILE GRINDING, HEATING, OR WELDING. BE SURE TO CLEAN OIL AND/OR FLAMMABLE MATERIALS FROM ANY SURFACE TO BE CUT. PROTECT ALL FLAMMABLE PARTS AND SURFACES FROM SPARKS AND/OR FLAMES. BE SURE TO PERFORM WORK IN A WELL VENTILATED AREA. KEEP SPARKS AND FLAMES AWAY FROM PAINT AND/OR SOLVENT. KEEP SPARKS AND FLAMES FROM CYLINDER RODS, SEALS, ELECTRICAL WIRES, AND/OR HYDRAULIC HOSES.

1-30

1. SAFETY INSTRUCTIONS ADJUSTING CRAWLERS TENSION The grease used to adjust the crawler shoe tension is under extreme pressure in the cylinder. Use extreme caution when adjusting crawler tension.

Keep face, hands and legs away from grease nipples.

Carefully and slowly loosen the grease nipple when adjusting crawler tension. Do not loosen the grease fitting more than one turn.

PAY ATTENTION TO BROKEN PIECES WHEN HAMMERING Flying particles may cause injury when hammering hard metal parts, such as pin, edge, tooth, bearing, etc.

Wear protective clothes such as protective glasses, safety hat, etc. during maintenance.

DISPOSE OF WASTE PROPERLY Dispose of oils, fuel, coolant, solvents, filters, batteries etc. according to federal, state and local codes and regulations regarding hazardous waste disposal. Contact local authorities for proper disposal methods of such materials.

1-31

1. SAFETY INSTRUCTIONS

1.6

PRECAUTIONS DURING BATTERY USE

WEAR PROPER PROTECTIVE CLOTHES Wear a long sleeve shirt, gloves and approved safety glasses or face protection when working with or around batteries. Battery electrolyte (acid) will cause severe burns if allowed to make contact with clothing, skin or eyes. Should electrolyte (acid) come in contact with clothes, skin or eyes, immediately remove effected clothing, flush area with clean water for 15 minutes and get prompt medical attention.

KEEP AWAY FROM FIRE OR FLAMES Never allow batteries in the vicinity of fire or naked flames and do not smoke when working with batteries. In batteries, an explosive mixture of hydrogen and oxygen is released. Always work with batteries in a well ventilated area.

USING BOOSTER CABLES • When using the another machine’s or vehicle’s battery to boost a discharged battery, make sure that the machine or vehicle does not come into contact with the disabled machine.

• Ensure the position of positive (+) and negative (-) terminals on booster battery and battery of disabled machine, before connecting booster cables.

• Connect the positive (+) cable first, then the negative (-) one.

• Disconnect the negative (-) cable first, then the positive (+) one.

A. Battery charging B. Battery discharging C. Red cable D. Black cable E. Upper structure of the stopped machine Cable connecting order: 1>2>3>4 Cable disconnecting order: 4>3>2>1

1-32

1. SAFETY INSTRUCTIONS

S WARNING IMPROPER BOOSTER CABLE CONNECTIONS CAN CAUSE AN EXPLOSION RESULTING IN PERSONAL INJURY. CONNECT BOOSTER CABLES USING FOLLOWING PROCEDURE: • CONNECT BOOSTER CABLE TO POSITIVE (+) BATTERY TERMINAL OF DISCHARGED BATTERY. CONNECT OTHER END OF BOOSTER CABLE TO POSITIVE (+) BATTERY TERMINAL OF NORMAL BATTERY. • CONNECT OTHER BOOSTER CABLE TO NEGATIVE (-) BATTERY TERMINAL OF NORMAL BATTERY. CONNECT THE OTHER END OF THE BOOSTER CABLE TO THE UPPER STRUCTURE OF THE TROUBLED MACHINE. START ENGINE AND REMOVE CABLES IN REVERSE ORDER.

BOOSTER

OTHER PRECAUTIONS • Pay attention to danger of sparks triggered off by unintended contact between the positive (+) terminal of battery and the machine body with a tool, etc.

• Make sure to correctly tighten the caps of the battery elements.

• Securely tighten up the battery terminals.

• Leave the waste battery to a specialist for disposal.

1-33

1. SAFETY INSTRUCTIONS

1.7

WARNING LABELS AND SAFETY DECALS

Warning labels and safety decals are applied to the machine to remind users and personnel of specific safety instructions to be observed with the various machine parts. See the following examples of warning labels and safety decals along with their location.

1.7.1

NOTES FOR WARNING LABELS AND SAFETY DECALS

• Do not remove the warning labels and safety decals.

• Confirm whether warning labels can be easily read.

If words or illustrations are illegible, clean off or replace the labels.

• Use a cloth, water and a detergent for cleaning.

Never use organic solvents or gasoline.

• If warning labels are damaged, missing or illegible, replace them with new ones.

Contact your Dealer for new safety labels.

LOCATION OF WARNING LABELS AND DECALS

1-34

1. SAFETY INSTRUCTIONS

1-35

1. SAFETY INSTRUCTIONS

1-36

1. SAFETY INSTRUCTIONS ARMS MOVEMENT WARNING PLATE

1

Located on seat stand cover.

It warns about the need to stop the engine before opening the hood.

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

HYDRAULIC OIL BLEEDING PLATE

2

Located aside the hydraulic tank.

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

Danger of pump seizure.

ELECTRICAL LINES SAFETY DECAL; SAFETY SYSTEMS

3

Located on seat stand cover.

It warns about danger in the case of work near electrical lines.

It is imperative for the operator, when leaving the cab with the engine running even for a very short time, to set the safety lock lever to the LOCKED position. Controls are thereby disconnected and any accidental equipment movement is impossible.

1-37

1. SAFETY INSTRUCTIONS HOT SURFACE DECAL

4

Located on hood hinge.

Immediately after the machine is operated, the temperature and pressure of the engine coolant, engine oil, and hydraulic oil are very high. Burns may result if caps are removed, or oil, water, or filters are changed under these conditions. Let the components cool down first.

PRESSURIZED FLUIDS AND LUBRICANTS

5

Located on radiator cover.

Always release pressure from hydraulic reservoir, engine coolant, fuel system and all systems under pressure before removing any caps or components.

Be cautious of hot fluids and gases from engines that have just been stopped. Carry out inspection and maintenance operations only after the systems have cooled down.

ENGINE STOP DECAL

6

Located on engine radiator.

It indicates that it is obligatory to stop the engine before opening the engine guard.

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

1-38

1. SAFETY INSTRUCTIONS DECAL, COUNTERWEIGHT SAFE OPERATING AREA

7

Located on radiator cover.

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

ENGINE STOP DECAL

8

Located on engine radiator.

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

Pay attention as no stops are provided to prevent this problem.

BOOSTER CABLES DECAL

9

Located on battery box cover.

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

1-39

1. SAFETY INSTRUCTIONS CRAWLER ADJUSTER DECAL

10

Located on crawler frame.

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

Danger of severe injuries.

KEEP WORKING AREA CLEAN

11

Located on both sides of the arm.

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

Always look around before you start the swing operation. Make sure that nobody stays in the operation range of the machine. Sound horn before moving the machine.

DOZER DECAL

12

Located on seat stand cover.

It indicates to consult this Manual before operating the dozer control lever.

1-40

1. SAFETY INSTRUCTIONS BATTERY DECAL

13

Located on battery box cover.

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

DECAL FOR WINDOW LOCK (CAB ONLY)

14

Located inside front window.

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

FRONT WINDOW FALL (CAB ONLY)

15

Located on front window.

Falling of front window can cause injury.

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

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

CAB DOOR DECAL (CAB ONLY)

16

Located inside cab door.

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

1-41

1. SAFETY INSTRUCTIONS REMOVING CAB (CAB ONLY)

17

Located inside the cab right.

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

1-42

18

1. SAFETY INSTRUCTIONS

1.8

FORBIDDEN USE

Here are some examples of a forbidden use of the machine. The machine should never be used in this way also by the most experienced operators. Such abuse and misuse of this machine and its attachments can result in serious injury, death, severe equipment damage and shortened service life of the machine. Under no circumstance should any of these operations be attempted. Use common sense in understanding and following the instructions for use given in this manual.

DO NOT USE TRACTIVE FORCE OF THE MACHINE FOR LOADING THE BUCKET ATTACHMENT Doing so will exert excessive force on the machine structure, front end attachments and could cause severe equipment damage. Use crawlers for normal travel operations only.

DO NOT USE THE ROTATION AND SLEWING FORCE OF THE MACHINE Doing so will exert excessive force on the machine structure, front end attachments and shorten the life of the rotation and slewing system of the machine.

Also, serious injury or death could result from such operations.

1-43

1. SAFETY INSTRUCTIONS DO NOT PERFORM HAMMERING OPERATIONS WITH THE BUCKET Performing operations such as hammering and piling will cause extensive damage to the machine and its components. Also, serious injury or death could result from such operations.

DO NOT USE THIS MACHINE FOR ANYTHING OTHER THAN ITS INTENDED PURPOSE This machine is designed and manufactured for digging, loading and ground levelling operations only.

Any other use could cause excessive strain to the machine, its components and systems and could cause serious accidents, even mortal, to the driver and to the personnel working near the machine.

DO NOT OPERATE BUCKET AND ARM CYLINDERS TO STROKE END REPEATEDLY If bucket and arm cylinders are forcibly driven to stroke end, to clean debris from the bucket, this will cause the vibration of the bucket cylinders and consequently their damaging.

Use high pressure water or manually remove stuck material from the bucket.

1-44

1. SAFETY INSTRUCTIONS DO NOT OVER EXERT THE MACHINE Know the limitations of the machine and its attachments and operate the machine within those specifications.

Do not exceed the values specified in the carrying capacity table.

Never tip or raise the machine to obtain power to move material.

This could cause extensive damage to the machine and its components as well as result in serious bodily injury or death.

MAKE SURE THAT THE DOZER DOES NOT HIT OBSTACLES Pay attention that the dozer does not hit any obstacles such as rock lumps.

It causes damage to the dozer and cylinder.

BE CAREFUL WHEN RETRACTING THE ATTACHMENT When the attachment is retracted for travel or transport, pay attention that the bucket does not to hit the dozer.

1-45

1. SAFETY INSTRUCTIONS DO NOT SUPPORT THE MACHINE ON ONE SIDE WITH THE DOZER When the dozer is used as a stabilizer, do not support the machine at one end of the dozer only, but at both ends.

CAUTION WITH DEEP EXCAVATIONS During deep excavations, pay attention to the dozer in front. The boom cylinder could come in contact with the dozer.

Place the dozer at the back of the machine for deep excavations, unless the working area does not permit it.

1-46

1. SAFETY INSTRUCTIONS

1.9

PRECAUTIONS AT THE END OF DAILY WORK

Perform all of the following procedures after each work shift is complete, to insure the machine is in optimal operating condition for the next work shift or job site: • move the machine to a level and firm ground; • lower the bucket to the ground; • fill the fuel tank to the “Full” mark to reduce air volume and condensation (moisture). This reduces the risk of ice and rust building in the fuel tank and prevents several problems at start-up and during operation; • close and lock all windows in place in order to prevent damage to the electrical systems of the machine due to water or moisture (for cab version only); • thoroughly clean and inspect the machine; • While washing the machine, pay attention not to direct the water jet directly onto the grids of the side doors, in order to prevent damage to the internal electrical components; • perform lubrication maintenance and repair or replace any problem areas found before restarting the machine; • if operating the machine in cold climates, it may be necessary to remove the batteries from the machine and store in a warm well ventilated area.

Install the batteries in the machine before next start up. This will help prevent premature battery deterioration; • remove the starter key, lock all doors with the key and lock all access covers.

1-47

1. SAFETY INSTRUCTIONS

1.10

TRANSPORTATION

Use the following general guidelines for loading or unloading the machine on a transportation vehicle.

The machine must be loaded and unloaded on firm, level ground, away from the road shoulder. Do not use the attachments to load or unload the machine onto/from the trailer.

When necessary, use a ramp capable of bearing the machine’s weight. Check the ramp’s width, length and thickness to secure the loading/unloading work.

And when much warp appears on the ramp structure, support them with safety blocks or alike.

Remove any mud, oil and grease from the ramp surface as well as from crawlers in order to prevent the machine from slipping.

Do not change the travelling direction on the ramp.

When required, back down the machine to the ground, reposition and try again.

Always use low travel speed for loading or unloading onto/from the trailer.

After loading the machine, stop the engine and set the safety lock lever from the UNLOCKED (B) to the LOCKED (up) position (A).

Use cables or wire ropes (1) with sufficient length to secure front and rear of the machine to trailer. Provide blocks to the machine crawlers, to avoid any movement of the machine.

Protect wire ropes against edges with pads (2).

1-48

1. SAFETY INSTRUCTIONS While transporting, observe the relevant regulations, keeping safety in mind.

Before transporting the machine, place the bucket against the dozer so that any involuntary rotation of the upper structure is prevented.

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

Refer to section “5. TRANSPORTATION” for the details of loading, unloading and fixing procedures of the machine.

A. Overall height B. Overall length

1-49

1. SAFETY INSTRUCTIONS

1.11

TOWING THE MACHINE

Should the machine become stuck in soft soil, it may be necessary to tow it. Attach a metal cable or a chain with sufficient strength to the lower frame.

Attach other end to the vehicle used for towing.

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

S WARNING WHILE TOWING, DO NOT ENTER THE AREA BETWEEN THE MACHINE AND TOWING VEHICLE. DO NOT APPLY A SHOCK LOAD ONTO THE TOWING ROPE. DO NOT USE EYES ON MACHINE LOWER FRAME TO TOW MACHINE. KEEP THE WIRE CABLE HORIZONTAL, AND PERPENDICULAR TO THE CRAWLER FRAME. TOW THE MACHINE SLOWLY AT LOW SPEED. FOR TOWING THE MACHINE BODY, APPLY PADS AT THE CORNERS OF THE CRAWLER FRAME TO PREVENT THE METAL WIRE AND THE CRAWLER FROM BEING DAMAGED. NOTE: do not tow the machine using the brackets welded to the lower plates of the lower frame. These brackets are provided for towing lightweight objects.

1-50

2. MACHINE FAMILIARIZATION

2-1

2. MACHINE FAMILIARIZATION

2-2

2. MACHINE FAMILIARIZATION

2.1

MACHINE FAMILIARIZATION

All operators, service mechanics and personnel responsible for operation, inspection and maintenance of the machine should become thoroughly familiar with the controls and components and their functions before working with or on this equipment.

Study the information in this section to become familiar with the controls and components of this machine.

2.2

GENERAL NOMENCLATURE

2.2.1

FRONT, REAR, RIGHT AND LEFT

In this manual, the “front” (A), “rear” (B), “right” (D) and “left” (C) directions are based on the conditions where the travel motors are positioned at the rear (1) and the operator is facing the direction in which the machine advances (forward).

2.2.2

MAIN COMPONENTS

The nomenclature drawing below points out the location of the main components of the hydraulic excavator. Study these areas and locate these components on the machine. Specific information regarding these components are explained on the following pages of this section.

2-3

2. MACHINE FAMILIARIZATION

1. Engine

20. Battery

2. Oil filter

21. Swivel joint

3. Radiator

22. Travel motor

4. Reservoir tank

23. Slewing ring

5. Air cleaner

24. Idler adjuster

6. Muffler

25. Lower roller

7. Fuel tank

26. Upper roller (E27.2SR)

8. Hydraulic oil tank

27. Rubber crawler

9. Hydraulic pumps

28. Dozer

10. Slewing motor

29. Dozer cylinder

11. Swing cylinder

30. Boom

12. Control valve

31. Boom cylinder

13. Travel lever

32. Arm cylinder

14. Safety lock lever

33. Light

15. Canopy

34. Arm

16. Operating lever

35. Link

17. Dozer control lever

36. Bucket cylinder

18. Throttle lever

37. Bucket

19. Gauge cluster

2-4

2. MACHINE FAMILIARIZATION

2.3

OPERATOR’S CAB NOMENCLATURE

The operator’s cab nomenclature, see figure below, points out locations of operator controls in the hydraulic excavator operator cab. Study these areas and locate these components on the machine. Specific information regarding these components are explained on the following pages of this section.

1. Right control lever

10. Gauge cluster

2. Left control lever

11. Work light switch

3. Safety lock lever

12. Throttle lever

4. Right travel lever

13. Starter switch

5. Left travel lever

14. Deceleration push-button

6. Swing control pedal

15. Dozer control lever

7. Option pedal (hydraulic breaker and nibbler)

16. Operator’s seat

8. Horn switch

17. Wiper and washer switch (cab only)

9. Travel speed select switch

18. Heater switch (option)

2-5

2. MACHINE FAMILIARIZATION

2.4

INSTRUMENT AND CONTROL NOMENCLATURE

The following information provides a brief description and function of the components and controls of the hydraulic excavator.

All personnel using this machine must read and understand this instructions before starting operation or working on this machine.

2.4.1

INSTRUMENT PANEL

The cluster consists of the following instruments.

TYPE A GAUGES

B WARNING LAMPS

C INDICATOR LAMP

No.

DESCRIPTION

1

COOLANT TEMPERATURE GAUGE

2

FUEL LEVEL GAUGE

3

ENGINE OIL PRESSURE LAMP (red)

4

COOLANT TEMPERATURE LAMP (red)

5

BATTERY CHARGE LAMP (red)

6

LOW FUEL WARNING LAMP (red)

7

HIGH TRAVEL SPEED LAMP (yellow)

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

2-6

2. MACHINE FAMILIARIZATION 2. FUEL LEVEL GAUGE This instrument indicates the amount of fuel in the tank. Full tank contains about 28 litres (7.4 gal). This instrument indicates the residual volume of fuel inside the tank. When the fuel level gauge needle (2) reaches the reference “F”, the fuel tank is full. Make sure to refuel when the indicator is approaching to reference “E”. Refill the fuel tank with diesel fuel only. Normally the gauge needle takes some time to move up to the appropriate level after turning the starter key on “ON”.

B. WARNING LAMPS

S CAUTION When one of these warning lamps turns on, immediately stop working. Then investigate the cause for it, and carry out appropriate inspection and maintenance referring to the section “4. MAINTENANCE”.

3. ENGINE OIL PRESSURE LAMP (red) The lamp turns on when the starter key is turned to ON, and must turn off after the engine has been started. During machine operation, if the engine oil pressure drops excessively, this lamp turns on. Stop the engine and check the quantity of engine oil.

S CAUTION The engine may undergo severe damage if the machine is operated while this lamp is on.

4. COOLANT TEMPERATURE LAMP (red) If the coolant temperature rises excessively, a warning lamp turns on.

The coolant temperature may rise irregularly, if the engine is overloaded.

S CAUTION The engine may undergo severe damage if the machine is operated while this lamp is on.

2-7

2. MACHINE FAMILIARIZATION If the engine is overheating, stop operation immediately and let the engine idle, to lower its temperature.

Once the coolant has cooled down, stop the engine.

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

S WARNING DO NOT PERFORM ANY KIND OF MAINTENANCE ON AN ENGINE THAT HAS JUST STOPPED WORKING. IMMEDIATELY AFTER ENGINE STOP, FLUIDS AND SURFACES WILL BE EXTREMELY HOT. ALLOW THE ENGINE TO COOL, BEFORE PROCEEDING TO INSPECTION AND/OR MAINTENANCE.

5. BATTERY CHARGE LAMP (red) It warns about a fault in the battery charging system during engine running. This lamp turns on when the starter key is turned to ON, and must turn off after the engine has been started. If this lamp does not switch off, the battery does not charge correctly.

Check the charging system.

6. LOW FUEL WARNING LAMP (red) If the fuel is low, a warning lamp lights up. Stop the engine immediately and refuel.

C. INDICATOR LAMP This lamp indicates the working conditions.

7. HIGH-SPEED TRAVEL LAMP (yellow) This lamp turns on when the travel speed is switched to high. The travel speed selector switch is located on the grip of the right travel lever.

2-8

2. MACHINE FAMILIARIZATION 2.4.2

SWITCHES

1. Key switch

6. Heater switch (canopy only)

2. Travel speed select switch

7. Wiper and washer switch (cab only)

3. Horn switch

8. Travel alarm select switch (option)

4. Deceleration select switch

9. 12 V electric power socket

5. Work light switch

1. KEY SWITCH This switch is used to start or stop the engine.

1. HEAT: When starting the engine is difficult due to a cold climate, turn the key to this position to activate the engine preheating. Hold the key in this position for about 15 seconds to ease up the engine start.

Release key after engine start.

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

3. ON: In this position all electrical circuits are powered.

Maintain the key in this position while the machine is operating.

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

2-9

2. MACHINE FAMILIARIZATION 2. TRAVEL SPEED SELECTOR SWITCH Use this switch to select HIGH (2nd gear) or LOW (1st gear) travel speed. When moving the starter key from ON to OFF, the travel speed automatically returns to LOW. Select the desired speed before starting travelling.

S WARNING TRAVEL WITH THE MACHINE IN LOW SPEED ON A SLOPE AND WHEN LOADING/UNLOADING THE MACHINE ONTO/FROM A TRUCK/ TRAILER. A SUDDEN CHANGE OF THE MACHINE’S TRAVEL SPEED MAY CAUSE THE MACHINE TO ROLL OVER.

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

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

3. HORN SWITCH Depress the symbol of this switch on top of left control lever to sound the horn.

S CAUTION Sound the horn before starting engine, travelling, slewing or operating the attachments.

4. DECELERATION SELECT SWITCH Press this switch while the engine rotates to set the same at low speed.

Press this switch again to release deceleration.

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

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

2-10

2. MACHINE FAMILIARIZATION 5. WORK LIGHT SWITCH This switch is used to activate the work lights on boom and canopy.

6. HEATING SWITCH (optional) This switch is used to warm up the cab interior.

“OFF”: Stop “L”: Low speed fan drive “H”: High speed fan drive NOTE: the heating operates with the engine coolant. This is the reason why the heating generates warm water only if the coolant is heated.

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

Through the cock (1) opening, by means of the hot water flow supplied from the engine, the cab can be heated. This operation has to be carried out at winter begin and later on when at hot season begin, the cock must be closed.

S WARNING BEFORE CARRYING OUT THESE OPERATIONS, STOP THE ENGINE, ENSURING THAT ALL ITS COMPONENTS HAVE COOLED DOWN.

7. WIPER AND WASHER SWITCH (cab only) This switch activates the wiper and washer liquid.

“WASH” (left wash): the water jet for washing activates.

“OFF”: stop.

“ON”: windscreen wiper operation.

“WASH” (right wash): Wipers and washer liquid jet activate.

NOTE: the windscreen washer motor can get damaged if the windscreen washer operates continuously over 20 seconds, or without liquid.

2-11

2. MACHINE FAMILIARIZATION 8. TRAVEL SELECT SWITCH (optional) The travel alarm switch is located on the right control panel.

When travel is engaged the alarm sounds automatically.

9. 12 V ELECTRIC POWER SOCKET This socket provides electric power for 12 V electrical appliances (inspection light, etc.).

NOTE: it can not be used as cigarette lighter.

2.4.3

LEVERS AND PEDALS

1. Safety lock lever 2. Right/left control levers 3. Travel levers 4. Throttle lever 5. Dozer control lever 6. Swing control pedal 7. Option pedal (hydraulic breaker and nibbler)

2-12

2. MACHINE FAMILIARIZATION 1. SAFETY LOCK LEVER In models provided with a cab there is only one lever on the left side (no access on the right side), while the models with canopy are provided with two safety lock levers, one on each side.

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

S WARNING ALWAYS SET THE SAFETY LOCK LEVER TO THE LOCKED (UP) POSITION BEFORE LEAVING THE OPERATOR’S SEAT. NEVER LEAVE THE MACHINE UNATTENDED WITH ENGINE RUNNING OR WITH SAFETY LEVER UNLOCKED (DOWN). NOTE THAT, EVEN WITH THE SAFETY LOCK LEVER IN LOCKED (UP) POSITION, THE DOZER AND BOOM FUNCTIONS ARE STILL ENABLED.

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

NOTE: the slewing and optional attachment controls are locked by means of the cover on the pedal. The dozer or track width enlargement controls cannot be locked.

B. CONTROL UNLOCK With the safety lock lever(s) in UNLOCKED position, all functions are enabled again.

2-13

2. MACHINE FAMILIARIZATION 2. CONTROL LEVERS (ISO CONFIGURATION) The control levers activate the functions illustrated on the right.

S WARNING • CONFIRM FOR SAFETY AROUND THE WORKING AREA. ALSO ENSURE THAT EACH LEVER OPERATION IS IN ACCORDANCE WITH THE OPERATING PATTERN INDICATED ON THE LABELS. • IF THE CONFIGURATION ON THE DECAL DOES NOT CORRESPOND TO THAT OF THE CONTROL LEVERS, IMMEDIATELY CHANGE THE DECAL TO PREVENT ACCIDENTS AND/ OR INJURY. NOTE: the control levers return to the NEUTRAL position when released, and the movement of the attachment is stopped.

All functions can be activated simultaneously.

LEFT CONTROL LEVER 2

E Arm out

RIGHT CONTROL LEVER 1

F Arm in 4

G Slewing left

A Boom down B Boom up

3

H Slewing right

C Bucket in D Bucket out

2-14

2. MACHINE FAMILIARIZATION 3. TRAVEL CONTROL LEVERS The travel control levers are located in front of the operator’s seat. The travel levers are used to move forward and backward the left or right machine crawler.

S WARNING USE CAUTION TO AVOID COMING IN CONTACT WITH OTHER MACHINES WHILE TRAVELLING. BE SURE TO KNOW THE LOCATION OF THE TRAVEL MOTORS BEFORE OPERATING THE TRAVEL FUNCTION. When travel lever is activated, the relevant alarm sounds to warn people nearby the machine.

S CAUTION If the travel alarm does not sound after the travel lever is operated, immediately stop the engine and contact the nearest authorized Dealer for repair.

Operation with a travel alarm failure may cause severe accidents resulting in injury or death.

A. To travel forward (push both control levers forward at the same time).

B. To travel in reverse (pull both control levers back at the same time).

C. Neutral position (release the levers to the central position to stop travel).

NOTE: the travel alarm function is optional.

4. THROTTLE CONTROL LEVER This lever is located on the right side of the operator’s seat and is used to adjust the engine rpm.

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

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

2-15

2. MACHINE FAMILIARIZATION 5. DOZER CONTROL LEVER This lever enables to control the dozer (1) up or down functions.

S WARNING EVEN THOUGH THE SAFETY LOCK LEVER IS SET IN LOCKED POSITION, THE TRAVEL LEVER REMAINS ACTIVE.

By pulling lever backward “C” dozer lifts, while by pushing lever forward “D” dozer lowers.

6. SWING CONTROL PEDAL This pedal operates the swing motion of the boom.

S WARNING LOCK OPTIONAL PEDAL IF THIS FUNCTION IS NOT USED. VERY SERIOUS ACCIDENTS MAY OCCUR, IF YOU PRESS ACCIDENTALLY THE UNLOCKED PEDAL. By pushing pedal down and right “A” the right swing is operated.

By pushing pedal down and left “B” the left swing is operated.

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

7. PEDAL FOR OPTIONAL EQUIPMENT (breaker and nibbler) Use this pedal to operate optional equipment.

S WARNING LOCK THE PEDAL IF ATTACHMENT IS NOT IN USE. CARELESS OPERATION OF THE UNLOCKED PEDAL MAY CAUSE SERIOUS ACCIDENTS. Refer to section “7. OPTIONAL ATTACHMENT” for the operation of hydraulic breaker and nibbler.

2-16

2. MACHINE FAMILIARIZATION Pedal locking device This device locks pedal controlling the optional equipment. The lock is released if relevant lock pin (1) of pedal is pushed forward.

A. Unlock position B. Lock position

2.4.4

SEAT BELT

OPENING/CLOSING Check if the belt is twisted. Completely insert the flip into the buckle (1) of the belt until you hear a click.

Adjust the belt length so that there is no looseness (2).

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

S WARNING INSPECT SEAT BELTS DAILY. REPLACE SEAT BELT IF IT SHOWS SIGNS OF DEFORMATION OR DAMAGE. ALWAYS ENSURE THE SEAT BELT SUPPORT CAPSCREWS ARE PROPERLY TIGHTENED.

2-17

2. MACHINE FAMILIARIZATION 2.4.5

CAB

The following equipment are provided for the cab to ventilate or to facilitate operation.

S WARNING WHEN USING THE EQUIPMENT IN THE CAB, SET THE SAFETY LOCK LEVER TO THE LOCKED POSITION TO AVOID UNEXPECTED MACHINE MOVEMENT IF A WORK LEVER IS ACCIDENTALLY ACTUATED. THIS MAY CAUSE INJURIES. LOCKING CAB DOOR To lock the door in the open position, slide the door fully open until it locks on the catch (1) located on the rear of the cab.

UNLOCKING DOOR FROM INSIDE To unlock the door, pull the lever (1) backward.

2-18

2. MACHINE FAMILIARIZATION (UPPER) FRONT WINDSHIELD OPENING The front windshield can be slided on cab ceiling and locked in this position.

S CAUTION Be sure to move the machine to level ground when opening/closing the front windshield, and lock it.

Especially, unlocking windshield in forward-inclined position of the machine causes the front windshield to fall down.

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

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

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

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

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

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

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

(LOWER) FRONT WINDSHIELD OPENING After the upper front windshield has been fastened, the lower front windshield can also be removed.

Once it has been removed from the frame guides (1), it is necessary to fix it by means of proper retainers on cab back holders.

S WARNING DO NOT START WORKING WITH LOWER FRONT WINDSCREEN DISASSEMBLED.

2-19

2. MACHINE FAMILIARIZATION ROOF LAMP Press relevant switch when required.

“ON”: the lamp turns on “OFF”: the lamp turns off

OPENING/CLOSING THE WINDOW ON THE RIGHT SIDE Release retainer (1) and slide the glass.

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

FILL WINDSCREEN WASHER RESERVOIR The washer reservoir is installed on the left rear of cab.

Check the washer reservoir (1) for liquid level.

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

S WARNING DURING WINTER USE ALL SEASONS WASHING LIQUID.

2-20

2. MACHINE FAMILIARIZATION 2.4.6

HOODS

S WARNING STOP THE ENGINE WHEN HOOD OR RADIATOR COVER ARE OPEN. Locking devices are provided for the engine guards.

Use the starter key to open and close engine guards.

OPENING Insert the key in the lock (1).

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

Fasten hood open with suitable stay (2).

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

Close the hood.

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

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

S CAUTION Always secure hoods with stays to hold them open.

2-21

2. MACHINE FAMILIARIZATION 2.4.7

ESCAPE ROUTES

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

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

S WARNING BEFORE BREAKING THE FRONT WINDSHIELD, IT IS NECESSARY TO WEAR SUITABLE GLOVES AND PROTECTIVE GLASSES. DANGER OF BODILY INJURIES.

2.4.8

SEAT ADJUSTMENT

Pull the seat adjustment lever to the right.

Move the seat forward or backward to desired position.

Release the lever to lock the seat in position.

2.4.9

ELECTRICAL EQUIPMENT

WORK LIGHTS A work light is provided on the boom and on the canopy to light up the visual field with poor visibility.

F26461

2-22

2. MACHINE FAMILIARIZATION 2.4.10

STORAGE BOX AND OTHERS

STORAGE BOX FOR MANUAL Store the manual in the storage box provided on the back of seat.

Keep the manual in the storage compartment of the ceiling.

TOOLS Use the standard tools supplied with the machine for maintenance work.

GREASE NIPPLE Use the grease nipple for machine lubrication with grease. After use, fold away the grease nipple handle, wipe off the grease with a cloth and store grease nipple in the usual place.

NOTE: use the grease nipple supplied with the machine for lubrication. After use, fold away the grease nipple handle, wipe off the grease with a cloth and store grease nipple in the usual place.

When grease nipple is used for the first time, it can be difficult to squeeze out grease from the nipple (1). In such a case, open completely the lever (2).

Always operate the lever (2) completely, otherwise the cartridge (3) is not able to suck grease.

It is possible that air penetrates in the cartridge up to next use: in this case grease oozes out hardly.

When this happens, remove the cartridge, empty it and place it back.

2-23

2. MACHINE FAMILIARIZATION NOTES:

2-24

3. MACHINE OPERATION

3-1

3. MACHINE OPERATION

3-2

3. MACHINE OPERATION

3.1

MACHINE OPERATION

3.1.1

DAILY INSPECTION

Before starting the engine, walk around the machine to check for any loose nuts and capscrews, any oil, fuel or coolant leaks. Check also the condition of attachment and hydraulic system. Check for any looseness in the wirings and for any accumulated material (leaves, dirt, etc.) in hot areas.

1. Check the engine for any oil, fuel or coolant leakage. Repair as necessary.

2. Check the area around the engine and radiator for any accumulated material and remove as required.

3. Check the hydraulic system components, the hydraulic oil tank, the hoses and the joints for oil leaks and repair as necessary.

5. Check the attachments, cylinders, linkages and hoses for any cracks, wear or looseness and repair as required.

6. Check the guards, steps and handrails for damage, and the capscrews for looseness.

Repair and tighten capscrews as required.

7. Check that the gauges and the instrument panel operate correctly.

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

3-3

3. MACHINE OPERATION 3.1.2

CHECKS BEFORE ENGINE START-UP

The following items should be inspected before starting machine operation: CHECK AND RESTORE ENGINE COOLANT LEVEL

S WARNING NEVER REMOVE RADIATOR CAP WHEN ENGINE IS HOT. WAIT FOR THE ENGINE TO COOL DOWN BEFORE REMOVING THE RADIATOR CAP. The radiator (3) reservoir (4) is located on the right side of the engine compartment.

Check the coolant level with cold engine only.

Open the radiator reservoir. The proper coolant level is between the “FULL” and “LOW” marks visible in the reservoir.

NOTE: engine coolant level is higher than normal when the engine is warm. The coolant level lowers with engine temperature.

Maintain coolant level at full mark when the engine is cold.

Open the cap (1) of the reservoir (4), fill with proper coolant up to the “LOW” mark on the reservoir.

Restore the level of the radiator coolant when it is below the “LOW” mark in the reservoir. Make sure to check the engine cooling system for leakages and repair as needed, before resuming operation.

Remove the radiator cap (2), and check for proper coolant level.

Top up with proper coolant until the level approximately reaches the “FULL” mark.

Install radiator cap (2) and tighten securely.

S WARNING BE CAUTIOUS OF HOT FLUIDS AND SURFACES. WEAR GOGGLES, SAFETY SHOES, HARD HAT, WORK CLOTHES AND WORK GLOVES TO PERFORM INSPECTION AND MAINTENANCE ON THIS MACHINE.

3-4

3. MACHINE OPERATION CHECK COOLANT LEAKS If the coolant level lowers in the radiator but not in the reservoir, it is possible that the cooling system is leaking. Make sure coolant level is to specifications and pressurize system to check for leakages. Contact your Dealer for suggestions and/or repairs. Be sure to repair leakages before resuming operation.

CHECK AND RESTORE ENGINE OIL LEVEL NOTE: make sure the machine is on firm and level ground, when checking oil level.

Always check engine oil level before starting the engine.

Keep the engine switched off for at least 30 minutes after use, to check the engine oil level.

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

Wait for the machine to cool down.

Open the engine guard with the starter key.

Pull out engine oil dipstick (1), clean it with a dry cloth and re-insert it completely. Pull it out again and check the oil level. The level must be between marks (H) and (L).

If the oil is heavily contaminated or deteriorated, change it regardless of periodical schedule.

If the oil level is too low, remove the filler plug (2) and restore level by pouring oil through the filler neck.

Make sure to check the oil level again after refilling.

Clean the plug (2) and reinstall it.

Close the engine guard and lock it with the key.

S WARNING DO NOT TOP UP USING OIL WITH DIFFERENT SPECIFICATIONS FROM THOSE OF OIL ALREADY IN THE HYDRAULIC OIL TANK.

3-5

3. MACHINE OPERATION CHECK AND TOP UP OF OIL LEVEL IN HYDRAULIC SYSTEM

S WARNING NEVER CHANGE OILS OR FILTERS ON A MACHINE THAT HAS JUST FINISHED WORKING. STOP THE MACHINE AND LET IT COOL DOWN BEFORE STARTING ANY INSPECTION: DANGER OF BURNS. RELEASE HYDRAULIC OIL TANK PRESSURE BEFORE ANY INTERVENTION ON THE SYSTEM: DANGER OF PERSONAL INJURIES.

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

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

Wait for the machine to cool down.

Open the engine guard with the starter key and fix it by proper stay.

Check the oil level through level gauge (1) provided on the side of the hydraulic reservoir. The oil level is correct when set between marks “H” and “L”.

Oil level varies according to oil temperature and must be settled between following values: Before starting: “L” level [oil temperature 10 ÷ 30 °C (50 ÷ 86 °F)] Normal operation: “H” level 50 ÷ 80 °C (122 ÷ 186 °F)]

[oil

temperature

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

3-6

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

Release the internal pressure in the reservoir.

Once ensured that hydraulic tank inner pressure is null, loosen screws (2) and remove plug (3). Fill tank with recommended hydraulic oil through filler, up to restore correct level.

Check the O-ring (5) of the cover (4), and if worn or damaged, replace it.

Install the cover (4) and fasten with the capscrews to the specified torque.

Tightening torque: 23.6 ± 1.9 Nm (17.4 ± 1.4 lbf•ft) Start the engine. Activate 5-10 times the cylinder at no-load. Return the machine in oil check position.

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

Remove stay and close engine guard.

CHECK FUEL LEVEL

S WARNING MAKE SURE TO USE DIESEL FUEL ONLY AND STOP THE ENGINE BEFORE REFUELLING. BE CAREFUL FUEL DOES NOT OVERFLOW WHEN REFILLING. CLEAN UP ALL SPILLED FUEL TO PREVENT FIRE. DISPOSE OF HAZARDOUS WASTE ACCORDING TO ENVIRONMENTAL LAWS AND REGULATIONS.

Turn the starter key (1) to ON, so that the warning lamps on the instrument panel turn on.

Check the fuel level indicator (2). If level is too low, refuel.

Park the machine on a level surface.

Rest the bucket to the ground.

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

3-7

3. MACHINE OPERATION Open the plug (3) with the starter key.

Fuel tank capacity: 28 litres (7.40 gal) Do not remove the fuel tank filter (4) while refuelling to prevent contamination.

After refuelling, install the plug (3) and lock it with the key.

Close the engine guard and lock it with the key.

We recommend refuelling at the end of the working day. In this way condensation will be avoided during overnight pause. Check that the tank does not run out of fuel, because this would cause air seepage in the fuel system and air should then be bled from the fuel tank.

CHECK FUEL LEAKS Check and repair any fuel leakage. Do not operate a machine leaking fuel. Fuel leaks can be caused by a faulty drain plug, by cracks in the hoses or by loose hose clamps.

Make sure to immediately stop the engine after detection of a fuel leak. Repair fuel leak before resuming operation.

INSPECT BELT CONDITION

S WARNING ROTATING PARTS CAN CAUSE PERSONAL INJURY. KEEP AWAY FROM FAN AND BELT WHEN ENGINE IS RUNNING. MAKE SURE TO STOP ENGINE BEFORE SERVICING.

Check the belt (1) for insufficient tension, wear or damage. Insufficient belt tension may cause battery charge failure, engine overheating, or abnormal belt wear. If too much tension is applied to the belt, the bearings or belt may be damaged prematurely.

Apply a force of 98 N to the centre of belt between pulleys, and measure the belt deflection.

Belt deflection: 8 ÷ 10 mm (0.31 ÷ 0.39 in)

3-8

3. MACHINE OPERATION CHECK WARNING LAMPS

S WARNING CARELESS MOVEMENT OF ANY OPERATING LEVER MAY CAUSE SUDDEN MOVEMENT OF THE MACHINE. BE SURE TO SET THE SAFETY LOCK LEVER TO THE “LOCKED” (UP) POSITION BEFORE LEAVING THE CAB. BLADE AND BOOM OPERATION ARE STILL ACTIVES, EVEN IF SAFETY LOCK LEVER IS LOCKED (UP).

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

RED: warning lamp YELLOW: indicator lamp

Make sure the safety lock lever is in the “LOCKED” (up) position.

Make sure all control levers are in the “NEUTRAL” position.

Operation HEATING → key OFF Lamp 1

Ensure that manual throttle lever is set at low idle.

2

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

3

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

5

4

Engine oil Pressure lamp Battery charge Lamp Engine coolant Temperature warning light Insufficient fuel Warning lamp 2nd Speed Travel lamp

Preheating

START-UP → OFF → ON ON Before start-up Just after startup

Lamp OFF

Lamp ON

Lamp OFF

Lamp OFF

Lamp ON

Lamp OFF

Lamp OFF

Lamp OFF

Lamp OFF

Lamp OFF

Lamp OFF

Lamp OFF

Lamp OFF

Lamp OFF

Lamp OFF

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

CHECK WORK LIGHT With the starter key in “ON” position, turn on the work light switch so as to check if it operates correctly.

If light does not turn on, presumably the bulb is burnt out or an electric fault is occurred.

F26461

3-9

3. MACHINE OPERATION 3.1.3

MACHINE WARM UP

S WARNING DO NOT RUN THE ENGINE IDLE FOR MORE THAN 20 MINUTES. EXTENDED PERIODS OF IDLING REDUCE THE LIFE OF THE ENGINE. Set the throttle lever (1) to intermediate position, between low and high idle. Turn the starter key to START to start the engine. Release key as soon as the engine starts. The key will return to ON by itself.

Let the engine run idle for at least 5 minutes.

OIL PRE-HEATING FOR HYDRAULIC SYSTEM The hydraulic oil temperature must be between 50 °C (122 °F) and 80 °C (176 °F).

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

Failure to do so will reduce the life of the hydraulic components.

After correct engine warm-up, as previously described, position throttle lever (1) on INTERMEDIATE SPEED. Set the safety lock lever (3) to the UNLOCKED (down) position.

Operate the boom control lever (2) to raise it all the way up.

Operate the bucket control lever to retract it or extend it completely against relief. Hold in this position for one minute, then release lever (2) and wait for another minute before repeating operation.

Repeat this operation for at least 10 times, until the oil temperature in the pilot hydraulic circuit warms up for oil operation.

After hydraulic oil warm up, slowly extend and retract slowly all cylinders several times. Start the travel and rotation motors to complete the warm-up operation.

IMPORTANT: in extremely cold climate it may be necessary to increase the preheating time to ensure proper and safe operation. While operating the machine with cold hydraulic oil, the operator may experience slow or unexpected movements of the functions. Likewise, cold hydraulic oil will not provide adequate lubrication to hydraulic components; thus, reducing the life expectancy of the machine.

3-10

3. MACHINE OPERATION 3.1.4

STARTING THE ENGINE

STARTING THE ENGINE IN NORMAL CONDITIONS Make sure that the safety lock lever (1) is in LOCKED (A) position.

Make sure all control levers are in NEUTRAL position.

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

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

Release key as soon as the engine starts.

The key will return to ON by itself.

If the engine does not start within 15 seconds, turn the starter key (3) to OFF and wait for 30 seconds.

Then repeat above mentioned operations to start the engine.

S WARNING MAKE SURE THAT THE SLEWING AREA IS CLEAR OF PERSONS AND OBSTACLES BEFORE STARTING THE ENGINE. ENSURE THE POSITION OF THE TRAVEL MOTORS, BEFORE STARTING TO TRAVEL AND SOUND THE HORN BEFORE BEGINNING THE WORK. NOTE: do not increase the engine speed (high idling) with cold engine.

3-11

3. MACHINE OPERATION START-UP WITH COLD WEATHER With cold weather, due to the increase of oil viscosity and the decrease of battery charge, starting the engine may be difficult. Use the pre-heater to start the engine easily under these conditions.

Perform the starting procedure in normal conditions.

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

Turn key to START position to start the engine.

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

If the engine does not start within 15 seconds, turn the starter key (1) to HEAT and wait for 10 seconds.

Then repeat above mentioned operations to start the engine.

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

3-12

3. MACHINE OPERATION EMERGENCY START-UP WITH BOOSTER CABLES Observe the following precautions when using booster cables to start the engine.

S WARNING • BATTERIES GENERATE EXPLOSIVE GAS, EASY FLAMMABLE. DO NOT APPROACH THE CHARGING AREA WITH SPARKS OR NAKED FLAMES TO AVOID FIRES AND AN EXPLOSION. • DO NOT ALLOW THE VEHICLE OR MACHINE USED FOR BOOSTING TO TOUCH METAL TO METAL WITH THE DISABLED MACHINE. • WEAR SAFETY GLASSES OR FACE PROTECTION, GLOVES AND OTHER SAFETY CLOTHING WHEN WORKING WITH BATTERIES. • NEVER ALLOW THE BOOSTER CABLE CLIPS TO COME IN CONTACT WITH EACH OTHER ONCE CONNECTED TO A BATTERY. • THE NEGATIVE CABLE, WHEN CONNECTED TO THE UPPER FRAME OF DISABLED MACHINE, MAY ARC, CAUSING SPARKS. MAKE SURE TO CONNECT THE BOOSTER CABLE TO A GROUND SURFACE IN THE ENGINE COMPARTMENT, AS FAR AS POSSIBLE FROM THE BATTERY. • WHEN THE BATTERY FLUID IS FROZEN, DO NOT START UP THE ENGINE WITH ANOTHER POWER SOURCE. • FOLLOW THE ORDER INDICATED IN THE NEXT PAGE FOR CONNECTING OR DISCONNECTING THE BOOSTER CABLES. NOTE: select booster cables and terminals with suitable sizes, according to batteries dimensions.

Use the booster cables and clips without any signs of damage or corrosion.

3-13

3. MACHINE OPERATION CONNECTING/DISCONNECTING BOOSTER CABLES Turn the starter key to OFF before connecting the booster cables. Connect booster cables as per following sequence.

S WARNING • ERRONEOUS CONNECTION OF BOOSTER CABLES MAY CAUSE EXPLOSION OF THE BATTERY. PAY SPECIAL ATTENTION WHEN CONNECTING AND DISCONNECTING THE BOOSTER CABLES. • THE ELECTRICAL SYSTEM OF THIS MACHINE WORKS WITH 12 V DC. Remove left hood (1). Then open the cover (2) under the operator’s seat.

Remove protection (3) from the battery terminals.

Connect the booster cable (red) terminal to the positive (+) terminal on the battery of the disabled machine.

Connect the other terminal of the positive cable (+) (red) to the positive terminal (+) of the battery of the normal vehicle.

Connect the terminal of the booster cable (black) to the negative terminal (-) of the battery of the normal vehicle.

Finally, connect the other terminal of the negative booster cable (-) (black) to the upper frame of the disabled machine, away from the battery.

Start the engine of the normal vehicle, and operate it for around 10 minutes at high idling.

Start the engine of troubled machine.

After starting the engine of the disabled machine, disconnect the booster cables exactly in the reverse order.

Make sure to check and repair the cause of the problem of the charging system on the disabled machine.

A. Booster battery B. Discharged battery C. Red cable D. Black cable E. To the upper frame of the troubled machine Cable connecting order: 1>2>3>4 Cable disconnecting order: 4>3>2>1

3-14

3. MACHINE OPERATION 3.1.5

CHECKS AFTER ENGINE START-UP

After the engine start, check following.

S WARNING • CARELESS CONTACT WITH ANY OPERATING LEVER WILL CAUSE UNEXPECTED SUDDEN MACHINE MOVEMENT. STAND UP OR CHANGE POSITION ONLY AFTER ENGAGING THE SAFETY LOCK LEVER. • MAKE SURE THAT THE SLEWING AREA IS CLEAR OF PERSONS AND OBSTACLES BEFORE STARTING THE ENGINE. ENSURE THE POSITION OF THE TRAVEL MOTORS, BEFORE STARTING TO TRAVEL AND SOUND THE HORN BEFORE BEGINNING THE WORK. CHECK THE INSTRUMENT PANEL Check all instruments and indicators. The lamp (1) turns on when the battery is discharged. The lamp (2) turns on when the engine oil pressure is too low.

Check that the fuel level gauge (3) and engine coolant temperature gauge (4) operate correctly.

SAFETY LOCK LEVER CONTROL When the engine is running, set the safety lock lever (1) to the LOCKED (up) position.

Move all control levers, except for the dozer and slewing control levers.

Make sure that all functions, except for the dozer and boom functions, are not active when the safety lock lever is in LOCKED (up) position.

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

NOTE: if a fault is found, immediately stop the engine, take the necessary measures and contact your Dealer for repair.

3-15

3. MACHINE OPERATION EXHAUST GAS COLOUR, IRREGULAR NOISES AND SMELLS With the engine running, check the following: • Check for anomalous exhaust gas colour.

If the engine exhaust is black, stop the machine immediately. Black exhaust is an indication of an excessively rich fuel/air mixture. Check and service the engine accordingly if this condition is present.

• Stop operation immediately when any abnormal sound is heard during the machine operation.

Check the cause of the abnormal sound, and repair as needed.

• Avoid operation at the speed range with resonance. There may be a certain rotating speed range at which the vibration suddenly becomes large due to resonance. Avoid the operation at such speed range, because some parts may be damaged due to vibration.

• If burning smell or smoke is generated, stop the engine immediately. Check for any abnormalities and repair as needed before resuming operation.

NOTE: if faults are detected after the above-mentioned checks, contact your Dealer for repairs.

NOTE: do not apply any heavy load on the new engine for the first 50 hours operation.

Confirm that all lamps turn off.

Carefully listen for any abnormal sound.

Check for oil and water leakages from the engine.

When you start the engine for the first time during the day, let it run idle for about 5 minutes: in this way the engine heats and the oil reaches all its components.

3-16

3. MACHINE OPERATION 3.1.6

STOPPING THE ENGINE

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

S CAUTION If the engine stop is abrupt, while it is running at high speed, the engine temperature increases rapidly. As a consequence, the engine oil is overheated and the joints jam.

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

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

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

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

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

Remove the starter key (3).

S WARNING ALWAYS REST THE BUCKET ONTO THE GROUND BEFORE STOPPING THE ENGINE. POSITION THE MACHINE ON A FIRM AND POSSIBLY LEVEL GROUND.

S WARNING NEVER LEAVE THE MACHINE UNATTENDED WHILE THE ENGINE IS RUNNING.

3-17

3. MACHINE OPERATION 3.1.7

MACHINE OPERATION

The following instructions are aimed to provide the operator with the basic functions of each hydraulic control. Following the instructions and putting them into practice will allow the operator to become more skilful in the operation of this equipment. Before operating the machine, carefully read and observe all precautionary measures given in this manual.

TRAVEL

S WARNING MAKE SURE THAT THE SLEWING AREA IS CLEAR OF PERSONS AND OBSTACLES BEFORE STARTING THE ENGINE. ENSURE THE POSITION OF THE TRAVEL MOTORS, BEFORE STARTING TO TRAVEL AND SOUND THE HORN BEFORE BEGINNING THE WORK. IF ANY FAULT OCCURS DURING MACHINE OPERATION, IMMEDIATELY STOP THE ENGINE. MAKE SURE TO REPAIR ANY FAULTY CONDITION BEFORE RESUMING OPERATION. NORMAL POSITIONING OF THE MACHINE, FOR THE PURPOSE OF DETERMINING FRONT, REAR, FORWARD AND REVERSE, IS WITH THE TRAVEL MOTORS LOCATED BEHIND THE OPERATOR’S CAB. Forward/reverse travel Make sure the safety lock lever (1) is in the UNLOCKED (down) position. Operate the boom, arm, and bucket control levers to raise the attachments from the ground.

Operate the control lever to raise the dozer.

3-18

3. MACHINE OPERATION To move the machine forward, push both (right and left) travel levers forward simultaneously (2). To move the machine in reverse, pull back both travel levers simultaneously (3).

Travel speed changes depending on how far you push or pull the levers.

Right turn Push the left travel lever forward (1) to turn the machine RIGHT.

Left turn Push the right travel lever forward (1) to turn machine LEFT.

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

3-19

3. MACHINE OPERATION Anticlockwise rotation Push the right travel lever forward (1) and at the same time pull the left travel lever backward (2).

Shifting from one travel speed to the other For a HIGH U travel speed (2nd gear), press and release the relevant switch on the grip of the right travel lever. The hare indicator (1) on the instrument panel turns on.

Start the machine by operating the travel levers.

To return to SLOW T travel speed (1st gear), stop travelling, press and release the relevant switch.

NOTE: the travel speed is always reset to SLOW each time the starter key is turned to OFF.

STOP TRAVELLING Move the left and right travel control levers to the NEUTRAL position to stop machine travel. Avoid stopping the machine travel suddenly. Stop the machine travel as slowly as possible.

3-20

3. MACHINE OPERATION TRAVEL PRECAUTIONS

S WARNING • USE A FLAGMAN WHEN TRAVELLING ON A ROAD SHOULDER OR IN CONFINED AREAS. • KEEP PEOPLE AWAY FROM LIFTED DEVICES, TO AVOID POSSIBLE INJURIES. Always move with lowered bucket, especially on slopes or during transfers. The bucket, however, should be sufficiently raised from the ground to overcome possible obstacles. Do not use the bucket as a man lift or to carry riders.

Make certain the travel motor (1) location is known before performing any travel operation. Travel with travel motors at the back of the machine for long distance travel.

Travel on flat and firm ground and in straight lines (or large angles) as much as possible. When turning the machine, move forward and backward alternately as much as possible instead of making a sharp turn.

Check the strength of bridges and road shoulders.

Reinforce them if necessary.

Make sure to keep a sufficient distance from bridges and electrical power lines. Prior to digging, check existence and location of electrical lines, gas ducts, water pipes or other public utilities installations. If in doubt, contact local authorities and/or the distributing companies (electric power, gas, telephone, water, telecommunications, etc.).

When travelling on rough ground, use low speed (1st) T (A) to reduce vibrations and make sure that the throttle control lever is in engine low idle (B) position.

Do not allow large or heavy objects to strike against travel motors. Likewise, do not travel over large objects such as boulders, rocks, etc.

On a snowy or icy roads, travel at slow speed. Avoid starting or stopping abruptly and avoid turning the upper structure suddenly.

For loading/unloading at the transport, remove any mud clogged in the crawler shoes to prevent the machine from side skidding on the ramps.

3-21

3. MACHINE OPERATION PRECAUTIONS FOR TRAVELLING ON SLOPES

S WARNING SHOULD IT BE NECESSARY TO OPERATE THE MACHINE ON SLOPES, CAREFULLY OBSERVE THE FOLLOWING PRECAUTIONS. THIS TO PREVENT INJURIES DUE TO ACCIDENTAL MACHINE OVERTURN.

S WARNING ALWAYS STOP THE MACHINE BEFORE SELECTING THE OTHER TRAVEL SPEED MODE. NEVER SHIFT GEARS WHILE TRAVELLING WITH THE MACHINE. AVOID ESPECIALLY SHIFTING TO QUICK TRAVELLING MODE WHILE TRAVELLING ON A SLOPE: IT MAY BE DANGEROUS.

When on slopes avoid as much as possible to travel across them.

Always travel at slow speed.

When travelling, lift the bucket up to 30 ÷ 40 cm (0.98 ÷ 1.31 ft) from the ground in the travelling direction. Do not travel down a slope in reverse run.

When the machine slips, immediately lower the bucket to the ground and operate the brakes.

Never attempt to rotate the upper structure downhill: the machine could tip over. If this operation is unavoidable, create on the slope a flat working area.

Never attempt to travel up or down a slope with a gradeability of 30° (÷ 58%) or more.

3-22

3. MACHINE OPERATION When the engine stops on a slope, immediately lower the bucket to the ground and move all control levers to the NEUTRAL position, then start the engine again.

If it is difficult to climb a slope with the travel motor due to skidding crawlers, etc., the power of the arm can be utilized to pull up the machine with the bucket engaged on the ground.

When the machine is parked on a slope, even for a short time, lower the bucket (1) and the dozer (2) to the ground, return all control levers to the NEUTRAL position, set the safety lock lever to the LOCKED (up) position and block both crawlers by means of wedges (3).

NOTE: when the hydraulic oil is not sufficiently warm, the machine may not be able to develop its full performance. Before travelling on a steep slope, pre-heat machine completely.

MACHINE OPERATION IN WATER/ON SOFT GROUNDS NOTE: the slewing bearing of the upper structure, the pinion of the rotation motor and the rotary control valve should never operate in water or mud.

If the machine is operated in water or mud, the slewing bearing and the other components may wear excessively. Immediate replacement of grease or overhaul of the slewing bearing, etc. is required.

E20.2SR E22.2SR

Where the river bottom is flat and water flow is slow, the machine may be operated in water, provided that water is not higher than the guide plate of the crawlers (1) (E20.2SR - E22.2SR) or upper roller (2) (E27.2SR).

When operating under such condition, use the machine carefully and check condition of river bed.

Never enter deeper waters.

On soft ground, the machine body sinks in some cases gradually. Therefore, pay full attention to the machine at all times during operation.

E27.2SR

After travelling in sea water, thoroughly wash up the machine to remove salt.

3-23

3. MACHINE OPERATION Make sure to lubricate bucket pins and bushing every 4 hours if working with materials in wet conditions, supply grease with a grease gun until grease oozes out.

3-24

3. MACHINE OPERATION GETTING OUT OF SOFT GROUND If possible, avoid travelling on soft ground. Avoid getting caught in the mud. In the event that the machine gets caught in the mud, get out of it as follows.

One crawler caught in mud When a crawler gets caught in mud, lay logs or boards on the mud to form a base. Operate boom and arm to form an angle between them of about 90°÷110°. Push outer side of bucket against the ground to lift the machine body.

Both crawlers caught in mud When both crawlers get caught in mud and the machine does not move because it skids, provide logs and boards, as described in the previous step and anchor the bucket firmly to the ground so that you can help the machine to come out from mud.

If the machine is unable to travel because the crawlers are stuck in mud, sand or gravel, raise each crawler side alternately by pushing the bucket against the ground and scraping off mud, sand or gravel. Gravel and mud may be cleared off by rotating the raised crawler back and forth.

S CAUTION Operate the machine from operator’s seat only. Do not allow any person to come near the machine.

3-25

3. MACHINE OPERATION ROTATION OF THE UPPER STRUCTURE

S WARNING • WHEN YOU WORK ON SLOPES THE MACHINE BECOMES UNSTABLE AND UNBALANCED. • MAKE SURE THE ROTATION AREA IS CLEAR OF PERSONS AND OBSTACLES BEFORE OPERATING THE ENGINE. • WORK UP AND DOWN INCLINES OR SLOPES, NEVER ACROSS. • NEVER SLEW OR TURN MACHINE AROUND ON SLOPES. • OPERATE CONTROL LEVERS CAREFULLY TO PREVENT SUDDEN MOVEMENTS THAT MAY CAUSE THE MACHINE TO SLIP OR TIP OVER. • PREPARE A LEVEL AREA FOR THE MACHINE TO OPERATE. • USE A FLAGMAN TO GUIDE THE OPERATOR.

PRACTICE TO IMPROVE EFFICIENCY

S WARNING • SLEWING THE UPPER STRUCTURE ON A SLOPE MAY CAUSE THE MACHINE’S OVERTURNING. ON A SLOPE, IT IS VERY DANGEROUS TO SLEW THE UPPER STRUCTURE DOWNHILL WITH FULL BUCKET. PREPARE A LEVEL AREA FOR THE MACHINE TO OPERATE SAFELY. • MAKE SURE THE ROTATION AREA IS CLEAR OF PERSONS AND OBSTACLES BEFORE OPERATING THE ENGINE. NOTE: the optional attachments offer a wider range of application other than the showed ones.

Refer to 4-34 for changing the bucket.

3-26

3. MACHINE OPERATION DIGGING INSTRUCTIONS Use mainly the mere arm force for digging. Use the full bucket rotation travel to fill it completely. Setting the bucket too deep will decrease the machine’s efficiency.

Maximum digging force position.

The attachment will provide maximum digging force when arm and boom are positioned at 90°÷110° from each other. Operate slowly to get maximum digging force.

Bucket teeth direction.

Direct bucket teeth parallel to digging direction. The bucket must be used for shallow diggings, so as to reduce the resistance and avoid damaging the teeth.

Operate boom carefully.

Activate boom operation by moving the control levers carefully. Do not perform sudden starts and stops of the boom as this creates unnecessary stress on the machine and its components.

Clean sand and soil from bucket.

Place the arm in horizontal position and bring the bucket to the dumping position. If sand and soil do not fall out, move the bucket lever right and left a few times to remove soil stuck to the bucket.

Digging ditches The working efficiency is much improved when the bucket is oriented correctly for digging ditches and parallel to a ditch.

For wide ditch digging, dig the two sides first, then dig the centre portion.

3-27

3. MACHINE OPERATION Operating the dozer The dozer is used to push the soil back into an excavated ditch or for ground levelling.

To distribute the earth heaped up on the ground using the dozer, start from the top or from the sides of the heap. If necessary, adjust the height of the dozer by means of the relevant control lever, to prevent overloading the engine.

Offset digging

S WARNING WHEN THE SLEWING RANGE OF THE BOOM IS WIDER, PAY ATTENTION TO THE CONDITIONS OF THE SURROUNDING AREA. By pressing the left and right side of the slewing pedal (1) alternately, the boom (2) slews in left and right direction, thus enabling offset digging in narrow spaces.

By pressing the left side of the slewing pedal, the boom slews leftwards, and by pressing the right side, the boom slews rightwards.

The advantage of this function is that it enables offset digging work as shown in the figure.

LOAD The working efficiency can increase, if the dump truck collecting the removed earth is parked so that the rotation angle of the arm is minimal. At the same time the operator sight remains the best.

It is recommended that loading be started from the front side of the dump truck body. This will make loading easier and more soil can be loaded than by loading from the side.

3-28

3. MACHINE OPERATION POSITION WITH MINIMUM ROTATION ANGLE Extend arm cylinder and bucket cylinder to maximum length, and fold bucket.

Extend boom cylinder to maximum length.

Press the left side of the slewing pedal, and then slew the boom fully to the left.

Operate the control lever for upper structure rotation.

NOTE: avoid interference with the attachment.

MINIMUM SLEWING RADIUS Unit: mm (in) BOOM

E20.2SR - E22.2SR Canopy

Cab

With swing

1560 (61.41) (left 70°)

1750 (68.89) (left 70°)

Without swing

1800 (70.86)

2030 (79.92)

Unit: mm (in) BOOM

E27.2SR Canopy

Cab

With swing

1570 (61.81) (left 70°)

1780 (70.07) (left 70°)

Without swing

1830 (72.04)

2060 (81.10)

3-29

3. MACHINE OPERATION 3.1.8

MACHINE PARKING

S WARNING • ALWAYS PARK THE MACHINE ON A LEVEL AND FIRM GROUND. • AVOID PARKING ON A SLOPE. WHEN PARKING ON A SLOPE IS UNAVOIDABLE, MAKE SURE THE BUCKET TEETH ARE STUCK IN THE GROUND, LOWER THE DOZER TO THE GROUND AND PROPERLY BLOCK THE CRAWLERS WITH WEDGES. • PROCEED WITH ENGINE STOPPING. TURN THE STARTER KEY TO OFF AND REMOVE IT. • MAKE SURE THAT THE SAFETY LOCK LEVER IS IN LOCKED (UP) POSITION TO PREVENT ANY UNEXPECTED MACHINE MOVEMENT. Move both travel control levers (1) to the NEUTRAL position.

Set the throttle lever (2) to LOW IDLING. Lower the bucket to the ground.

Place the dozer on the ground.

Block both crawlers by means of chocks.

Stop the engine by turning the starter key to OFF.

Set the safety lock lever (3) to the LOCKED (A) position.

Close all windows.

3-30

3. MACHINE OPERATION Lock with key (4) the access door of the cabin and the engine guards, cooler and fuel filler covers.

3.1.9

CHECKS AND VERIFICATION AFTER WORK

Regularly check the instrument panel.

If the fuel level in the tank is low, stop the engine and refuel.

If the warning lamps for the coolant temperature and/or engine oil temperature are on, move the machine to a safe place, immediately stop the engine and carry out the necessary repairs before resuming operation.

3.1.10

PRECAUTIONS AFTER OPERATION

Check for any oil or coolant leaks in the machine.

Check the attachment, the machine’s outside and the crawlers. Repair as needed before resuming operation.

Refuelling. Do not overfill fuel tank (up to the top).

With temperature increase the fuel can expand and overflow.

Remove mud from the crawlers.

3-31

3. MACHINE OPERATION 3.1.11

MEASURES AFTER AN EMERGENCY STOP OF ENGINE

Avoid emergency stops of the engine as much as possible.

It should be kept in mind that the engine is to be operated for around 5 minutes with no load, before stopping the engine.

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

Even if the engine is not running, keep the safety lock lever in the “LOCKED” position.

When an emergency stop is made and there is no time to lower the bucket to the ground, support it with wood wedges (1) to lock the crawlers.

When the emergency stop is activated on a slope, block both crawlers at their lower sides.

While you are waiting to restart the engine and the machine, free the working area from people and possible obstacles. Set limits around the machine, taking the appropriate measures so that nobody penetrates this area.

If the trouble cause is not clear or a repair is required, contact your Dealer.

After an emergency stop, restart the engine only when the coolant is completely cool.

3-32

3. MACHINE OPERATION 3.1.12

EMERGENCY MEASURES FOR SUDDEN FAILURE OF MACHINE

REMOVAL OF TRAVEL MOTOR LOCK While travel motors are at a standstill, they are hydraulically locked by the counter balance valve, and also mechanically locked by the brake system.

When the machine becomes unable to travel due to failure of the travel motors, etc., it is possible to temporarily move it by releasing the lock for the travel motor with one of the following methods.

REMOVING GEARS FROM TRAVEL REDUCTION UNIT This is the preferred method.

S WARNING MAKE CERTAIN CHOCK BLOCKS ARE SECURE AT FRONT AND REAR OF EACH TRACK BEFORE ATTEMPTING TO RELEASE BRAKES. NEVER STAND IN THE PATH OF THE TRACKS WHEN RELEASING BRAKES. Park the machine on a level surface. The lateral reduction unit should be positioned in such a way that plugs (1) and (2) are placed as shown. The respect of this position is essential for the correctness of the maintenance operation.

Place chock blocks at front and rear of each track to prevent machine from moving.

Lower attachment to ground.

Bring throttle control lever to minimum speed, stop the engine and remove starter key, then position safety lock lever on “LOCK”. Wait until the machine is cold.

Provide an empty container under the travel motor to collect drained oil.

Slowly unscrew upper plug (1), allowing in this way the inside pressure of the reduction unit to decrease gradually. Then remove draining (2) and level (3) plugs slowly, to discharge the oil of reduction unit.

3-33

3. MACHINE OPERATION

S CAUTION Avoid oil spills, use containers, rags, and/or paper towels to contain any oil leakage. Dispose all waste oils, fluids, lubricants, used filters and other hazardous waste properly, according to current legislation.

Unscrew the plug (5). Attach eyebolt (A) to the threaded hole of plug (1) and insert pry-bar (B) in the eye hole, and turn the bar until snap ring (6) can be seen through the threaded hole of plug (5). Take out the snap ring when it becomes visible.

Remove the cover (4), sun gear assy (14), holder (15), planetary gear (7), needle bearing (8), inner race (9), drive gear (10) and thrust plate (11).

Remove the thrust plate (12) and screw (13).

NOTE: the sprocket for this crawler becomes free from the travel motor.

Temporarily install the cover (7).

Repeat the previous steps on the reduction gear at the opposite side.

Tow the machine to a safe place to proceed with the appropriate repairs.

NOTE: after all repairs are made, reinstall the inner parts on both travel reduction units in reverse order and make sure to use fresh gear oil.

S CAUTION Clean up all spilled oil. Dispose of all hazardous waste in accordance with current legislation relevant to the environment.

3-34

3. MACHINE OPERATION Replace O-ring (17) with new one. Lubricate the Oring (17) with grease and fit this in the cover (4) groove.

Install cover (4) with snap ring (6).

S CAUTION Be very careful when installing the cover not to damage the O-ring.

Install the drain plug (2).

Tightening torque: 58.8 ± 9.8 Nm (43.3 ± 7.2 lbf•ft) Add specified gear oil through oil filling port (1), until oil starts to flow out from oil level port (3).

Reinstall filling plug (1).

S CAUTION Clean up all spilled oil.

REMOVING SPOOL AND BRAKE Remove the tracks.

Make sure to use safety blocks (14) under the crawler frames (travel motor side).

Remove the travel motor covers (1) from both sides of lower frame loosening three capscrews (2).

Provide an empty container (15) under the travel motor to catch drain oil, then disconnect the hoses (16), see the right figure. Make sure to release hydraulic system and tank pressure. Make sure to mark all hydraulic lines connecting to travel motors and remove them.

S CAUTION Never allow an hydraulic line or component to become contaminated. This could cause severe system damages. Contact an authorized Dealer to obtain the proper caps and plugs to be used on this machine.

3-35

3. MACHINE OPERATION Remove the socket capscrews (3) to remove the travel motor from the lower (track) frame. Gradually loosen the capscrews paying attention not to drop off the travel motor.

Unscrew the plug (4).

Remove the spool (5). Be careful not to damage the spool during removal. Place spool (5) and loose parts (6) and (7) in a clean container with clean oil to protect them from rust and contamination.

Install plug (4) to prevent contamination.

Remove 6-socket capscrew (12), and separate the bodies (10) and (11) from assembly.

Make sure to contain oil spillage and dispose of all hazardous waste in accordance with local government regulations.

Remove 10-spring (13) for parking brake.

Temporarily reassemble bodies (10) and (11) in without springs (13).

Install the travel motor on the lower (track) frame and reinstall hydraulic lines.

Repeat the previous steps on the opposite track side to remove the other travel motor.

Install tracks and move the machine to a safe place to proceed with repairs.

By removing the spools and springs, the travel motors are released from locked condition. Move the machine to a safe place and call a service-man.

NOTE: after all repairs are made, reinstall the counter balance spools and brake springs on both travel motors. Make sure hydraulic oil level is to specifications.

S CAUTION Never allow an hydraulic line or component to become contaminated. This could cause severe system damages. Contact an authorized Dealer to obtain the proper caps and plugs to be used on this machine.

3-36

3. MACHINE OPERATION LOWERING THE BUCKET IN EMERGENCY SITUATIONS

S WARNING • THIS PROCEDURE IS TO BE USED ONLY AS AN EMERGENCY TO LOWER THE POSITION OF THE BUCKET. USE EXTREME CAUTION, SINCE THE WEIGHT OF THE BUCKET WILL TEND TO MOVE THIS ABRUPTLY, WHEN THE HOSES OF THE HYDRAULIC SYSTEM ARE DISCONNECTED. • BE SURE TO BLOCK THE ATTACHMENTS TO AVOID SUDDEN CHANGE OF POSITION. REMOVE THE HOSES OF THE HYDRAULIC SYSTEM SLOWLY, UNTIL OIL PRESSURE IS COMPLETELY RELEASED. THEN CONTROL THE BUCKET MOVEMENT BY SLOWLY REMOVING THE BLOCK. To lower the bucket, proceed as follows: when the bucket is in digging position (A) (bucket cylinder completely extended), disconnect hose (H), conversely, when the bucket is in dump position (B) (bucket cylinder completely retracted), disconnect the hose (R).

S CAUTION Make sure that the hydraulic system or a component of this are not contaminated from polluting agents. This could cause severe system damages.

Contact your Dealer to obtain the proper caps and plugs to be used on this machine.

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

3-37

3. MACHINE OPERATION LOWERING THE ARMS

S WARNING • THIS PROCEDURE IS TO BE USED ONLY AS AN EMERGENCY TO LOWER THE POSITION OF THE BUCKET. USE EXTREME CAUTION, SINCE THE WEIGHT OF THE BUCKET WILL TEND TO MOVE THIS ABRUPTLY, WHEN THE HOSES OF THE HYDRAULIC SYSTEM ARE DISCONNECTED. • BE SURE TO BLOCK THE ATTACHMENTS TO AVOID SUDDEN CHANGE OF POSITION. REMOVE THE HOSES OF THE HYDRAULIC SYSTEM SLOWLY, UNTIL OIL PRESSURE IS COMPLETELY RELEASED. THEN CONTROL THE BUCKET MOVEMENT BY SLOWLY REMOVING THE BLOCK. • DO NOT ENTER THE AREA UNDER ATTACHMENTS, WHILE LOWERING THEM. Arm lowering (step 1) Gradually loosen the hose, connected to the arm cylinder, from rod side (R).

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

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

Keep the attachment at 30 ÷ 40 cm (0.98 ÷ 1.31 ft) from the ground and take the possible movements of the machine into consideration.

Securely retighten the hoses so that the attachment stops lowering.

After moving the machine to a safe place, place the attachment to the ground.

NOTE: if necessary, contact your Dealer for repairs.

3-38

3. MACHINE OPERATION 3.1.13

CAUTION WHILE USING RUBBER CRAWLERS

PROPER USAGE The rubber crawlers offers excellent features which steel crawlers do not possess.

However, if they are used the same way as the steel crawlers, then their advantages cannot be fully exploited. Operation of the machine varies upon working site and conditions.

Rubber belt

Although the rubber crawler offers many advantages thanks to the properties of its material, it also has disadvantages in terms of strength. As a consequence, it is necessary to be familiar with the characteristics of this kind of crawler.

Less vibration

⊗

Smooth operation

⊗

Low noise

⊗

Harmless for paved road

⊗

Easy handling

⊗

Resistant

Δ

Large traction force

⊗

⊗: Excellent

RUBBER CRAWLER WARRANTY The warranty does not cover such damages to the rubber crawlers resulting from improper working or if their tension is inaccurate.

FORBIDDEN OPERATIONS Do not carry out the following operations: Do not travel nor work on following surfaces: gravelmixed land, rugged and solid rock bed, reinforced concrete, steel plate edges.

Do not operate and/or travel in such places as river beds where there are lots of stones of different sizes. Rocks may get caught into the grooves of the rubber crawlers, thus damaging the crawler or causing it to come off. The life of rubber crawler is shorter, if it skids or rubs against the soil.

3-39

Ο: Good

Δ: Normal

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

Do not enter such hot places as an open-air fire, steel plate left in the open sun.

Do not work in asphalt levelling.

When storing the machine for a long period (more than three months), keep it in a closed room where it will not be exposed to direct sunshine or rain.

When the machine travels only on one side of the crawler, and keeps the other side floating, the crawler may come off of the rollers or get damaged.

3-40

3. MACHINE OPERATION PRECAUTIONS FOR USE Use care of the following when working.

Rubber crawlers slip easily on icy surfaces.

Take the necessary safety precautions.

Avoid making a spin turn on concrete surfaces.

Avoid abrupt changes of direction as this will cause an early wear or damage of the rubber crawlers.

Use care so that the bucket does not damage the rubber crawler while working.

Do not move the machine pressing the bucket against a concrete surface or walls.

Lower the machine slowly, if it had previously been lifted by means of the attachment.

If the machine is operated in salty corrosive places, the core metal can detach easily. Do not use the rubber crawler under such circumstances. If the rubber crawlers come in contact with these substances wash them with water.

The rubber crawlers have to be used with a temperature range between -25 °C (-13 °F) and +55 °C (131 °F).

NOTE: use the rubber crawlers under proper tension, to prevent them from coming off the rollers.

Operate the rubber crawler carefully even when tensioning is proper.

Avoid changing direction of the machine on places with different level (about 20 cm (0.65 ft)). To overcome the gap, place the machine perpendicular to the obstacle.

3-41

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

If you travel on a slope with the machine higher at one side, this will risks to damage the rubber crawler. Both machine sides must travel at the same level.

Do not change the direction of the machine with the rubber crawlers positioned on earth heaps, as this could cause the rubber crawler to come off or get damaged.

3-42

3. MACHINE OPERATION 3.1.14

MACHINE OPERATION WITH ADVERSE WEATHER CONDITIONS

OPERATION WITH EXTREME COLD

S CAUTION When the temperature is extremely low, oil flow is reduced due to increased viscosity, making start-up difficult. Coolant may freeze damaging cooler and/ or engine.

FUEL AND OIL Use fuel and oil of high quality and low viscosity for each system.

Coolant In cold climates, the ratio of mixing antifreeze into the cooling system should conform with the lowest predicted ambient temperature. If coolant freezes, the radiator, crankcase and cylinder head may be damaged. To avoid freezing hazard, it is necessary to check that the cooling system is filled with an antifreeze mixture: otherwise, replace the radiator coolant with this mixture.

When shipped from the factory, the machine contains coolant mixed with all-season-type LONG LIFE COOLANT. It is recommended to inspect the coolant to maintain proper viscosity.

NOTE: in extremely frigid climates, covering the radiator is a method to aid the machine warm-up. If necessary to maintain temperatures, cover the outer edges of the radiator, leaving an opening in the centre part of the cover; thus, avoiding fan overloading. Check the instrument panel for warning icons during operation. It may be necessary to use thermal protections for cooling, fuel and engine systems and/or additional power for the battery to help start the engine. Likewise, mix coolant to a protection temperature of 5 °C (41 °F), lower than the machine will experience during operation, storage or transport.

Battery When the temperature becomes low, the charging power decreases or the battery may freeze. Keep the charging rate as around 100% as possible and cover the battery with insulation material.

NOTE: keep battery terminals free of ice and snow to avoid short circuits. In extremely cold climates, remove the battery and store it overnight at room temperature.

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

Remove water adhering to the travel system thoroughly and park on dry ground to prevent the travel system from freezing.

• Retract the hydraulic cylinder rods as much as possible to reduce the exposed areas of the rods.

This will prevent mud or water on the rod faces from damaging the seal.

OPERATION ON THE SEASHORE OR IN SALTY ENVIRONMENTS Inspection before start-up Check all plugs, cocks, covers and protections for proper tightness. Torque to proper value to aid in preventing salt from entering the machine systems.

Apply grease to the electrical equipment as required to prevent corrosion.

Precautions after operation Wash the machine thoroughly to remove salt. Apply oil or grease as necessary to prevent corrosion of mechanical pieces.

3-43

3. MACHINE OPERATION CARE FOR ELECTRICAL EQUIPMENT The electrical equipment is especially sensitive to water. Be careful not to expose the electrical equipment to water when washing the machine or when it is raining. The electrical components (relays, fuses, etc.) are installed in the vicinity of the operator’s seat.

Never expose the operator’s seat to water.

OPERATION IN DUSTY AREAS Air cleaner Clean or replace the filter element at the corresponding intervals. See “Maintenance” section for details.

Radiator Clean the radiator regularly to prevent the radiator core from becoming clogged with dust.

Fuel Be careful not to let contamination in the fuel when refuelling. Inspect the elements and filters at the corresponding interval.

Electrical equipment Clean the starter and generator especially, at the corresponding interval, to prevent dust from accumulating.

3-44

3. MACHINE OPERATION 3.1.15

PRECAUTIONS WHEN STORING THE MACHINE FOR A LONG PERIOD

When storing the machine for more than one month, observe the following points to prevent the machine function from deteriorating.

ITEM

ACTION

CLEAN THE MACHINE

Wash the machine thoroughly.

Check the travel system for any malfunctions and service as required.

Lubricate every required part.

LUBRICATION

Check the lubrication oil to make sure it is at the proper level and for contamination.

If necessary, add oil to the motor. If engine oil is contaminated, discharge it.

• Lubricating oil deteriorates even when the machine is not used.

• Check the oil before operating the machine again.

BATTERY

Remove the battery and store it in a dry protected place. If the battery is not removed, disconnect its negative terminal.

COOLANT

If there is a possibility that the coolant may freeze, add antifreeze in the coolant suitable for the outside temperature.

Normally, long life coolant is mixed in, so it is not necessary to change the coolant.

DUST AND HUMIDITY PREVENTION

Store the machine in a dry and protected place. Should the machine has to be left outside, position it on a wooden table and cover it with a waterproof sheet, placed so as to allow ventilation.

• Retract as far as possible all cylinders rods.

Otherwise, coat the exposed cylinder rods with grease.

• Lower the bucket to the ground and place wedges under the crawlers.

• Lubricate all greasing points.

• Paint parts needing it to prevent rust formation.

3-45

3. MACHINE OPERATION ITEM PERIODICAL LUBRICATION DURING STORAGE

ACTION If the applied oil layer is insufficient, irregular wear may occur during the machine use.

Start the engine, operate the machine and the attachment, etc. once a month to lubricate all of the parts.

• Before starting the engine, check the engine oil and coolant level. Top up, if necessary.

• Remove rust preventing agent covering cylinders and rods.

• Apply rust inhibitors to cylinder rods.

• After starting the engine, warm up the machine completely.

Operate the travel, rotation and digging functions 2 or 3 times to lubricate the sliding surfaces.

• Ensure proper ventilation during warm-up operations.

USING THE MACHINE AFTER PROLONGED STORAGE

Before placing the machine back into operation, proceed as follows before starting up.

• Fully wiped off the rust inhibitors from the cylinders and piston rods.

• Refill fluids to proper levels and lubricate as required.

• Thoroughly check all systems prior to operating the machine at full load.

• Check condition of all hoses and connections.

• Replace engine oil and fuel filters and top up engine oil.

3-46

4. MAINTENANCE

4-1

4. MAINTENANCE

4-2

4. MAINTENANCE

4.1

GENERAL SAFETY INFORMATION

S WARNING READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS AND PROCEDURES FOUND IN THIS MANUAL BEFORE ATTEMPTING ANY OPERATION, INSPECTION, MAINTENANCE OR REPAIR OF THIS MACHINE, ATTACHMENT OR ANY OF ITS SYSTEMS. NOTE: consult your Dealer to adjust, disassemble and repair the engine, the reduction unit and the electronic devices (controller, etc.).

It is recommended, that an inspection and maintenance schedule be developed and maintained on a regular basis for this machine. Developing and maintaining such a schedule helps to keep the machine in optimum operating condition.

The information contained in this section gives the proper procedures for performing inspection and maintenance functions for this machine. This procedure illustrates all operations one after the other.

The time interval of such operations is indicated in the inspection and maintenance tables.

Basically, lubrication and maintenance intervals are determined by the hourmeter. It is also possible to perform those operations according to calendar time (daily, weekly, monthly, etc.), referring to the service hours displayed. Issues for which a precise service time cannot be specified are explained in chapter “4. WHEN NECESSARY”.

NOTE: the inspection and maintenance charts provided in this section give only general time intervals.

If necessary, a special plan with shorter maintenance intervals will have to be prepared, according to the special situation, for difficult working conditions, such as in dusty or humid environments, etc.

Be sure to dispose of all waste materials correctly.

Use only specified oils, fluids, lubricants, filters and replacement parts to keep machine in optimum operating condition. Only use oils and greases with the correct viscosity for the ambient temperature.

Store the containers and cans of lubricating oil, hydraulic oil and grease etc. in closed rooms. Take necessary measures to protect them from dust, water etc.

4-3

4. MAINTENANCE

4.2

GENERAL RULES AND SAFETY PRECAUTIONS

Do not attempt any other inspection or maintenance procedures other than those specified in the manual.

Carry them out after parking the machine in a flat and accessible place.

KEEP MACHINE CLEAN Thoroughly clean machine before performing inspection and maintenance procedures. This facilitates and makes certain the faults detection and the maintenance work. In this way the premature wear of some machine’s components is reduced.

READ THE SERVICE HOURMETER Read the hourmeter daily, and check with the scheduled maintenance book. Proceed with any maintenance as required.

STAY CLEAR OF MOVING PARTS Never attempt any maintenance with engine running. Always stop the engine.

Otherwise, entanglement in moving parts can cause serious injury.

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

4-4

4. MAINTENANCE APPLY NOTICE OF MAINTENANCE IN PROGRESS Before beginning any inspection or maintenance procedure, hang a “Maintenance in progress” tag to the operator’s console or to the cab door, to inform that it is forbidden to operate the machine. This tag will help prevent an accidental starting of the machine.

OBSERVE PRECAUTIONS Start the inspection and maintenance operations only if you fully understand the meaning of the safety decals.

PREVENT BURNS Use caution and wear the proper safety equipment when working around hot areas. Never change oil, engine coolant or filters immediately after a machine has been stopped. Before performing any maintenance procedure, stop the engine and let it and the radiator cool down. Skin contact with hot water or steam jets, can cause severe burns.

Engine oil, gear oil and hydraulic oil also become hot during operation. Wait for the oil and components to cool down before starting any maintenance or repair.

4-5

4. MAINTENANCE AVOID HIGH PRESSURE FLUIDS Escaping fluid under pressure can penetrate the skin causing serious injury. Release the residual pressure from ducts, before disconnecting the hydraulic lines.

PREVENT CONTAMINATION Always cap or plug lines when hydraulic components are removed, to help prevent hydraulic system contamination caused by dirt, dust or foreign bodies entering the system.

S CAUTION Never allow an hydraulic line or component to become contaminated by polluting agents. This could cause severe system damages. Contact your Dealer to obtain spare parts to be used on this machine.

INSPECT WASTE OILS AND FILTERS Check all waste oils and filters for debris and foreign matters.

It is recommended to cut the oil filters to detect possible traces.

4-6

4. MAINTENANCE CAUTION WHILE REFUELLING During the refilling of fuel or oil, avoid to remove possible strainers fitted in the filling ports.

DISPOSE OF WASTE PROPERLY Improperly disposing of waste can threaten the environment. Potentially harmful waste on excavators includes such items as lubricants, 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.

Obtain information on the proper way to recycle or dispose of waste from local environmental authorities or recycling centres, or from your Dealer.

SEALS AND O-RINGS After removing the O-ring or gasket, clean the installing face, and replace with a new one.

Always replace O-rings with new ones.

Never reuse a gasket during reassembly of components. Be sure to lubricate all new gaskets with the appropriate oil before installation.

4-7

4. MAINTENANCE SUPPORT MACHINE PROPERLY Never attempt to work on the machine without securing the machine first. Always lower the attachment to the ground before any intervention on the machine. If you must work with the machine or attachment lifted, support them securely.

CAUTION DURING BUCKET REPLACEMENT Never insert your finger into the pin bore.

When aligning the pin bores, never insert your finger, hands or arms into them.

The alignment check must be carried out visually.

4-8

4. MAINTENANCE DUSTY ENVIRONMENT When the machine is operated in dusty environments, take the following precautions.

• Frequently check for the indicator for air filter restriction. Clean the filter element before the end of the specified interval.

• Clean up the radiator before the specified period, to prevent its clogging.

• Replace the filter element before the end of the specified interval.

• Clean the electric equipment, especially starter and generator, to not allow deposit of dust on them.

AVOID PIECES TO FLY OFF Oil in the travel reduction gears and grease in the idler adjusters are under pressure.

As pieces may fly off, be sure to keep body and face away from air release valve and plug to avoid injuries. Reduction gear oil overheats. Wait for it to cool down, then gradually loosen the venting plug to release pressure.

WEAR SAFETY EQUIPMENT Wear a hard hat, safety goggles or face protection, work gloves, safety shoes and well fitting work clothes when performing inspection and maintenance procedures on this machine.

4-9

4. MAINTENANCE CLEANING PARTS Use only approved cleaning solvents and proper equipment to clean parts.

S WARNING NEVER USE GASOLINE, OR OTHER FLAMMABLE SOLVENTS TO CLEAN PARTS. ALWAYS CLEAN PARTS IN A WELL VENTILATED AREA. PRESSURE IN THE HYDRAULIC TANK Always release the internal pressure of the hydraulic tank before performing inspection or maintenance procedures.

Slowly loosen the cap (1) to release pressure from the tank.

S CAUTION Gases from hydraulic tanks may be hot.

Wear safety clothes.

SAFETY DURING WELDING Turn the starter key to OFF. Wait 4 seconds for electrical power to disconnect.

Disconnect the negative (-) cable of the battery from the clamp.

Attach welder ground cable with 1 m (3.28 ft) from component being welded.

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

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.

4-10

4. MAINTENANCE

4.3

LUBRICANT, FUEL AND COOLANT SPECIFICATIONS

The following table indicates the proper oils, lubricants and fuels to be used with various climates and service conditions.

Components

Technical name

Quantity

Operating range (ambient temperature °C)

Specifications

-20° -10° 0° 10° 20° 30° 40° (-4) (14°) (32°) (50°) (68°) (86°) (104°) Selenia IDRAULICAR AP31 Hydraulic oil tank

Engine oil pan

ISO VG 32

Tank: Selenia IDRAULICAR AP46 20 l (5.30 gal) Selenia IDRAULICAR AP51 System: 38 l (10 gal) Ambra HI-TECH 46 Ambra Supergold

Fuel tank

ISO VG 46 * ISO VG 68

QFK 583/HD

ISO VG 46

H level: 5.5 l (1.2 gal) L level: 1.9 l (0.4 gal)

15 W 40 * 10 W 30

28 l (7.40 gal)

API CH4 ACEA E5 QFK 583/HD EN590

1.3 l (0.30 gal) Cooler

Ambra Agriflu

Travel motor Upper rollers

50% LLC

Total q.ty 3.8 l (1.00 gal)

(long life coolant)*

NH 900 A

0.35 l (0.10 gal) X 2 Ambra HYPOIDE 90

35 cc (2.14 in3) X 2

Idle wheels

45 cc (2.75 in3) X 2

Attachment and dozer pin

20-places

SAE 80 W-90

API GL5 NH 520 A

Swing cylinder pin Swing bearing

Ambra GRS PLUS

Idler adjuster

2 - place

Operating lever and pedal

When required

Rotation gear

MG 2

NLGI 2 QFK 586/GR

1 - place

NLGI 2 QFK 586/GR

1 - place

(*) The systems are filled with the products indicated with the asterisk.

NOTE: USE OF BIO-DEGRADABLE OILS When you use bio-degradable oil, please refer to following: • there are two types of bio-degradable oil available: vegetable-based and synthetic-based. We recommend using synthetic oils, because vegetable ones have a maximum operating temperature of 80 °C (176 °C).

For this reason, the degradation of vegetable-based oil occurs more rapidly, and they have a reduced service life; • do not mix Bio-oil with original factory-filled mineral oil; in case it is necessary to use Bio-oil, flush the hydraulic system that was filled with bio-oil three times; • if you use Bio-oil, the performance of the rotation brake and that of the parking/travel brake will be reduced, because of the lower friction factor of Bio-oil compared to that of mineral oil; • for further information about the type of bio-degradable lubricant and the relevant specifications for use and maintenance, please refer to chapter 4.21 BIODEGRADABLE HYDRAULIC OIL.

4-11

4. MAINTENANCE

4.4

MAINTENANCE GENERAL TABLE

PARTS TO BE REPLACED During maintenance, replace parts subjected to wear before expiry, as filters and cartridges. The machine operates more efficiently if worn parts are replaced with new parts.

No. 1

Device

Parts name

Hydraulic oil tank Return filter

Q.ty 1

(O-ring)

Replacement interval After 50 hours (first change) Every 500 hours (from 2nd change) (Breaker specification: every 250 hours)

2

Hydraulic oil tank Suction strainer

1

Every 2000 hours

(O-ring) Element (outer) (3a)

After 6th time cleaning or maintenance interval.

3

Air cleaner

Element (inner) (3b)

1

For machines equipped with W (double) element and inner element. Do not fail to replace the inner element with a new one.

4

Engine oil filter

Cartridge

1

After 50 hours (first change) Every 250 hours

5

Fuel filter

Cartridge

1

Every 500 hours

6

Water separator

Cartridge

1

When required

7

Bucket

Side cutter (right) (7a)

1

When required

Side cutter (left) (7b)

1

Screw

6

Nut

6

Tooth

3

Safety pin

3

Rubber locking pin

3

8

Bucket

4-12

When required

4. MAINTENANCE

4.5

TAG MAINTENANCE IN PROGRESS

No.

TOOL NAME

1

Tag maintenance in progress

2

Tool case

3

Wrench

NOTES

For engine oil filter

4

Wrench For fuel filter

5

Pipe wrench For grease nipple of idler adjuster

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

4-13

4. MAINTENANCE

4.6

TORQUE SPECIFICATIONS FOR CAPSCREWS AND NUTS

The following torque specifications are indicated in case the actual torque value of a fastener is unknown.

Check the capscrews and nuts for their looseness and dropping off before the start of daily work and at the periodical maintenance intervals. Retighten the loose screws and nuts, and install new ones to replace the dropped ones. For the new machine, the check and retightening of loose screws and nuts must be carried out after the first 50 hours operation. When replacement is needed, make sure to use genuine parts to the same dimensions. Check the table hereunder for proper torque.

• The table hereunder, is not valid for plastic screws used to fasten hoods, etc.

• For the tightening torque of this kind of screws, contact your Dealer. Over-tightening may cause the damages of the parts to be fixed.

• If this manual specifies a different torque, use such value regardless of the table below.

• Numerical indication on the capscrew head shows the classification (A) strength (e.g.: 8.8). No indication is provided for smaller size of capscrews, M5 or less.

Standard tightening torque values.

Be certain to tighten all capscrews and nuts to proper torque values.

Torque value unit: Nm (lbf•ft) Resistance class

6.8

8.8

Nominal dimension

10.9

12.9

Tightening torque

M3

P = 0.5

1.19 (0.88)

1.59 (1.17)

2.24 (1.65)

2.69 (1.98)

M4

P = 0.7

2.73 (2.01)

3.64 (2.68)

5.12 (3.78)

6.15 (4.54)

M5

P = 0.8

5.41 (3.99)

7.21 (5.32)

10.14 (7.48)

12.17 (8.98)

M6

P=1

9.29 (6.85)

12.39 (9.14)

17.43 (12.86)

20.91 (15.42)

M7

P=1

15.40 (11.36)

20.54 (15.15)

28.88 (21.30)

34.66 (25.56)

M8

P = 1.25

22.46 (16.57)

29.94 (22.08)

42.10 (31.05)

50.53 (37.27)

M10

P = 1.5

45.10 (33.26)

60.14 (44.36)

84.57 (62.38)

101.49 (74.86)

M12

P = 1.75

77.20 (56.94)

102.94 (75.92)

144.75 (106.76)

173.70 (128.11)

M14

P=2

123.23 (90.89)

164.30 (121.18)

231.05 (170.41)

277.26 (204.50)

M16

P=2

189.51 (139.78)

252.69 (186.37)

355.34 (262.08)

426.41 (314.50)

M18

P = 2.5

261.17 (192.63)

348.22 (256.83)

489.69 (361.18)

587.63 (433.41)

M20

P = 2.5

370.15 (273.01)

493.53 (364.01)

694.02 (511.88)

832.83 (614.26)

M22

P = 2.5

501.62 (369.98)

668.82 (493.30)

940.53 (693.70)

1128.64 (832.44)

M24

P=3

639.61 (471.75)

852.82 (629.01)

1199.27 (884.53) 1439.13 (1061.45)

M27

P=3

943.17 (695.65)

1257.56 (927.53) 1768.45 (1304.34) 2122.14 (1565.21)

M30

P = 3.5

1280.89 (944.08) 1707.86 (1259.65) 2401.67 (1771.38) 2882.01 (2125.66)

4-14

4. MAINTENANCE

4.7

TORQUE SPECIFICATIONS FOR JOINTS AND HYDRAULIC HOSES

SLEEVE-TYPE HOSE FITTINGS Hose dimensions outer diameter x thickness mm (in)

Wrench dimension mm (in)

10 x 1.5 (0.39 x 0.06)

19 (0.75)

44 ± 4.9 (32.45 ± 3.61)

15 x 2.0 (0.59 x 0.08)

27 (1.06)

147 ± 20 (108.42 ± 14.75)

18 x 2.5 (0.71 x 0.10)

32 (1.26)

177 ± 20 (130.55 ± 14.75)

22 x 3.0 (0.87 x 0.12)

36 (1.42)

216 ± 20 (159.31 ± 14.75)

28 x 4.0 (1.10 x 0.16)

41 (1.61)

275 ± 29 (202.83 ± 21.39)

35 x 5.0 (1.38 x 0.20)

55 (2.17)

441 ± 44 (325.26 ± 32.45)

Tightening torque Nm (lbf•ft)

JOINTS FOR PIPINGS (with O-rings) Normal screw dimension (PF)

Wrench dimension mm (in)

Tightening torque Nm (lbf•ft)

1/8

14 (0.55)

17 ± 2 (12.54 ± 1.48)

1/4

19 (0.75)

36 ± 2 (26.55 ± 1.48)

3/8

22 (0.87)

74 ± 5 (54.58 ± 3.69)

1/2

27 (1.06)

108 ± 9.8 (79.66 ± 7.23)

3/4

36 (1.42)

162 ± 9.8 (119.48 ± 7.23)

1

41 (1.61)

255 ± 9.8 (188.08 ± 7.23)

Normal screw dimension (PF)

Wrench dimension mm (in)

Tightening torque Nm (lbf•ft)

1/8

17 (0.67)

15 ± 2.0 (11.06 ± 1.48)

1/4

19 (0.75)

29 ± 4.9 (21.39 ± 3.61)

3/8

22 (0.87)

49 ± 4.9 (36.14 ± 3.61)

1/2

27 (1.06)

78 ± 4.9 (57.53 ± 3.61)

3/4

36 (1.42)

118 ± 9.8 (87.03 ± 7.23)

1

41 (1.61)

137 ± 15 (101.05 ± 11.06)

HYDRAULIC HOSE

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

4-15

4. MAINTENANCE

4.8

INSTALLING FITTINGS, HYDRAULIC HOSES AND TUBES

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

FITTING WITH O-RING The O-ring (2), allows to insulate the oil pressure inside of hose (1) and to avoids oil spillages.

The tightening torque of the joint of each hydraulic hose (1) is determined by the diameter of the hose fitting thread. If you notice a fault of operation, repair hose connection or replace it.

When connecting worn parts, pay particular attention to keep sealing surfaces clean from dirt and try not to damage them.

O-ring If the fitting is loose and oil leaks may occur, do not tighten it. It is necessary to install a new O-ring and to check again for tightness.

Never install a damaged and deteriorated O-ring even if it is new one. The use of an O-ring other the specified one, causes oil leakage and short life of hydraulic equipment.

Joint Be careful not to damage hoses, pipes or seal faces, this can impair the tightness.

Keep seal surfaces free from dirt.

Fitting with foreign matter inside causes oil leakage.

Hose Avoid high pressure hoses to twist during connection. Life of twisted hoses is drastically reduced.

Wash pipes and hoses, both inside and outside, with washing fluid and accurately dry them before reconnection.

4-16

4. MAINTENANCE

4.9

RELEASING INTERNAL PRESSURE FROM THE HYDRAULIC SYSTEM

S WARNING HYDRAULIC SYSTEM COMPONENTS AND HOSES CAN REACH VERY HIGH TEMPERATURES DURING OPERATION. THEREFORE STOP THE MACHINE AND LET IT COOL DOWN BEFORE STARTING ANY INSPECTION OR MAINTENANCE. DANGER OF BURNS. THE HYDRAULIC OIL TANK IS UNDER PRESSURE. PRESS THE PRESSURE RELIEVE BUTTON ON THE TANK, TO RELIEVE PRESSURE BEFORE MAINTENANCE. DANGER OF PERSONAL INJURIES. RELEASING HYDRAULIC SYSTEM AND OIL TANK PRESSURE

S WARNING NEVER CHANGE OILS OR FILTERS ON A MACHINE THAT HAS JUST FINISHED WORKING. ALLOW MACHINE TO COOL FIRST UNTIL OILS AND FLUIDS ARE WARM, NOT HOT. RELEASE HYDRAULIC TANK PRESSURE, BEFORE WORKING WITH ANY HYDRAULIC COMPONENT, ACCORDING TO THE PROCEDURES PROVIDED BELOW. WHEN REPLACING ANY HOSE OR SEALS, MAKE SURE THE ATTACHMENTS ARE WELL SECURED TO AVOID SUDDEN MOVEMENT OF ATTACHMENT. SLOWLY REMOVE BOLTS TO RELEASE ANY HYDRAULIC PRESSURE DURING DISASSEMBLY.

Park the machine on a level surface. Fully retract the arm cylinder and bucket cylinder. Lower the boom to rest the bucket onto the ground, and lower the dozer.

In case of pilot operating lines (boom, arm, bucket, slewing) stop the engine, then operate the control levers to release pressure from each system.

NOTE: the above procedure is the only way to release internal pressure.

4-17

4. MAINTENANCE Bring the throttle lever to low idle. Set the safety lock lever to “LOCKED” position.

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

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

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

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

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

Check and service the hydraulic system.

4-18

4. MAINTENANCE

4.10

BLEEDING AIR FROM FUEL SYSTEM

If air contaminates the fuel system, the engine may become hard to start or it may malfunction. Proceed with the bleeding of the air that, during the replacement of the pre-filter (1), was introduced into the fuel system. Perform this operation as follows: Park the machine on a level surface.

Rest the bucket to the ground.

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

Wait until the machine is cold.

Open engine guard and lock it in this position.

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

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

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

4-19

4. MAINTENANCE

4.11

REPLACEMENT OF RUBBER CRAWLER

S WARNING THIS WORK MUST BE DONE CAREFULLY BY TWO PEOPLE. THE OPERATOR MUST OPERATE THE MACHINE AS INSTRUCTED BY THE SIGNALS OF THE PARTNER. HAVING TO CARRY OUT VISUAL CONTROLS WITH THE CRAWLER IN MOTION, REMAIN ALWAYS AT AN EMERGENCY DISTANCE AND OUTSIDE FROM THE MOVING RANGE OF THE MACHINE. WHATEVER SERVICE TO THE CRAWLERS MUST BE CARRIED OUT WITH THE MACHINE SET UP IN THE FOLLOWING WAY: • THROTTLE LEVER AT IDLE RUN; • ENGINE SHUT DOWN; • STARTER KEY REMOVED; • SAFETY LOCK LEVER IN LOCKED POSITION. GREASE IN THE CRAWLER IDLER ADJUSTER IS UNDER EXTREME PRESSURE AND CAN PENETRATE SKIN CAUSING SEVERE INJURY. KEEP FACE AND BODY AWAY FROM GREASE FITTING AREA. IF GREASE DOES NOT COME OUT AFTER ONE TURN OF THE GREASE NIPPLE, CONSULT YOUR DEALER FOR ASSISTANCE. BEFORE REMOVING THE RUBBER CRAWLER, CHECK THAT THE GREASE PRESSURE HAS BEEN COMPLETELY RELEASED. PERSONNEL MUST OBSERVE THE INSTRUCTIONS GIVEN IN PARAGRAPH “REPLACEMENT OF RUBBER CRAWLER”, OTHERWISE THERE IS A RISK OF INJURY.

4-20

4. MAINTENANCE 4.11.1

REMOVING OF RUBBER CRAWLER

Turn the upper structure by 90° and lower the bucket to lift the crawler as shown.

Keep the angle between the boom and the arm to 90° and 110° and position the round part of the bucket on the ground. Place some supports (1) under the frame to support the machine.

Open the grease nipple (2) slowly so as to let grease come out and to relieve the pressure.

One turn, one turn and a half of the grease nipple (2) is sufficient, to loosen the crawler.

Insert some steel pipes (3) in the rubber crawler, then slowly rotate the sprocket backward.

When the rubber crawler leans on the pipes, slide it aside to remove it.

4-21

4. MAINTENANCE 4.11.2

INSTALLING RUBBER CRAWLERS

Turn the upper structure by 90° and lower the bucket to lift the crawler as shown.

Keep the angle between the boom and the arm to 90° and 110° and position the round part of the bucket on the ground. Place some supports (1) under the frame to support the machine.

Engage the crawler into sprocket and engage it into the crawler idler.

Slowly rotate the sprocket backwards and set the rubber crawler into position.

Engage a steel pipe (2) into the rubber crawler, and rotate the sprocket backward again to securely engage the rubber crawler with the idler adjuster.

Stop the sprocket (3) and check whether the rubber crawler (4) is correctly positioned on the crawler idler, on the lower rollers (5) and on the sprocket.

4-22

4. MAINTENANCE 4.11.3

CHECK AND ADJUSTMENT OF TENSION ON RUBBER CRAWLER

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

S WARNING SINCE THE ADJUSTMENT CHECK OF THE RUBBER CRAWLER TENSION IS CARRIED OUT WITH THE MACHINE LIFTED, THE SERIOUS DANGER THAT THE MACHINE FALLS IS ALWAYS REAL. NEVER MOVE THE MACHINE WHILE CHECKING AND ADJUSTING IT. WORK HAS TO BE PERFORMED BY TWO PERSONS, AND THE OPERATOR MUST OPERATE THE MACHINE IN ACCORDANCE WITH THE SIGNAL FROM THE PARTNER.

The friction of the rubber crawler with the soil varies according to working conditions and soil nature. It is therefore necessary to check frequently the crawler tension and wear.

Therefore, frequently check crawlers tension during the first 30 hours of new crawlers service.

Turn the upper structure by 90° and lower the bucket to lift the crawler.

Keep the angle between the boom and the arm to 90° and 110° and position the round part of the bucket on the ground. Place some supports (1) under the frame to support the machine.

4-23

4. MAINTENANCE Measure the clearance (A) between the lower face of crawler frame and the upper face of crawler shoe at the center position of crawler frame.

Correct value (tension) (A): (R) Rubber crawler: 80 ÷ 90 mm (3.14 ÷ 3.54 in) (S) Steel crawler: 115 ÷ 130 mm (4.52 ÷ 5.11 in) If tension is not within the specified values, loosen or tension the crawler.

NOTE: if the machine is operated with loose rubber crawler, there is the risk that the crawler springs and wears prematurely.

NOTE: check the tension of crawler after accurate removal of possible earth stuck in the crawler, by washing with pressurized water.

NOTE: in case the machine is employed mainly on gravelly, muddy grounds or surfaces with rocky bumps, we recommend checking the crawler tension daily.

Adjustment It is required to adjust the tension on the crawler depending on the working place of the machine.

When working on a place with a lot of gravel or boulder, looser tension (upper limit range of tension) is preferable. With hard grounds, stronger tension (lower limit range of tension) is preferable.

S WARNING GREASE IN THE CRAWLER IDLER ADJUSTER IS UNDER EXTREME PRESSURE AND CAN PENETRATE SKIN CAUSING SEVERE INJURY. KEEP FACE AND BODY AWAY FROM GREASE FITTING AREA. IF GREASE DOES NOT COME OUT AFTER ONE TURN OF THE GREASE NIPPLE, CONSULT YOUR DEALER FOR ASSISTANCE.

4-24

4. MAINTENANCE Tension the crawler Provide a grease gun.

Feed grease to the grease nipple (1) with suitable grease gun (2), so that the crawler achieves proper tension.

Move the machine forwards and backwards to equally tension the crawlers on both sides.

Again check for the tension on the crawlers, and repeat the adjustment to obtain the proper tension on both crawlers.

NOTE: if the crawler is still too loose even after grease nipple has been filled, it could be that the cylinder joint or the machine are defective.

4-25

4. MAINTENANCE Making tension looser

S WARNING GREASE IN THE CRAWLER IDLER ADJUSTER IS UNDER EXTREME PRESSURE AND CAN PENETRATE SKIN CAUSING SEVERE INJURY. IF GREASE DOES NOT COME OUT AFTER ONE TURN OF THE GREASE NIPPLE, CONSULT YOUR DEALER FOR ASSISTANCE.

To loosen the crawler, open the grease nipple (1) slowly counterclockwise. Grease will ooze out from grease nipple base.

One turn, one turn and a half of the grease nipple (1) is sufficient, to loosen the crawler. If grease does not come out evenly, slowly rotate the raised crawler.

When the expected crawler tension is achieved, turn grease nipple (1) clockwise and tighten it.

Tightening torque: 73.5 ± 14.7 Nm (54.21 ± 10.84 lbf•ft) Move the machine forward and backward to confirm the correct tension on the crawler belts.

Again check the tension, and if it is not correct, adjust it again.

S WARNING WHEN THERE IS MATERIAL (GRAVEL, MUD, ETC.) STUCK BETWEEN THE WHEEL AND THE CRAWLER, REMOVE IT BEFORE LOOSENING THE CRAWLER.

4-26

4. MAINTENANCE

4.12

INSPECTION AND MAINTENANCE TABLE

The following table gives the recommended intervals for regular inspection and maintenance procedures. Perform inspection and maintenance according to the calendar time or operation time shown by the hourmeter, whichever comes first.

See the inspection and maintenance procedure mentioned below for details.

S WARNING READ, UNDERSTAND AND FOLLOW ALL SAFETY INSTRUCTIONS FOUND IN THIS MANUAL BEFORE PERFORMING INSPECTION AND MAINTENANCE. Symbols and their meanings:

Components

4: inspection and/or maintenance is needed.

Detail

Range

When required

Checking the level Engine oil

Prestart 8h

Every week 50 h

Every 3 months 250 h

Every 6 months 500 h

Every 12 months 1000 h

2000 h

Lubricant etc. (piece to be replaced)

3-5

O

4

Replacement

Page

Engine oil

O

4-48

(1°)

4

Engine oil filter

Cartridge

O

4-51

(1°) Water separator

Draining/Cleaning

Fuel filter

Replacement

Air cleaner

Engine

Radiator / coolant

Belt

4-44

O Cartridge

O

Checking / cleaning

O

Replacement

Element

O

Checking the level Replacement Check

O

4-55 4-56

O O

4-54 3-4

O

Leakages check

4-58

3-18 3-8

Adjustment

4-50

O

Clogged radiator

O

4-29

Radiator cap

O

4-30

Engine cooling system hoses Checking / replacing Check for anomalous colour, noise and odour of the exhaust gas

4-53

O

3-16

O

Valve clearance

4-61

O

Compression pressure

O

Injection timing Checking / adjusting

O

Starter and generator Checking / adjusting

4-61

O

Check and adjustments for contact surface of suction and exhaust valve

O

4-27

4-71

4-71

Fuel system Components

4. MAINTENANCE

Detail

Fuel tank

Range

Fuel Checking / adjusting

Suction strainer

Every week 50 h

Every 3 months 250 h

Every 6 months 500 h

Lubricant etc. (piece to be replaced)

Checking the level

Page

3-7 4-45

O

3-8 3-6

O Hydraulic Oil

Replacement

O

Checking / replacing

O

4-62

Checking oil leakage and damage of cylinders, etc.

4

O

(1°)

(Breaker)

Filter Element

O

4-56 4-40

O

In-line filter / cleaning Upper structure

2000 h

O

Return filter

4-64

O

Slewing bearing lubrication (balls)

Grease

4-49

O

Grease

4-71

O

Gear oil

4-67

O

Slewing bearing Checking / lubrication (pinion/slewing replacing bearing)

Travel reduction motor

Every 12 months 1000 h

O

Leakages check

Hydraulic oil tank

Prestart 8h

Drain water and deposits

Hydraulic oil Hydraulic system

When required

4

Oil change

Lower frame

(1°) Checking / adjusting for tension of rubber belt Checking wear and damage of rubber belt Crawler idler and wheel

Attachment Electrical equipment Others

4-36

O

Check

4-41

O

Change

4-67

O

Checking oil leakage and wear of sprocket/travel reduction motor Greasing of pins

4-23

O

4-41

O

Bucket

O

Boom, arm cylinder and dozer

O

Grease

4-43

Grease

4-48

Bucket

O

Replacing / adjusting mounting gap

O

Checking wear and damage of the tooth and side cutters

O

4-32

Check of the electric wiring and fuses

O

4-38

4-34

Battery Checking the fluid level Measuring the specific gravity

O

Checking the function of warning lamps

O

Checking switches/levers

O

Work light replacement (lamp)

Sterile water

4-46 3-9 3-15

12V 55W (Halogen lamp)

O

4-31

Checking abnormal deformation and damage of the machine exterior

O

4-39

Checking looseness and missing of the bolts and nuts

O

4-39

Control lever

4-38

O

4-28

4. MAINTENANCE

4.13

WHEN NECESSARY

Carefully read and understand section “1. SAFETY INSTRUCTIONS” before operating or servicing the machine.

CLEAN RADIATOR

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.

Park the machine on a level surface.

Rest the bucket onto the ground.

Bring the throttle control lever to minimum speed, stop the engine and remove the starter key, then set the safety lock lever to the LOCKED position.

Remove the left side guard.

Check if radiator fins are clogged with dust or mud.

Clean accurately using compressed air or pressure water, directing the jet from cooler upper part downwards.

Adjust the jet pressure so that the radiator fins are not deformed.

Once cleaning is completed, close the left side guard and the cover under the seat.

4-29

4. MAINTENANCE CLEANING OR REPLACEMENT OF RADIATOR CAP

S WARNING USE EXTREME CARE WHEN REMOVING THE RADIATOR CAP. THE COOLANT IS UNDER HIGH PRESSURE WHEN IT IS HOT. NEVER REMOVE THE RADIATOR CAP WHEN THE SYSTEM IS HOT. WAIT UNTIL THE ENGINE HAS COOLED DOWN BEFORE REMOVING THE RADIATOR CAP.

S CAUTION If the cap is not sufficiently tight, there might be the risk of burning, due to the spouting out of hot water or steam during operation.

Remove the radiator cap after the engine has cooled down, so that it can be touched with bare hands.

Slowly loosen the cap to release the inside pressure.

Remove the cap from the radiator after pressure has been relieved.

Check the cap for damages or adhesion of dust.

Clean it and/or replace it if needed.

Securely tighten the cap.

4-30

4. MAINTENANCE WORK LIGHT CONTROL A light bulb of 55W is used for the work light.

S CAUTION Since the light bulb develops high temperature during use, the service life of it becomes shorter if oil or grease adhere to it.

When replacing the light bulb, hold it at the flange portion without touching its glass portion.

When the working does not turn on after switch activation, the light bulb or fuse may be blown. If the bulb is in good conditions, check the fuse.

Lamp replacement Place the bucket on the ground and set safety lock lever to “LOCKED” position, then stop the engine.

Disconnect the connector, then remove the work light from the boom with a wrench.

Remove the screws (1) (4 pieces), then remove the rim (2) and lens (3) from the housing (4).

Remove the spring (6) fixing the socket (5).

Remove the bulb (7) from the socket (5) and install a new one.

Assemble the work light proceeding in the reverse order from above.

NOTE: pay attention not to break the light bulb during replacement. Hold the lens when removing the screw (1), otherwise, it falls off.

4-31

4. MAINTENANCE CHECK WEAR AND SLACKENING OF THE BUCKET TEETH TIPS AND SIDE CUTTERS Park the machine on a level surface.

Rest the bucket onto the ground.

Bring the throttle control lever to minimum speed, stop the engine and remove the starter key, then set the safety lock lever to the LOCKED position.

Their lifetime is not only determined according to the number of operating hours; it is also necessary to consider the working conditions.

Replacement of tooth tips Replace the bucket teeth in the following cases.

• When little holes appear on the teeth tips.

• When the edge lines of the teeth tips are worn.

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 locking pin (2).

Inspect the safety pin (3) and the rubber pin (2).

Replace them if the locking pin (3) is too short or if the rubber pin (2) is worn.

Clean the surface of the adapter (4) with a putty knife to remove the soil stuck.

Fit the tooth tip (1) onto the adapter (4).

Push the rubber pin (2) into the hole of the adapter (4).

Drive the locking pin (3) until it is aligned with the point face.

4-32

4. MAINTENANCE Replacement of the side cutters

S WARNING WEAR GOGGLES, SAFETY SHOES, HARD HAT, WORK CLOTHES AND WORK GLOVES TO PERFORM INSPECTION AND MAINTENANCE ON THIS MACHINE. Remove completely all sand and soil stuck on the capscrews. Use an acetylene torch to cut off the capscrews, then remove the side cutters (2).

Clean the mounting face and install a new side cutter (2). When replacing the side cutter, also replace the capscrews (3) and nuts (1).

Tightening torque: 279 ± 19.4 Nm (10.98 ± 0.76 lbf•ft) After tightening the nuts (1), spot-weld them.

4-33

4. MAINTENANCE BUCKET REPLACEMENT

S WARNING THE BUCKET REPLACEMENT HAS TO BE CARRIED OUT ON A FIRM AND FLAT SURFACE. PAY CLOSE ATTENTION TO SAFETY INSTRUCTIONS. WHEN ALIGNING THE PIN BORES, DO NOT INSERT YOUR FINGER INTO THE BORES. IT MAY CAUSE SEVERE INJURY. ALWAYS USE SUITABLE TOOLS TO ALIGN HOLES.

Bucket removal Lower the bucket (6) to the ground.

If the bucket leans too heavily on the ground, you will have some problems of movement.

Slightly operate the boom and the arm to remove load from pins (4) and (5) from the weight of the bucket.

Shift the O-rings (1) onto the bucket boss, so as not to damage it.

Disassemble the retainer rings (2) and the safety pins (3). Then extract the pins (4) and (5) with the shims (10). Take off the bucket (6).

NOTE: pay attention not to let any sand or dust stick to the pins removed.

NOTE: pay attention not to damage the dust seals (9) installed on arm ends (7) and on bucket link (8).

4-34

4. MAINTENANCE Bucket assembly Clean each pin and pin hole and grease sufficiently.

Move the bucket cylinder so as to match the pins bores (6) and bucket link bores (8). Then position the pins (4) with the shims (9).

Raise the boom and slightly raise the bucket from the ground.

Align bucket (6) with the bucket bores and arm bores (7). Then position the pins (5) with the shims (9).

Insert the safety pins (3) and snap rings (2) into dowels (4) and (5).

Return the O-ring (1) to normal position.

Apply grease in the grease nipples, until this oozes out from the spaces between pins and bores.

NOTE: replace broken or loose O-rings (1).

S WARNING ALWAYS USE SUITABLE TOOLS TO ALIGN BORES. DO NOT USE HANDS OR FINGERS.

4-35

4. MAINTENANCE INSPECTING RUBBER CRAWLER Repair or replace the rubber crawler under the following conditions.

Contact your Dealer for the repair or the replacement of the rubber crawlers.

Rib height When the height (A) of the ribs (1) wears off, the tractive force decreases. Replace the crawler (2) with a new one if its dimension (A) is lower than 5 mm.

Replace the crawler (2) if the lug (3) is so worn that the steel casing (1) is exposed on two links.

Breakage of steel cord If the steel cords of the rubber shoe (1) are broken by more than one half of one side row, replace the shoe with a new one.

Crack of rubber shoe If a crack (A) about 60 mm (2.3 in) long or more is noticed between crawler and lug, repair the rubber crawler. However, repair the crawler immediately even though the steel cord is exposed, because of a small and short crack (B).

(C) repair not yet required.

NOTE: contact your Dealer for the repair or the replacement of the rubber crawlers.

4-36

4. MAINTENANCE Detachment of the metal core of the rubber crawler According to usage of the rubber crawler (3), there may occasionally be peeling off of metal core (2) (inner side), due to contact (A) with the lower rollers (1) and idler/sprocket, or because of the rubbing, even though there are no external damages or abrasion on the lug (outer side). the metal core can detach easily if the rubber crawler shoe is not used correctly.

Note that the warranty is not valid if rubber crawlers are wrongly used or if their tension is inaccurate.

Replace the rubber crawler on which the metal core (1) detaches itself, even only in one point.

Replace the torn rubber crawler on which the metal core (1) is exposed.

The rubber crawler does not need to be replaced, if the contact surface (1) between metal core and roller is cracked.

NOTE: the metal core can detach easily if the rubber crawler shoe is not used correctly.

4-37

4. MAINTENANCE LUBRICATION OF CONTROL LEVERS When a control lever becomes heavy to operate or does not move smoothly, apply grease to the sliding and rotating portion (4) and the top portion (5) of the universal joint (3).

Place the machine on a firm and level ground, and engage safety control lever on “LOCK” position.

Stop the engine, pull out the starter key.

Carefully raise up the rubber boot (2) and the control lever (1) paying attention not to damage them.

Apply grease on the sliding parts and on the 4 places of rotating portion (4) and the top (5) of the universal joint (3).

Set back the rubber boot (2) to the original position.

CHECK ELECTRIC WIRING AND FUSES

S WARNING IF SHORT CIRCUIT TRACES ARE NOTICED ON THE WIRING HARNESS, CONTACT YOUR DEALER. BEFORE CHECKING THE ELECTRICAL SYSTEM, DISCONNECT THE NEGATIVE (-) BATTERY CABLE. ERRONEOUS SHORT CIRCUITING MAY CAUSE FIRE.

S WARNING ALWAYS MAKE SURE TO INSTALL FUSES OF CORRECT AMPERAGE, TO AVOID OVERLOADING AND DAMAGING THE ELECTRIC SYSTEM.

4-38

4. MAINTENANCE

4.14

PRE-START (EVERY 8 HOURS) INSPECTION AND MAINTENANCE

Carefully read and understand section “1. SAFETY INSTRUCTIONS” before operating or servicing the machine. The following inspection and maintenance shall be carried out before and after start up and at the end of work.

Refer to section “3. MACHINE OPERATION”.

Checking the coolant level

3-4

Checking the work light

3-9

Checking the engine oil level

3-5

Checking the warning lamps

3-9

Checking the hydraulic oil level

3-6

Checking all switches and levers

3-15

Checking the fuel level

3-7

Exhaust gas anomalous colour, noise and odour 3-16

Check fuel leaks

3-8

Machine operation

Check belt conditions

3-8

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 outside the components daily, before starting the work or at the end of it, to assess their condition.

CHECK FOR DETACHED PIECES OR LOOSE FASTENINGS Check and make sure all capscrews and nuts are properly tight. Likewise, check and make sure that all clamps are properly tightened.

An abnormal sound during operation may cause leakage or fire.

4-39

3-18

4. MAINTENANCE VISUAL CHECK OF HYDRAULIC SYSTEM

S WARNING THE HYDRAULIC OIL TANK IS UNDER PRESSURE. BE SURE TO RELEASE THE PRESSURE IN THE SYSTEM BEFORE STARTING SERVICE AND/OR MAINTENANCE, OR REFILLING. NEVER USE HANDS TO CHECK FOR POSSIBLE LEAKS. HIGH PRESSURE OIL LEAKS CAN PENETRATE THE SKIN AND CAUSE SEVERE INJURY.

Possible hydraulic oil leaks, generate slower machine motion.

Stop the machine on a level surface and position the attachment as shown in the figure.

Bring the throttle control lever to minimum speed, stop the engine and remove the starter key, then set the safety lock lever to the LOCKED position.

To locate the leak, wait for the machine to cool down. Be sure to wear protective glasses and gloves for the check.

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

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

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

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

NOTE: if a fault is found, immediately stop working and contact your Dealer for the necessary repairs. If the coolant level becomes too low due to a leakage, a warning lamp turns on to indicate the fault.

4-40

4. MAINTENANCE CHECKING THE TRAVEL MOTORS AND THE ROLLERS Park the machine on a level surface.

Rest the bucket onto the ground.

Bring the throttle control lever to minimum speed, stop the engine and remove the starter key, then set the safety lock lever to the LOCKED position.

Wait for the machine to cool down.

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

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

Slowly travel the machine and check for any abnormal sound.

4-41

4. MAINTENANCE

4.15

50-HOUR (WEEKLY) INSPECTION AND MAINTENANCE

Carefully read and understand section “1. SAFETY INSTRUCTIONS” before operating or servicing the machine.

Perform together with the daily maintenance operations.

CHECKING AND TENSIONING THE RUBBER CRAWLER An appropriate adjustment of tension on the rubber crawlers is vital both for the rubber crawler and the machine life.

S WARNING THE CRAWLER TENSION IS CARRIED OUT WITH A MACHINE SIDE LIFTED. THIS CAN GENERATE A FALLING RISK IF THE MACHINE IS HIT ERRONEOUSLY. NEVER OPERATE THE MACHINE DURING THE INSPECTION. BE SURE TO CARRY OUT THE WORK WITH THE HELP OF ANOTHER PERSON. THE OPERATOR MUST OPERATE THE MACHINE AS INSTRUCTED BY THE SIGNALS OF THE PARTNER.

4-42

4. MAINTENANCE GREASING PINS AROUND BUCKET Greasing intervals Generally the greasing is carried out every 50 hours of service.

Move the machine to a level and firm ground. Rest the bucket onto the ground.

Bring the throttle control lever to minimum speed, stop the engine and remove the starter key, then set the safety lock lever to the LOCKED position.

Wait for the machine to cool down.

Clean the grease nipples before greasing. Replace if damaged.

Grease the pins using a grease gun as shown on the right (see arrows).

Properly wipe off any grease oozed out around the pin connection.

S CAUTION Dispose of all hazardous waste in accordance with current legislation.

No.

GREASING POINTS

Q’TY

A

Bucket cylinder rod pin

1

B

Idler link/arm connecting pin

1

C

Bucket link pin

1

D

Arm/bucket connecting pin

1

4-43

4. MAINTENANCE SEPARATOR FILTER CLEANING If red float (5) lowers to cup bottom (8), water is drained. If float (5) floats, there is water in the cup and this must be drained as follows:

S WARNING PAY ATTENTION, DURING THE REMOVAL PHASE, TO AVOID SPILLING THE FUEL IN THE FILTER: DANGER OF FIRE. Shut down the engine, pull out the starter key and set the safety lock lever on “LOCK”.

Wait until the machine is cold.

Open engine guard and lock it in this position.

Shift the knob (1) of separator filter in “A” to “CLOSE” it.

Loosen ring (2) and disassemble the cup (8). Drain water into a container.

NOTE: pay attention not to lose the red float (5) and spring (6).

S CAUTION Dispose of all hazardous waste in accordance with environmental regulation.

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

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

Replace the O-ring (7).

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

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

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

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

NOTE: do not clean up the element with petrol.

4-44

4. MAINTENANCE DRAIN DEPOSITS FROM FUEL TANK

S WARNING EXTINGUISH ALL SMOKING MATERIALS AND NAKED FLAMES BEFORE CHECKING FUEL LEVEL, REFUELLING, REPLACING FILTERS, OR REMOVING THE CONDENSATE DRAIN PLUG, BECAUSE OF FLAMMABLE VAPOURS. THOROUGHLY WIPE OFF ANY SPILLED FUEL. Park the machine on a level surface with the upper structure turned by 90° in order to make access easier.

Rest the bucket onto the ground.

Bring the throttle control lever to minimum speed, stop the engine and remove the starter key, then set the safety lock lever to the LOCKED position.

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

Loosen filling plug (1).

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

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

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

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

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

4-45

4. MAINTENANCE CHECKING THE BATTERY

S WARNING BATTERY GAS MAY EXPLODE. KEEP AWAY SPARKS AND FLAMES. USE A POCKET TORCH TO CHECK ELECTROLYTE LEVEL. SULPHURIC ACID CONTAINED IN THE BATTERY ELECTROLYTE IS POISONOUS. IT CAN BURN THE SKIN, CORRODE CLOTHES AND CAUSE LOSS OF SIGHT IF SPRAYED INTO THE EYES. IF ACID COMES IN TOUCH WITH THE SKIN: • WASH SKIN WITH WATER. • IF ACID HAS REACHED THE EYES, WASH WITH WATER FOR AT LEAST 15 MINUTES. IMMEDIATELY SEEK MEDICAL ATTENTION. Check the warning lamp (A) on the battery; the lamp turns on green when the battery is charged. If the light is red, this means that the battery is discharged.

Park the machine on a level surface with the upper structure turned by 90° in order to make access easier.

Rest the bucket onto the ground.

Bring the throttle control lever to minimum speed, stop the engine and remove the starter key, then set the safety lock lever to the LOCKED position.

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.

4-46

4. MAINTENANCE ARMS AND ATTACHMENT LUBRICATION NOTE: under normal conditions, apply grease every 50 working hours or every week. Under particular working conditions, observe following lubrication intervals: • when operating the machine with special attachments, apply grease to each of these devices before starting working.

• for underwater digging, apply grease to the areas immersed in water every day.

Make sure that the machine is parked on a level surface.

Rest the bucket onto the ground and position the boom to obtain easy access to all greasing points shown. If necessary, use only safety ladders during lubrication.

Bring the throttle control lever to minimum speed, stop the engine and remove the starter key, then set the safety lock lever to the LOCKED position.

Make sure to clean the grease fittings before the greasing. Replace if damaged.

Use table below for lubrication. Inject grease in the grease nipples of the links indicated by the arrows, until grease oozes out.

Completely eliminate the used grease.

No.

GREASING POINTS

Q.ty

1

Dozer cylinder rod pin

1

2

Dozer cylinder bottom pin

1

3

Dozer fastening pins

1

4

Boom foot pin

1

5

Boom cylinder foot pin

1

6

Boom cylinder rod pin

1

7

Arm cylinder foot pin

1

8

Arm cylinder rod pin

1

9

Boom/arm connecting pin

2

10 Bucket cylinder foot pin

1

11

Bucket cylinder rod pin

1

12 Swing cylinder foot pin

1

13 Swing cylinder rod pin

1

14 Swing pin

14

4-47

4. MAINTENANCE

4.16

250-HOUR (3-MONTH) INSPECTION AND MAINTENANCE

Carefully read and understand section “1. SAFETY INSTRUCTIONS” before operating or servicing the machine.

ENGINE OIL CHANGE

S WARNING DO NOT CHANGE THE ENGINE OIL IMMEDIATELY AFTER THE ENGINE HAS STOPPED. ALLOW SUFFICIENT TIME FOR THE ENGINE TO COOL DOWN. THE FIRST OIL CHANGE MUST BE CARRIED OUT AT 50 HOURS OPERATION FOR A NEW MACHINE ENGINE.

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.

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

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

Remove plug (1) and slide out the level dipstick (2).

These two actions allow faster draining of the oil from the sump.

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

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

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

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

4-48

4. MAINTENANCE GREASING THE SLEWING BEARING

S WARNING NEVER SLEW THE UPPER STRUCTURE WHILE APPLYING GREASE TO THE SLEWING BEARING.

S WARNING THE LUBRICATION OF THE BALLS MUST BE CARRIED OUT BY ONE PERSON ONLY. BEFORE LUBRICATING THE SLEWING BEARING, KEEP PEOPLE AWAY FROM THE MACHINE’S WORKING RANGE. Before leaving the cab, arrange machine and controls as follows: Place the machine on a level surface.

Rest the bucket onto the ground.

Bring the throttle control lever to minimum speed, stop the engine and remove the starter key, then set the safety lock lever to the LOCKED position.

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

Start the engine, raise the bucket approximately 20 cm (0.66 ft) from the ground and slew the upper structure by 45° (1/8 of a turn).

Rest the bucket onto the ground.

Repeat the procedure above three times. Always observe the safety indications prescribed.

Grease should be injected until it comes out of the seals. Do not inject grease excessively.

4-49

4. MAINTENANCE BELT TENSION ADJUSTMENT

S WARNING DO NOT APPROACH BELTS OR MOVING PARTS WITH YOUR BODY. BE PARTICULARLY CAUTIOUS NEAR FANS (ALTERNATOR AND COOLER FAN).

S CAUTION The engine, when in operation, can reach high temperatures. Therefore, before performing this operation, stop the machine and let it cool down. 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 scalds and personal injuries.

Check the fan belt for its tension, wear conditions and damages.

Be sure to adjust tension properly.

Adjusting the fan belt Place the machine on a level surface.

Rest the bucket onto the ground.

Stop the engine, remove the starter key and set the safety lock lever to the LOCKED position.

Wait for the machine to cool down.

Remove cover (1).

Loosen mounting bolt (2) and adjusting bolt (3) slightly.

Loosen adjusting bolt (4) to set the tension of the fan belt. Tighten fastening screw (2) and adjusting bolt (3).

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

Reinstall cover (1).

4-50

4. MAINTENANCE REPLACEMENT OF ENGINE OIL FILTER

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

S WARNING REMEMBER THAT ENGINE AND OIL CAN REACH HIGH WORKING TEMPERATURES; THEREFORE, WHILE CARRYING OUT THIS OPERATION WHEN THE ENGINE IS STILL HOT, PROTECT YOUR BODY WITH SUITABLE CLOTHING AND REPAIRS, SO AS TO AVOID 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.

NOTE: the oil filter is a cartridge-type filter, that cannot be re-used or cleaned.

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

The filter wrench provided on the machine is used for the removing.

Stop the engine and open the engine guard to remove the lower cover.

Place the filter wrench (2) on the filter cartridge (1), and turn the wrench with wrench turning counterclockwise to remove it.

Wipe off any dirt on the seal face of filter base, and avoid contamination.

Park the machine on a level surface.

Rest the bucket to the ground.

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

4-51

4. MAINTENANCE Wait until the machine is cold.

Open engine guard and lock it in this position.

Remove the support area and the area around the filter.

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

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

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

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

Start engine and let it run idle for several minutes.

Recheck if fitting surface shows leaks.

Close engine guard.

IMPORTANT: if the machine is operated in very dusty conditions, change the oil filter at a reduced hours interval.

If metal particles or foreign material are noticed in the oil filter, contact your Dealer.

IMPORTANT: dispose of all hazardous waste in accordance with government environmental regulations.

CHECKING RADIATOR HOSES Replacing the hoses before any problems occur is both economical and good maintenance practice.

This will reduce costs and minimize unexpected interruption of working. Replace an old and damaged hose immediately. In this way troubles are avoided. Carefully inspect the sleeves for integrity and sealing (replace if necessary) and tighten possibly loose straps. Check the there are no leakages from the radiator, damages or accumulation of dirt.

4-52

4. MAINTENANCE REPLACING RADIATOR HOSES

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

S WARNING LIQUID UNDER PRESSURE; TURN RADIATOR CAP SLOWLY TO RELIEVE PRESSURE. TO AVOID SCALDS DO NOT LOOSEN RADIATOR CAP WITH ENGINE STILL HOT. DO NOT PERFORM THIS OPERATION WHEN THE MACHINE IS STILL HOT. CONTACT WITH ENGINE COOLANT AT WORKING TEMPERATURE MAY CAUSE SCALDS AND PERSONAL INJURIES. Park the machine on a level surface.

Rest the bucket onto the ground.

Bring the throttle control lever to minimum speed, stop the engine and remove the starter key, then set the safety lock lever to the LOCKED position.

Wait for the machine to cool down.

Open the door of the radiator compartment and the engine guard and lock them open.

Open radiator plug (1) slowly, so as to relieve pressure.

Remove the under cover located lower position of radiator, and loosen the drain plug (2). Then drain the coolant into a suitable container. When this operation is finished, reinstall plug (2).

Loosen the clamp and remove damaged hose or replace it with a new one.

Fill the radiator (3) and the tank (4) through the plug (1).

After filling, tighten securely the radiator cap (1).

4-53

4. MAINTENANCE CHECKING AND CLEANING THE AIR FILTER

S WARNING OPERATIONS TO BE CARRIED OUT ALSO IF THE RELEVANT LAMP TURNS ON.

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.

Cleaning and replacement of the outer and inner filter element.

• Cleaning: When warning is indicated on multi display.

• Replacement: After cleaning for the 6th time or an interval of 6 months (500 hours).

Cleaning the filter element Park the machine on a level surface.

Rest the bucket onto the ground.

Bring the throttle control lever to minimum speed, stop the engine and remove the starter key, then set the safety lock lever to the LOCKED position.

Open the engine guard.

Unhook the clamp (1).

Turn the cover (2) counterclockwise and remove it.

Clean the inside of the air filter body (4).

To clean the element (3), blow compressed air (less than 0.3 MPa) up and down along the folds of the filter element interior to remove clogged dust or other contaminants.

Check that there are no holes or cuts in the filter placing a proper light inside the filter. If the light shows holes or cuts in the element, it must be replaced. In any case, the element must be replaced every year.

Insert the element (3), making sure that it is correctly positioned.

Install the cover (2), locking it by means of the two clamps (1), and orient the “TOP” mark of the cover, tilting it by 15°.

Close the engine guard.

4-54

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

REPLACEMENT OF INNER ELEMENT

S WARNING THE NORMAL MAINTENANCE INTERVAL PRESCRIBES THE REPLACEMENT OF THE AIR FILTER OUTER ELEMENT EVERY 1000 HOURS. UNDER PARTICULAR ENVIRONMENT CONDITIONS, (VERY DUSTY AREAS) IT IS RECOMMENDED TO REDUCE THE REPLACEMENT INTERVAL AT LEAST OF 50%.

Park the machine on a level surface.

Rest the bucket to the ground.

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

Press on tongue (1).

Turn the cover (2) counterclockwise and remove it.

Check that dust ejection valve (3) is clean.

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

Fit cover (2) and turn it clockwise.

Close engine guard.

4-55

4. MAINTENANCE REPLACEMENT OF HYDRAULIC RETURN FILTER The return filter keeps the hydraulic oil clean by removing any foreign material that may be in the oil.

This will prevent the hydraulic equipment from becoming damaged and prolong the equipment's life. Thus, since the return filter is a very important part, treat it with care.

S WARNING HYDRAULIC SYSTEM COMPONENTS AND HOSES CAN REACH VERY HIGH TEMPERATURES DURING OPERATION. THEREFORE STOP THE MACHINE AND LET IT COOL DOWN BEFORE STARTING ANY INSPECTION OR MAINTENANCE. DANGER OF BURNS. THE HYDRAULIC OIL TANK IS UNDER PRESSURE. PRESS THE PRESSURE RELIEVE BUTTON ON THE TANK, TO RELIEVE PRESSURE BEFORE MAINTENANCE. DANGER OF PERSONAL INJURIES. Stop the machine on a flat ground and place the attachment as shown in the figure.

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

Wait until the machine is cold.

4-56

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

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

Take out spring (4), valve (5) and element (6).

Replace O-ring (7) and element (6).

Clean the parts taken out with light oil.

Install the new filter element (6) and spring (4) into the tank seat.

Install cover (3) with a new O-ring (7).

Fit the fastening screws (1) of cover (3).

Tightening torque: 23.5 ± 2 Nm (17.3 ± 1.4 lbf•ft) Start the engine, activate all control levers and recheck oil level.

NOTE: for a machine with a hydraulic breaker, the deterioration of hydraulic oil is hastened by the breaker work compared to the standard digging with bucket. It is therefore necessary to carry out maintenance at shorter intervals.

4-57

4. MAINTENANCE

4.17

500-HOUR (6-MONTH) INSPECTION AND MAINTENANCE

Carefully read and understand section “1. SAFETY INSTRUCTIONS” before operating or servicing the machine.

Perform together with the daily and 250-hour maintenance operations.

REPLACEMENT OF FUEL FILTER

S WARNING NEVER USE GASOLINE, OR OTHER FLAMMABLE SOLVENTS TO CLEAN PARTS. USE ONLY PROPRIETARY CERTIFIED SOLVENTS, NONFLAMMABLE AND NON-TOXIC. ALWAYS ENSURE THAT ENGINE GUARD IS CORRECTLY LOCKED IN THE RAISED POSITION: DANGER OF 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.

S WARNING PAY ATTENTION, DURING THE REMOVAL PHASE, TO AVOID SPILLING THE FUEL IN THE FILTER: DANGER OF FIRE. Park the machine on a level surface.

Rest the bucket to the ground.

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

Wait until the machine is cold.

Open engine guard and lock it in this position.

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

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

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

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

4-58

4. MAINTENANCE

4.18

1000-HOUR (12-MONTH) INSPECTION AND MAINTENANCE

Carefully read and understand section “1. SAFETY INSTRUCTIONS” before operating or servicing the machine.

Perform this operation at the same time of inspection and maintenance, that have to take place every day and after 500 service hours.

REPLACEMENT OF COOLANT

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

S CAUTION Liquid under pressure; turn the radiator cap slowly to relieve pressure before removing it.

To prevent scalds, do not loosen the radiator cap with engine still hot.

Do not perform this operation when the machine is still hot. Contact with engine coolant at working temperature may cause scalds and personal injuries.

S WARNING 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.

4-59

4. MAINTENANCE Park the machine on a level surface.

Rest the bucket to the ground.

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

Wait until the machine is cold.

Open engine guard and lock it in open position.

With cold engine, remove plug (1) from radiator and plug (2) from level tub (3).

Remove draining plug (4) and let coolant drain inside a container of suitable capacity. When this operation is finished, reinstall plugs (4) and (2).

Carefully inspect the sleeves for integrity and seal (replace them if necessary) and tighten possibly loose clamps. Check the radiator for leaks, damages and/or dirt build-up.

Proceed with system filling through plug (1) until the radiator is completely full.

NOTE: when adding coolant, proceed slowly to avoid formation of air bubbles in the system.

Install cover (1).

Start the engine and let it run for several minutes, so as to heat the coolant.

Stop the engine, wait until it cools down and check the coolant level on the level tub (3). The coolant level should be set between references FULL and LOW. If the level is low, remove plug (2) and restore level.

Close engine guard and radiator compartment lid.

NOTE: handle and dispose of coolant according to current legislation. Use only authorised disposal procedures. If in doubt, contact authorities concerned.

NOTE: if “Long life coolant” is not used, replace the coolant twice a year (in spring and autumn).

4-60

4. MAINTENANCE CHECKING AND ADJUSTMENT FOR VALVE CLEARANCE This is to correct the time lag at which exhaust and intake valves open and close. If this maintenance operation is ignored, faults may occur.

CHECKING AND ADJUSTMENT FOR STARTER AND GENERATOR There is a possibility of worn-out brushes and/or lack of grease lubrication on bearing.

This is of the adjustment to get good start ability and power generation.

4-61

4. MAINTENANCE

4.19

2000-HOUR SERVICE INSPECTION AND MAINTENANCE

Carefully read and understand section “1. SAFETY INSTRUCTIONS” before operating or servicing the machine. Perform this operation at the same time of inspection and maintenance, that have to take place every day and after 1000 service hours.

OIL CHANGE IN HYDRAULIC OIL TANK AND CLEANING OF SUCTION FILTER

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

S WARNING HYDRAULIC SYSTEM COMPONENTS AND HOSES CAN REACH VERY HIGH TEMPERATURES DURING OPERATION. THEREFORE STOP THE MACHINE AND LET IT COOL DOWN BEFORE STARTING ANY INSPECTION OR MAINTENANCE. DANGER OF BURNS. THE HYDRAULIC OIL TANK IS UNDER PRESSURE. PRESS THE PRESSURE RELIEVE BUTTON ON THE TANK, TO RELIEVE PRESSURE BEFORE MAINTENANCE. DANGER OF PERSONAL INJURIES. Park the machine on a level surface with the upper structure turned by 90° in order to make access easier.

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

Wait for the machine to cool down and open the side guard.

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

Press the valve (several times 5 to 7) together with the breather cap (3), and bleed the inner pressure.

Place an oil (1) collecting container under the draining plug (2). Remove drain plug (1) with a spanner (27 mm), and drain oil.

4-62

4. MAINTENANCE Once the oil has been drained retighten the draining plug (2).

Tightening torque: 73.5 ± 5 Nm (54.21 ± 3.6 lbf•ft) Loosen four screws (4) and washers (5) and remove cover (6).

NOTE: When loosening the drain plug (2), pay attention not to pour fluid over yourself.

Do not drop tools or capscrews and so on into hydraulic tank.

S CAUTION Dispose of all hazardous waste in accordance with environmental regulation.

Remove suction filter (8) and O-ring (7).

Clean suction filter (8) with diesel oil. If the filter has to be replaced, install a new one.

Install new O-ring (7), the suction filter (8) and make sure that the complete suction filter is correctly placed.

Fill the hydraulic oil tank through filling neck (9).

Install cover (6) with screws (4) and washers (5).

Tightening torque: 23.5 ± 2 Nm (17.3 ± 1.0 lbf•ft) Close the side hood.

Once the engine has started up and has operated for several minutes (5/7) to low idle, carry out telescopic motion of each cylinder. Reposition the machine in the hydraulic oil check position, and if this latter is low, restore oil level checking through level indicator (10).

4-63

4. MAINTENANCE CLEANING OF PILOT VALVE AND SOLENOID VALVE LINE FILTERS

S WARNING THE HYDRAULIC OIL TANK IS UNDER PRESSURE. DO NOT CARRY OUT ANY CHECK AND SERVICING BEFORE RELEASING THE INSIDE PRESSURE. TO RELEASE INSIDE PRESSURE IN THE HYDRAULIC OIL TANK, DEPRESS RUBBER CAP ON THE RESERVOIR SEVERAL TIMES (5 TO 7 TIMES).

ESCAPING FLUID UNDER PRESSURE CAN PENETRATE THE SKIN CAUSING SEVERE INJURIES. The right and left pilot valve and solenoid valve are equipped with a filter adapter. Dirt in the filter decreases oil flow. If dust, etc. enter in the valve it may cause trouble.

Take out and clean filter, regularly.

PILOT VALVE LINE FILTER CLEANING Carry out the lifting work on level ground.

Rest the bucket to the ground.

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

Carry out the air releasing from the hydraulic system.

Loosen the 2 screws (3) of the gear box and remove the cover.

Disconnect first hose (1) connected to “P” port of pilot valve (4). Then remove connector with filter (2).

After removal, plug the bore to prevent entry of foreign matters.

Clean the fuel filter and use compressed air to remove dust.

Inspect O-rings (5) for damage or excessive wear, replace them if necessary.

After cleaning, carry out reassembly, in the reverse order as described under (5) and (6).

4-64

4. MAINTENANCE Remove the right-hand hood (6).

After removing the hose, remove the filter assy (7) from the joint (9) installed on the solenoid valve (8).

After removal, the holes of the joint and of the hose should be plugged.

Unscrew and remove the joint (7d), then remove the filter (7b) by using a screwdriver.

Spray oil on the air filter (7b) to clean it or eventually replace it if damaged. Do not forget to clean the inside of the case (7a). Check O-ring (7c) and if damaged, replace it with a new one.

Reassemble the filter (7b) in the housing (7a). Screw and tighten the joint (7d).

Tightening torque: 60 to 80 Nm (44.2 to 59 lbf•ft) Reinstall the filter assy (7) onto the joint (9) of the solenoid valve (8).

Tightening torque: 40 to 79 Nm (29.5 ± 58.2 lbf•ft) Install the hose.

Remove the 90°-fitting (13) from the valve (10).

Clean the 90°-fitting (13) from dust. After cleaning, carry out reassembly in the reverse order of removal sequence.

Remove the floor plate and cover. First remove the hose (11) connected to “P” port on the pilot valve (10), then remove the 90°-fitting (13). After removal, plug the bore to prevent entry of foreign matters.

4-65

4. MAINTENANCE Remove dust accumulated inside the 90°-fitting (13).

Inspect O-rings (12) for damage or excessive wear, replace them if necessary.

After cleaning, carry out reassembly in the reverse order of removal sequence.

4-66

4. MAINTENANCE OIL CHANGE FOR TRAVEL REDUCTION UNIT

S WARNING REMEMBER THAT ENGINE AND OIL CAN REACH HIGH WORKING TEMPERATURES; THEREFORE, WHILE CARRYING OUT THIS OPERATION WHEN THE ENGINE IS STILL HOT, PROTECT YOUR BODY WITH SUITABLE CLOTHING AND REPAIRS, SO AS TO AVOID SCALDS AND PERSONAL INJURIES. SLOWLY REMOVE SCREW PLUG FOR OIL FILLING, DRAIN AND LEVEL FROM REDUCTION UNITS. THIS IN ORDER TO DISCHARGE SLOWLY THE PRESSURE ACCUMULATED IN THE REDUCTION UNITS. WHEN YOU CARRY OUT OIL REPLACEMENT, STAY BACK WITH RESPECT TO THE REDUCTION UNIT SIDE AND ALWAYS WEAR PROTECTION GLASSES. THE ALIGNMENT OF FILLING, DRAIN AND LEVEL PLUGS ON REDUCTION UNITS, IS DESCRIBED BELOW AND HAS TO BE CARRIED OUT WITH THE HELP OF ANOTHER PERSON. THIS MUST THOUGH REMAIN STRICTLY OUTSIDE THE MANOEUVRING RANGE OF THE ENGINE. NEVER CARRY OUT MAINTENANCE OR INSPECTION ON TRANSLATION MOTOR CIRCUITS ON SLOPES. THEY ARE HIGHLY PRESSURIZED BECAUSE OF THE MACHINE WEIGHT. With a new machine the first oil change is to carry out after the first 50 service hours.

Park the machine on a level surface. The reduction units should be positioned as to have the plugs (1), (2) as shown. The respect of this position is essential for the accuracy of the maintenance operation.

Rest the bucket onto the ground.

Bring the throttle control lever to minimum speed, stop the engine and remove the starter key, then set the safety lock lever to the LOCKED position.

Place a container under the drain port (1) to collect oil.

4-67

4. MAINTENANCE Slowly remove the filler (2) and level (3) plugs with an Allen wrench.

Then remove the plug of drain port (1) to discharge oil into the container.

Apply a sealing (teflon) tape on the thread of drain plug (1), and securely tighten the plug (1).

Slowly fill with oil through filling port (2), until oil comes out from level port (3). Oil flowing out indicates that the correct level is reached.

Apply sealing (teflon) tape on the threads of the level (3) and filler (2) plugs, then retighten them.

Thoroughly wipe off oil residues.

Travel at low speed and check for oil leaks.

NOTE: check used oil. If metal particles are found, contact your Dealer.

4-68

4. MAINTENANCE OIL CHANGE FOR IDLER ADJUSTER AND IDLER WHEEL

S WARNING GREASE IN THE CRAWLER IDLER ADJUSTER IS UNDER PRESSURE AND CAN PENETRATE THE SKIN, THUS CAUSING SEVERE INJURY. KEEP FACE AND BODY AWAY FROM GREASE FITTING AREA. IF GREASE DOES NOT COME OUT AFTER ONE TURN OF THE GREASE NIPPLE, CONSULT YOUR DEALER FOR ASSISTANCE. Remove lower roller and idler wheel to discharge oil.

The procedures for removal, installation and change of gear oil are described hereunder.

Crawler idler adjuster For oil discharge, remove rubber crawler according to relevant side.

S WARNING THE INSPECTION OF THE CRAWLER TENSION IS CARRIED OUT WITH ONE SIDE OF MACHINE RAISED. THIS CAN GENERATE A FALLING RISK IF THE MACHINE IS HIT ERRONEOUSLY. NEVER OPERATE THE MACHINE EXCEPT THE RUBBER CRAWLERS DURING SUCH WORK. Turn the upper structure by 90° and lower the bucket to lift the crawler as shown.

Keep the angle between the boom and the arm to 90° and 110° and position the round part of the bucket on the ground.

Place some supports under the frame to support the machine.

Pull off the idler wheel (1) and adjuster (2) from the crawler frame.

Weight of the idler wheel: 40 kg (88 lb) Loosen the cap (3) and let the oil drain into a container.

Fill gear oil through the plug hole (3).

4-69

4. MAINTENANCE Apply a sealing (teflon) tape on the thread of the plug (3), then tighten the plug. Dry oil residues.

Apply grease to the sliding surface (A) of the piston (4), of the cylinder (5) and of the crawler idler (2).

Install the idler so that the plug (3) and the grease nipple (6) of the crawler idler are facing outwards.

Tension the rubber crawler.

After confirmation of rubber crawler engagement with the idler and the conditions for tension, lower the machine to the ground, removing the safety support, etc.

UPPER ROLLER (E27.2 SR) For oil discharge, remove rubber crawler according to relevant side.

After stopping the engine, ensure that the machine is in parking position.

Loosen the rubber track (1) of the side on which gear oil (2) is to be changed.

Raise the track with an hydraulic jack (3).

Remove the nuts (4) and the capscrews (5) from the support fixing the shaft of the upper roller (7).

Remove roller.

Remove oil filling plug (8) by means of a wrench and drain oil from reduction unit into a container.

Fill reduction gear oil [45 cm3 (74 in3)] through filling port (8).

Apply sealing (teflon) tape on the thread of drain plug (8), and securely tighten it.

Wipe off any oil around the plug.

Install the roller in reverse order from removal.

After applying thread lock sealant on thread of the capscrews (5), tighten the screws.

Tightening torque: 66 ± 7 Nm (48.6 ± 5.6 lbf•ft)

4-70

4. MAINTENANCE REPLACEMENT OF GREASE IN SLEWING GREASE BATH When the machine works immersed in water up to the upper structure, the grease (1) inside the slewing bearing (2) of the upper structure can deteriorate.

Therefore, the pinion of the rotation motor and the internal gears of the slewing bearing may suffer damage. Contact your Dealer to know if grease has to be changed.

S WARNING THE LUBRICATION OF THE SLEWING BEARING, OF THE GEAR AND OF THE UPPER STRUCTURE ROTATION SHOULD BE CARRIED OUT BY ONE PERSON ONLY. BEFORE LUBRICATING THE SLEWING BEARING, KEEP PEOPLE AWAY FROM THE MACHINE’S WORKING RANGE.

NOTE: the following procedures require professional skill, because they are for the inspection and maintenance inside the engine. Since the adjustment requires special knowledge, contact your Dealer.

Grease by means of the grease nipple (3).

CHECKING AND ADJUSTMENT FOR FUEL INJECTION TIMING This is to adjust the fuel injection timing to optimise the engine performance.

CHECK AND ADJUSTMENT OF THE CONTACT SURFACE OF THE SUCTION AND DRAIN VALVE This is to ensure the gas-tightness on the exhaust and suction valves to optimise the engine performance.

4-71

4. MAINTENANCE

4.20

INSPECTION AND MAINTENANCE TABLE

MACHINE MODEL:_____________ SERIAL No.:________________ MACHINE HOURS:______________ Ref.

Ok

Maintenance performed

Engine oil level Engine coolant level Check for fluid leaks Check belt tension Check fuel level Water separator drain Check air filter Check engine electrical Drain water from fuel Change engine oil Change oil filter Change fuel filter Change water separator Check air intake indicator Check fan assembly Check belt tensioner Clean radiator Change engine coolant Change air filter elements Adjust valve clearance Hydraulic oil level Check hydraulic functions Check for oil leaks Check hoses/lines Clean suction screen Change return filters Pilot manifold filter Change hydraulic oil Clean hydraulic tank Inspect all wiring Battery electrolyte Battery service Hydraulic function operation Check switches Check warning lights Check horn Check display monitor

Ref.

Ok

Maintenance performed

Slewing reduction oil Slewing ring gear Grease bath level Slewing ring pinion Slewing ring seal Swivel joint seal Drain water from bath Check frame structure Change grease bath Check bolts/hardware Check lines Check steps Check frame structure Check crawlers Check sprocket wear Check the crawler idler wear Check roller wear Check crawlers tension Adjusting crawlers tension Travel reduction unit Boom / arm check Bucket teeth Side cutters Grease boom pins Grease arm pins Grease bucket pins Grease swing pin Grease dozer pin Check coolant additive Crawler

This item is not included in the machine equipment as per specifications.

MECHANIC: SIGNATURE:

DATE:

4-72

4. MAINTENANCE

4.21

BIODEGRADABLE HYDRAULIC OIL

Specifications Recommended oils PANOLIN AG. - HLP SYNTH 46 Ambra HYDROSYSTEM 46 BIO-S. Operating range Ambient temperature: from -20 °C (-4 °F) to +40 °C (104 °F).

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 the Oil Manufacturer, who will carry out the necessary checks. The Dealer will inform the customer if the oil features necessary for use have changed.

IMPORTANT: if special equipments (hydraulic breaker, etc.) are used, oil sampling for analysis should be done every 250 hours.

IMPORTANT: if the Dealer informs the customer that the oil has exceeded the service limits, proceed to its replacement. Failure to observe this measure will invalidate the warranty and may cause damages to the machine.

To change the biodegradable hydraulic oil, please proceed as indicated in the preceding pages.

Replacing mineral hydraulic biodegradable hydraulic oil

oil

with

IMPORTANT: when buying a machine filled with mineral hydraulic oil and wanting to replace it wit biodegradable oil (optional), it is necessary to have the replacement operation carried out by the Dealer. This because an accurate drainage of mineral oil and a complete wash of the hydraulic system is necessary. Remember that mineral hydraulic oil must not be mixed with biodegradable hydraulic oil.

4-73

4. MAINTENANCE NOTES:

4-74

5. TRANSPORTATION

5-1

5. TRANSPORTATION

5-2

5. TRANSPORTATION

5.1

WHEN PREPARING TRANSPORTATION PLANS

Before preparing the machine for transport, refer to section “6. SPECIFICATIONS” and following parameters: total weight, height, width and total length, speed and pressure on soil, etc.

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).

Before transporting the machine on a trailer, check width, height, length and weight of the trailer with the machine loaded.

NOTE: the dimensions and weight may differ according to the type of tyres and/or front attachment installed.

LOADING AND UNLOADING THE MACHINE

S WARNING ALWAYS SELECT THE SLOW TRAVEL SPEED MODE T, PROCEED WITH EXTREME CARE AND ATTENTION. AVOID STEERING WHILE DRIVING THE MACHINE ONTO THE RAMP: DANGER OF MACHINE OVERTURN. SHOULD CORRECTIVE STEERING BE NECESSARY, MOVE BACK TO GROUND OR TRAILER SURFACE, CHANGE TRAVEL DIRECTION AND RESUME DRIVING. THE RAMP END (LINK SPOT WITH THE TRAILER) CAUSES A SUDDEN BUMP; TRAVEL OVER THE BUMP WITH EXTREME CARE AND INCREASE MACHINE STABILITY USING THE FRONT ATTACHMENT.

5-3

5. TRANSPORTATION USE OF A RAMP The loading and unloading ramp should be of sufficient width, length, and strength; also ensure that ramp angle is lower than 15°.

Make the ramp strong enough so that the machine does not turn over during the loading/unloading operations and the slope sides do not break. If necessary, provide some supporting posts to reinforce both side of the banking.

The height of the platform or ramp must correspond to that of the base of the truck/trailer.

1. Wedges 2. Blocks 3. Ramps

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

5-4

5. TRANSPORTATION TRANSPORT IN SAFETY CONDITIONS After the machine is loaded and positioned, immobilize it as follows: Lower the dozer.

Fully extend the bucket and arm cylinders. Then slowly lower the boom.

Make sure to block the involuntary rotation of the upper structure by resting the bucket on the ground.

NOTE: to prevent the bucket cylinder from damages during transport, apply a wooden block to the edge of bucket link in order not to get down it to the floor.

Pull up the safety lock lever and set it to the LOCKED position (B).

Deactivate all switches and remove the starter key.

Close all covers and the cab door (cab version).

Place some wedges under the front and the rear of the crawlers. Fix them with a wire rope (1) of sufficient strength. This will prevent the machine from moving forward/backward or rolling due to vibration from the truck/trailer.

5-5

5. TRANSPORTATION

5.2

LIFTING PROCEDURES OF COMPLETE MACHINE (E20.2SR - E22.2SR)

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.

Fully extend the arm and bucket drive cylinders and tuck in the front attachment.

Lower the boom and gently rest the bucket onto the ground.

Pull up the safety lock lever and set it to the LOCKED position.

Stop the engine, then remove the key from the starter switch.

Hook the steel cables at both dozer ends (A).

Hook wire cable at (B) point of the boom.

Arrange carefully some protections, where the steel cables are in direct contact with the machine, so as to avoid possible damages during lifting.

Slightly lift the machine to ensure its balance. Then lift up the machine.

Machine total weight Canopy version: - with rubber crawler: 2380 kg (5246 lb) - with steel crawler: 2510 kg (5533 lb) Cab version: - with rubber crawler: 2700 kg (5952 lb) - with steel crawler: 2830 kg (6238 lb)

5-6

5. TRANSPORTATION

5.3

LIFTING PROCEDURES OF COMPLETE MACHINE (E27.2SR)

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.

Fully extend the arm and bucket drive cylinders and tuck in the front attachment.

Lower the boom and gently rest the bucket onto the ground.

Pull up the safety lock lever and set it to the LOCKED position.

Stop the engine, then remove the key from the starter switch.

Hook the steel cables at both dozer ends (A).

Hook wire cable at (B) point of the boom.

Arrange carefully some protections, where the steel cables are in direct contact with the machine, so as to avoid possible damages during lifting.

Slightly lift the machine to ensure its balance. Then lift up the machine.

Machine total weight Canopy version: - with rubber crawler: 2700 kg (5952 lb) - with steel crawler: 2840 kg (6261 lb) Cab version: - with rubber crawler: 2840 kg (6261 lb) - with steel crawler: 2980 kg (6569 lb)

5-7

5. TRANSPORTATION

5.4

LOAD SPECIFICATIONS

BOOM WITH ARM CYLINDER (E20.2SR - E22.2SR) LxHxW

mm (ft)

1960 x 760 x 220 (6.43 x 2.49 x 0.72)

Weight

kg (lb)

102 (225)

BOOM WITH ARM CYLINDER (E27.2SR) LxHxW

mm (ft)

2230 x 730 x 220 (7.31 x 2.39 x 1.72)

Weight

kg (lb)

125 (276)

ARM AND STANDARD BUCKET (E20.2SR - E22.2SR) LxHxW

mm (ft)

1870 x 400 x 450 (6.13 x 1.31 x 1.47)

Weight

kg (lb)

133 (293)

ARM AND STANDARD BUCKET (E27.2SR) LxHxW

mm (ft)

2050 x 400 x 550 (6.72 x 1.31 x 1.80)

Weight

kg (lb)

161 (355)

5-8

5. TRANSPORTATION ARM (E20.2SR - E22.2SR) LxHxW

mm (ft)

1280 x 390 x 250 (4.19 x 1.27 x 0.82)

Weight

kg (lb)

75 (165)

LxHxW

mm (ft)

1440 x 400 x 500 (4.72 x 1.31 x 1.64)

Weight

kg (lb)

96 (211)

ARM (E27.2SR)

STANDARD BUCKET (E20.2SR - E22.2SR) Capacity

m3 (ft3)

0.066 (2.33)

LxHxW

mm (ft)

640 x 530 x 450 (2.09 x 1.73 x 1.47)

Weight

kg (lb)

54 (119)

STANDARD BUCKET (E27.2SR) Capacity

m3 (ft3)

0.08 (2.82)

LxHxW

mm (ft)

650 x 550 x 550 (2.13 x 1.80 x 1.80)

Weight

kg (lb)

62 (137)

5-9

5. TRANSPORTATION DOZER (E20.2SR - E22.2SR) LxHxW

mm (ft)

1020 x 285 x 1400 (3.34 x 0.93 x 4.59)

Weight

kg (lb)

95 (209)

LxHxW

mm (ft)

1110 x 290 x 1500 (3.64 x 0.95 x 4.92)

Weight

kg (lb)

117 (258)

DOZER (E27.2SR)

5-10

6. SPECIFICATIONS

6-1

6. SPECIFICATIONS

6-2

6. SPECIFICATIONS

6.1

MAINTENANCE OPERATIONS SUMMARY DECAL

Under the operator’s seat there is a summary plate (1) indicating the main lubrication and replacement operations to be carried out periodically.

Greasing

Replacement of engine oil filters

Replace reduction gear oil, axle oil and transmission oil

Replacement of engine coolant

Replacement of hydraulic system oil

Replacement of engine oil

Replacement of hydraulic system return oil filter

Replacement of air filter

Replacement of fuel filters

Grease slewing ring

6-3

6. SPECIFICATIONS

6.2

DIMENSIONS

6.2.1

MACHINE DIMENSIONS (E20.2SR - E22.2SR)

CANOPY Unit: mm

CAB

6-4

6. SPECIFICATIONS 6.2.2

MACHINE DIMENSIONS (E27.2SR)

CANOPY Unit: mm

CAB

6-5

6. SPECIFICATIONS

6.3

GENERAL SPECIFICATIONS

6.3.1

GENERAL SPECIFICATIONS (E20.2SR - E22.2SR)

SPEED AND GRADEABILITY Rubber crawler

Item

Steel crawler

Slewing speed

8.7 rpm Low (1 )

High (2 )

Low (1st)

High (2nd)

2.3 km/h (1.42 mph)

4.1 km/h (2.54 mph)

2.3 km/h (1.42 mph)

4.1 km/h (2.54 mph)

st

Travel speed

nd

Gradeability

58% (30°)

ENGINE Model

4TNV88–XYB

Type

Vertical, 4-cycle water-cooled diesel engine

Number of cylinders-Bore x stroke

3 - 82 mm x 84 mm (0.11 - 3.22 in x 3.30 in)

Total displacement

1.331 l (0.40 gal)

Power

15.9 ± 2200 rpm

Maximum torque

80.1 Nm (59.07 lbf•ft) / 1440 rpm

Starter motor

12 V / 1.7 kW

Generator

12 V / 40 A

HYDRAULIC COMPONENTS Hydraulic pump

Variable displacement, with axial pistons, with pilot gear pump

Hydraulic motor

Axial piston

Hydraulic motor with reduction gear (travel)

2-axial pistons, 2-speed motor

Control valves

10-spool multiple control valve

Cylinder (boom, arm, swing, bucket, dozer)

Double action cylinder

Return filter

Safety valve containing / Filter type (30μ)

SWING AND DOZER Type Boom swing angle Stroke of dozer (up/down)

Boom swing by hydraulic cylinder Right

55°

Left

60°

mm (in)

425 / 290 (16.73 / 11.41)

6-6

6. SPECIFICATIONS 6.3.2

GENERAL SPECIFICATIONS (E27.2SR)

SPEED AND GRADEABILITY Item

Rubber crawler

Slewing speed

Steel crawler 8.8 rpm

Travel speed

Low (1st)

High (2nd)

Low (1st)

High (2nd)

2.3 km/h (1.42 mph)

4.1 km/h (2.54 mph)

2.3 km/h (1.42 mph)

4.1 km/h (2.54 mph)

Gradeability

58% (30°)

ENGINE Model

4TNV88–XYB

Type

Vertical, 4-cycle water-cooled diesel engine

Number of cylinders-Bore x stroke

3 - 82 mm x 84 mm (0.11 - 3.22 in x 3.30 in)

Total displacement

1.331 l (0.40 gal)

Power

15.9 ± 2200 rpm

Maximum torque

80.1 Nm (59.07 lbf•ft) / 1440 rpm

Starter motor

12 V / 1.7 kW

Generator

12 V / 40 A

HYDRAULIC COMPONENTS Hydraulic pump

Variable displacement, with axial pistons, with pilot gear pump

Hydraulic motor

Axial piston

Hydraulic motor with reduction gear (travel)

2-axial pistons, 2-speed motor

Control valves

11-spool multiple control valve

Cylinder (boom, arm, swing, bucket, dozer) Return filter

Double action cylinder Safety valve containing / Filter type (30μ)

SWING AND DOZER Type Boom swing angle Stroke of dozer (up/down)

Boom swing by hydraulic cylinder Right

55°

Left

60°

mm (in)

425 / 290 (16.73 / 11.41)

6-7

6. SPECIFICATIONS 6.3.3

CRAWLER TYPE (E20.2SR - E22.2SR)

Type

Width mm (in)

Wheel base between driving wheel and free wheel mm (in)

250 (9.84)

250 (9.84)

Basic pressure kPa CANOPY

CAB

1400 (55.11)

26

27

1400 (55.11)

27

29

Rubber crawler

Steel crawler

6.3.4

CRAWLER TYPE (E27.2SR)

Type

Width mm (in)

Wheel base between driving wheel and free wheel mm (in)

250 (9.84)

250 (9.84)

Basic pressure kPa CANOPY

CAB

1500 (59.05)

28

30

1500 (59.05)

30

31

Rubber crawler

Steel crawler

6-8

6. SPECIFICATIONS 6.3.5

BUCKET TYPE (E20.2SR - E22.2SR) Heaped Capacities m3 (ft3)

0.0066 (0.23)

6.3.6

Outer thickness mm (in) with side cutter

without side cutter

450 (17.71)

405 (15.94)

Number of teeth

Weight kg (lb)

3

54 (119)

Number of teeth

Weight kg (lb)

3

62 (137)

BUCKET TYPE (E27.2SR) Heaped Capacities m3 (ft3)

0.08 (2.82)

Outer thickness mm (in) with side cutter

without side cutter

550 (21.65)

515 (20.27)

6-9

6. SPECIFICATIONS

6.4

DIGGING PERFORMANCE

6.4.1

DIGGING PERFORMANCE (E20.2SR - E22.2SR)

CANOPY

Unit: mm (in)

No.

Arm

STANDARD ARM 0.98 m (3.21 ft)

LONG ARM 1.33 m (4.36 ft)

Bucket

0.066 m3 (2.33 ft3)

0.066 m3 (2.33 ft3)

Attachment

A

Maximum digging reach

4190 (164.96)

4520 (177.95)

A’

Maximum digging reach at ground level

4060 (159.84)

4400 (173.22)

B

Maximum digging depth

2300 (90.55)

2650 (104.33)

C

Maximum digging height

3960 (155.90)

4190 (164.96)

D

Maximum dumping clearance

2720 (107.08)

2950 (116.14)

E

Minimum dumping clearance

1130 (44.48)

790 (31.10)

F

Maximum vertical wall digging depth

1790 (70.47)

2130 (83.85)

G

Minimum front slew radius

1800 (70.86)

1900 (74.80)

H

Height at minimum slew radius

3000 (118.11)

3000 (118.11)

J

2.44 m (8 feet) digging depth

1720 (67.71)

2170 (85.43)

K

Horizontal digging stroke at ground level

Stroke

1620 (63.77)

2090 (82.28)

Minimum

1470 (57.87)

1330 (52.36)

Above

425 (16.73)

425 (16.73)

Below

290 (11.41)

290 (11.41)

L X Y

Dozer strokes

6-10

6. SPECIFICATIONS CAB

Unit: mm (in)

No.

Arm

STANDARD ARM 0.98 m (3.21 ft)

LONG ARM 1.33 m (4.36 ft)

Bucket

0.066 m3 (2.33 ft3)

0.066 m3 (2.33 ft3)

Attachment

A

Maximum digging reach

4190 (164.96)

4520 (177.95)

A’

Maximum digging reach at ground level

4060 (159.84)

4400 (173.22)

B

Maximum digging depth

2300 (90.55)

2650 (104.33)

C

Maximum digging height

3660 (144.94)

3850 (151.57)

D

Maximum dumping clearance

2470 (97.24)

2650 (104.33)

E

Minimum dumping clearance

975 (38.38)

625 (24.60)

F

Maximum vertical wall digging depth

1790 (70.47)

2130 (83.85)

G

Minimum front slew radius

2030 (79.92)

2070 (81.49)

H

Height at minimum slew radius

2850 (112.20)

2850 (112.20)

J

2.44 m (8 feet) digging depth

1720 (67.71)

2170 (85.43)

K

Horizontal digging stroke at ground level

Stroke

1620 (63.77)

2090 (82.28)

Minimum

1470 (57.87)

1330 (52.36)

Above

425 (16.73)

425 (16.73)

Below

290 (11.41)

290 (11.41)

L X Y

Dozer strokes

6-11

6. SPECIFICATIONS 6.4.2

DIGGING PERFORMANCE (E27.2SR)

CANOPY

Unit: mm (in)

No.

Arm

STANDARD ARM 1.12 m (3.67 ft)

LONG ARM 1.37 m (4.49 ft)

Bucket

0.08 m3 (2.82 ft3)

0.08 m3 (2.82 ft3)

Attachment

A

Maximum digging reach

4640 (182.67)

4890 (192.51)

A’

Maximum digging reach at ground level

4510 (177.55)

4770 (187.79)

B

Maximum digging depth

2540 (99.99)

2790 (109.84)

C

Maximum digging height

4470 (175.98)

4690 (184.64)

D

Maximum dumping clearance

3170 (124.80)

3380 (133.07)

E

Minimum dumping clearance

1250 (49.21)

1010 (39.76)

F

Maximum vertical wall digging depth

2320 (91.33)

2560 (100.78)

G

Minimum front slew radius

1830 (71.04)

1880 (74.01)

H

Height at minimum slew radius

3310 (130.31)

3310 (130.31)

J

2.44 m (8 feet) digging depth

2010 (79.13)

2340 (92.12)

K

Horizontal digging stroke at ground level

Stroke

1990 (78.34)

2350 (92.51)

Minimum

1510 (59.44)

1400 (55.11)

Above

445 (17.51)

445 (17.51)

Below

335 (13.18)

335 (13.18)

L X Y

Dozer strokes

6-12

6. SPECIFICATIONS CAB

Unit: mm (in)

No.

Arm

STANDARD ARM 1.12 m (3.67 ft)

LONG ARM 1.37 m (4.49 ft)

Bucket

0.08 m3 (2.82 ft3)

0.08 m3 (2.82 ft3)

Attachment

A

Maximum digging reach

4640 (182.67)

4890 (192.51)

A’

Maximum digging reach at ground level

4510 (177.55)

4770 (187.79)

B

Maximum digging depth

2540 (99.99)

2790 (109.84)

C

Maximum digging height

4260 (167.71)

4470 (175.98)

D

Maximum dumping clearance

2970 (116.92)

3170 (124.80)

E

Minimum dumping clearance

1140 (44.88)

890 (35.03)

F

Maximum vertical wall digging depth

2320 (91.33)

2560 (100.78)

G

Minimum front slew radius

2060 (81.10)

2080 (81.88)

H

Height at minimum slew radius

3200 (125.98)

3200 (125.98)

J

2.44 m (8 feet) digging depth

2010 (79.13)

2340 (92.12)

K

Horizontal digging stroke at ground level

Stroke

1990 (78.34)

2350 (92.51)

L X Y

Dozer strokes

Minimum

1510 (59.44)

1400 (55.11)

Above

445 (17.51)

445 (17.51)

Below

335 (13.18)

335 (13.18)

6-13

6. SPECIFICATIONS

6.5

MACHINE WEIGHTS Models

Versions

E20.2SR E22.2SR E27.2SR E27.2SR

Canopy Cab Canopy Cab

Rubber belt Long arm Standard counterweight Small bucket (33 kg) (72 lb) Fuel (22 kg) (48 lb) Operator (75 kg) (165 lb)

Total weight kg (lb) ISO 6016* 2380 (5246) 2700 (5952) 2700 (5952) 2840 (6261)

* The weight is measured with this configuration

Models

Versions

E20.2SR E22.2SR E27.2SR E27.2SR

Canopy Cab Canopy Cab

Additional weights kg (lb) Differential of rubber- Differential of longsteel crawler short arm 130 (286) -20 (-44) 130 (286) -20 (-44) 140 (308) -20 (-44) 140 (308) -20 (-44)

6-14

Additional counterweight 172 (379) ⎯ 172 (379) 172 (379)

7. OPTIONAL ATTACHMENT

7-1

7. OPTIONAL ATTACHMENT

7-2

7. OPTIONAL ATTACHMENT

7.1

HYDRAULIC BREAKER AND NIBBLER ATTACHMENT

7.1.1

SELECTION OF HYDRAULIC BREAKER AND NIBBLER

During the fitting of the hydraulic breaker on the excavator, it is necessary to choose a model satisfying the required features as to stability, hydraulic pressure, and oil quantity of the hydraulic system. In order to choose the most suitable hydraulic breaker for the machine specifications, contact your Dealer.

7.1.2

BEFORE OPERATING HYDRAULIC BREAKER AND NIBBLER

Contact your Dealer for pipings, for the installation of the hydraulic breaker and nibbler, and for the replacement of the hydraulic oil return filter, according to the maintenance schedule enclosed. Thoroughly read the hydraulic breaker operation manual and the safety instructions described in this manual to prevent damaging the machine or the hydraulic breaker during operation. When the hydraulic breaker is used, the excavator is subjected to working conditions more critical than usual, that speed up hydraulic oil deterioration and contamination. To avoid damaging the hydraulic system of the excavator and of the hydraulic breaker, follow maintenance procedures observing the time schedule indicated in this manual.

7.1.3

PREVENTION OF HYDRAULIC OIL CONTAMINATION

When the hydraulic breaker is not installed on the machine, apply blanking plugs on the tube ends of arm and hydraulic breaker, to prevent the penetration of foreign bodies.

Before starting operation, check the fixing clamps for looseness, and the tubes and hoses fittings for leakage.

7-3

7. OPTIONAL ATTACHMENT 7.1.4

ATTACHMENT OPERATION

S CAUTION Before using the machine, carefully read the safety instructions and the instructions for use given in this manual; make sure to understand and observe them.

Push the safety lock lever downwards (B) and set it to the UNLOCKED position.

Set the throttle lever to HIGH IDLING. Lower slowly the attachment until it rests on the surface to be hit.

Lift the locking device (2) to allow access to the pedal (1).

Unlock pedal of nibbler (2) pushing the pedal lock device (1) downward “A”.

Then activate pedal (2) to carry out nibbler opening and closing operations.

To cut-off the operation of the nibbler, release pedal (2).

S WARNING • TO OPERATE BREAKER OR NIBBLER LONGER THAN 30 SECONDS, COULD CAUSE PREMATURE WEAR OR DAMAGE TO THE MACHINE ATTACHMENT. IF MATERIAL IS NOT BREAKING, REPOSITION BREAKER OR NIBBLER AND REPEAT OPERATION AT 30 SECONDS INTERVALS. • NEVER LEAVE THE OPERATOR CAB WITH ENGINE RUNNING.

7-4

7. OPTIONAL ATTACHMENT ATTACHMENT PEDAL CONTROL The installed attachments are controlled by pedal (1) located left of the operator’s seat.

S CAUTION Precaution during pedal operation.

The operation varies in the specifications, so before operating, read the operator’s manual carefully.

Never place your foot on the pedal. If you place your foot on the pedal and press it by error, the machine can suddenly move. This can cause serious accidents.

Breaker Foot pedal depressing section

Operating condition

Pedal in neutral position

Breaker stops operating

Depress heel section (B)

Breaker starts operation

Nibbler Foot pedal depressing section

Operating condition

Depress toe section (A)

Nibbler closes

Depress heel section (B)

Nibbler opens

S WARNING NEVER LEAVE THE OPERATOR CAB WITH ENGINE RUNNING.

PEDAL LOCK DEVICE By means of lock device (1) you are able to lock the pedal in position (A).

S CAUTION Make sure to set the pedal lock in locked position while the breaker or nibbler are not used. Careless contact with unlocked pedal may cause severe accident and injury.

A. Unlock position B. Lock position

7-5

7. OPTIONAL ATTACHMENT 7.1.5

SETTING SELECTOR VALVE

Check that selector valve (1), is positioned so as to connect the attachment return to the control valves block.

NOTE: • Wrong switching of the selector valve, may decrease the work efficiency and operating speed of the machine and also damage it.

Switch selector valve anyway.

• Be sure to switch selector valve one or twice a month.

SETTING PROCEDURE NOTE: before switching selector valve, be sure to stop the engine and lower the attachment to the ground, so as not to impair the machine stability.

Use an Allen wrench (2) to loosen and remove the screw (3).

Allen wrench: 5 mm Use a wrench (4) to turn the selector valve (1) to proper position.

Wrench: 24 mm When the valve is positioned correctly, tighten the screw (3).

Selector valve shifting position: B. Breaker use N. Nibbler use

7-6

7. OPTIONAL ATTACHMENT 7.1.6

SETTING THE STOP VALVE

Stop valves (1) placed on the arm top end (2) are used to stop the hydraulic oil flow.

Lock (A): Hydraulic oil flow stop.

Unlock (B): Hydraulic oil regular flow.

Before removing attachment, set stop valve to “STOP” position.

7-7

7. OPTIONAL ATTACHMENT

7.2

SAFETY INSTRUCTIONS

The following safety precautions should be used in conjunction with all other safety precautions found in this MANUAL.

S WARNING READ, UNDERSTAND AND FOLLOW ALL SAFETY INSTRUCTIONS AND OPERATING PROCEDURES FOUND IN THIS MANUAL BEFORE OPERATING THE MACHINE OR ANY ATTACHMENT. PASSENGERS This equipment is not intended or designed for the transportation of persons. Nobody is allowed on the machine except for the driver. Serious injury or death can result from allowing passengers on or in the machine.

PROTECTIVE EQUIPMENT If there is the risk of rocks falling down, assemble the protective grid and close all windows in order to protect the driver. Also the operator and all personnel in the vicinity of the machine should wear protective clothing such as safety shoes, hard hat, gloves and face shield or goggles.

USE FOR INTENDED PURPOSE Use the attachment only for its intended purpose. If not used in accordance with the Manufacturer’s instructions, the excessive pressure exerted on the boom, arm and frame structure of the machine will cause premature failure of the components.

7-8

7. OPTIONAL ATTACHMENT CYLINDERS Avoid operating with the excavator cylinders at stroke end (maximum extension or maximum retraction) in order not to damage the attachment structure and the cylinders.

AVOID CONTINUOUS OPERATION Operate the breaker with intervals of 30 seconds.

A prolonged attachment use can cause a temperature increase and the risk of serious damages to the pressure accumulators, to the cylinder seals and to the pump.

HOSE SWELLING Should the hydraulic hoses begin swelling or vibrating during the operation of the hydraulic breaker, immediately stop working and consult your Dealer.

This inconvenient is often due to pressure accumulators being damaged.

7-9

7. OPTIONAL ATTACHMENT DO NOT USE THE FORCE OF GRAVITY Do not use the force of gravity by letting the attachment drop onto the material. This will cause extensive damage to the attachment and machine structure.

DO NOT USE THE ROTATION / SWING FORCE Do not use the rotation/swing force of the machine for pushing objects. This will cause premature failure of the attachment and other machine components.

DO NOT PRY WITH HYDRAULIC BREAKER Do not use the breaker to pry open and break rocks or concrete. This may damage the hydraulic breaker, and also boom, arm and cylinder.

7-10

7. OPTIONAL ATTACHMENT ARM IN VERTICAL POSITION Do not operate with arm set perpendicular to soil.

The piston rod joint and the same piston can get damaged.

DO NOT LIFT Never use an optional attachment to lift or transport objects or material. Failure to observe this instruction can cause extensive damage to the attachment and to the machine structures and cause injury or death.

WORKING RANGE

S WARNING NEVER OPERATE AN OPTIONAL ATTACHMENT OVER THE SIDES OF THE MACHINE. OPERATE THE ATTACHMENT ONLY OVER THE FRONT OR REAR OF THE MACHINE. Do not operate the breaker to the side of the machine. The machine may become unstable and the components of the lower frame would wear off more rapidly.

NOTE: • Refer to this section also for other attachments fitted on the machine, further to the hydraulic breaker.

• When working with hydraulic breaker, etc. use reinforced arm. If you use the standard arm, you can damage it.

7-11

7. OPTIONAL ATTACHMENT

7.3

HANDLING OF HANGING LOADS

S WARNING THE MACHINE HAS BEEN SPECIALLY DESIGNED FOR DIGGING/LOADING OPERATIONS. THE MOVING OF HANGING LOADS TO COMPLETE THE WORKING CYCLE DIGGING AND/OR LOADING, IS ALWAYS ALLOWED, ONLY IF THE MACHINE IS EQUIPPED WITH SPECIFIED OPTIONAL EQUIPMENT. CARRY OUT THE HANDLING OF HANGING LOADS BY STRICTLY FOLLOWING THE NATIONAL LAW CONCERNING THE PRESCRIBED SAFETY RULES, THE NATIONAL SAFETY RULES, THE RULES LISTED HEREBELOW AND THOSE DESCRIBED ON CHAPTER SAFETY RULES. BOOM ANTIDROP VALVES, LOCATED ON CYLINDERS, THE ACOUSTIC ALARM, THE LOADS TABLE HANGING IN THE CABIN AND THE LINK ROD HOOK ARE SAFETY DEVICES, BELONGING TO THE HANGING LOADS HANDLING OPTION. WHEN ONE OF SAID SAFETY DEVICES IS MISSING OR DAMAGED, THE MACHINE CANNOT BE USED TO HANDLE HANGING LOADS.

For the handling of hanging loads, observe following:

S WARNING BEFORE STARTING TO WORK CHECK THE VALVES FOR ANY REMARKABLE DAMAGE OR ABNORMAL NOISE. IF TROUBLES ARE NOTICED, REFER TO YOUR DEALER AND, IN THE MEANTIME, DO NOT USE THE MACHINE FOR HANDLING HANGING LOADS. TO AVOID INJURIES, DO NOT EXCEED THE MACHINE LOAD RATED CAPACITY. IF THE MACHINE IS NOT SET ON A LEVEL GROUND, LOAD CAPACITIES ARE REDUCED. ANYWAY, ALWAYS OPERATE WITH CARE. Lower the blade to the ground to increase machine stability.

Pre-arrange the engine rpm according to the hydraulic effort required.

Evaluate (if unknown) the weight of the object to be handled and compare it with the data of the table located in the cab and shown in this chapter. Do not lift loads exceeding the maximum values shown on the table.

Before any lifting operation, press switch (1) to connect anti-tipping sensor. This sensor activates the acoustic alarm when reaching safety limit load.

7-12

7. OPTIONAL ATTACHMENT Fasten the load by means of the appropriate hook (2), provided on the connecting rod of the bucket linkage, by means of hooking devices and chains suitable for the load to be lifted.

S WARNING CHECK FOR LIFTING DEVICES (HOOKS, CHAINS, ETC.) INTEGRITY AND MAKE SURE THEY ARE NOT TOO MUCH WORN OUT. KEEP TO THE RULES IN FORCE CONCERNING CHECKING PROCEDURES OF SAID DEVICES (NOT SUPPLIED WITH THE MACHINE). THE DEVICE CAN ONLY BE USED FOR LIFTING OBJECTS THAT ARE NOT ANCHORED TO THE GROUND. IT CANNOT BE USED FOR TOWING, UPROOTING AND BREAKOUT.

In order to avoid the load swing, do not sling a load with too long ropes and/or chains.

Check the working area and make sure the load run is free from obstacles.

Lift the load slowly avoiding sudden motion that can cause load swing. As a rule, keep the load close to the machine in order to increase stability and operate lengthwise rather than crosswise.

Lift the load from the ground at the minimum distance from ground.

S WARNING LOADS CAN TURN AND SWING IN ALL DIRECTIONS, THEREFORE THEY MIGHT HIT PERSONS OR MACHINE CAB. IN ORDER TO LIMIT THIS DANGER, KEEP PEOPLE WITHIN MACHINE SAFE AREA OF OPERATION AND SHIFT THE LOAD SLOWLY. IN CASE THE LOAD TURNS OR SWINGS DURING TRANSPORT, SLOW DOWN UNTIL YOU STOP AND SLOWLY LOWER IT TO THE GROUND, THEN CORRECT THE HOOKING SYSTEM. IN CASE SOUND ALARM IS ACTIVE DURING LOAD HANDLING, LOWER THE LOAD TO THE GROUND AND CHECK FOR LOAD CONDITIONS WITH THE HELP OF THE SPECIAL TABLE IN THE CAB. Lay the load onto the desired position and make sure it is firmly and safely rested on a solid surface.

Remove chains.

7-13

7. OPTIONAL ATTACHMENT 7.3.1

LIFTABLE LOADS TABLE LOCATED IN THE CAB

E20.2SR CANOPY

E22.2SR CAB

NOTE: the indicated values are calculated by using a 450 mm (17.71 in) standard bucket weighing 54 kg (119 lb).

1.

2.

3.

4.

5. Maximum liftable load in kg to roll-over limit according to ISO 10567 6. Counterweight weight 7. Setting pressure of main overpressure relief valve/hydraulic system safety valves

Boom length Length (LD) of arm alternatively Bucket width Distance of load from slew centre

7-14

7. OPTIONAL ATTACHMENT E27.2SR CANOPY

E27.2SR CAB

NOTE: the indicated values are calculated by using a 550 mm (21.65 in) standard bucket weighing 62 kg (137 lb).

1.

2.

3.

4.

5. Maximum liftable load in kg to roll-over limit according to ISO 10567 6. Counterweight weight 7. Setting pressure of main overpressure relief valve/hydraulic system safety valves

Boom length Length (LD) of arm alternatively Bucket width Distance of load from slew centre

7-15

7. OPTIONAL ATTACHMENT

7.4

REGULAR INSPECTION AND MAINTENANCE

REPLACEMENT INTERVAL Contamination and deterioration of hydraulic oil may develop malfunctioning of control valves, early wear and seizure of hydraulic pump. Operation of the breaker hastens deterioration of hydraulic oil, if compared with normal operation with bucket.

Replace hydraulic oil filters, referring to the following table: REPLACEMENT INTERVAL INSPECTION AND MAINTENANCE TABLE

LOCATION

HYDRAULIC OIL RETURN FILTER

FIRST

2nd REPLACEMENT

REGULAR

Hydraulic oil tank

-

-

Every 600 hours

Hydraulic oil tank

50 hours

250 hours

Every 250 hours

MAINTENANCE RECORD SHEET (EXAMPLE) DATE

HOURS

FILTER REPLACEMENT

7-16

HYDRAULIC OIL CHANGE

8. TROUBLESHOOTING

8-1

8. TROUBLESHOOTING

8-2

8. TROUBLESHOOTING

8.1

GENERAL TROUBLESHOOTING

This troubleshooting information covers the components and systems as described in this MANUAL. Should in-depth troubleshooting, repair or replacement of certain components, or valve adjustment become necessary, contact your Dealer.

PROBLEM All operating speeds are slow or power is lost.

POSSIBLE CAUSE Low hydraulic oil level.

Fill oil to specified level.

Air in 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 not adjusted correctly.

Adjust or replace.

Relief valve of pilot circuit not adjusted correctly.

Adjust or replace.

OPERATION

A specific cylinder Cylinder seal is scored. functions improperly or Defective control valve or overload valve or loses power. presence of air in the cylinder.

The cylinder position will not hold with operating lever in neutral.

Repair or replace / remove air from cylinder.

Repair or replace.

Pilot valve piping is loose.

Tighten.

Cylinder seal is scored.

Repair or replace.

The 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.

Slewing bearing is damaged.

Anomalous noise during rotation.

Repair or replace.

Pilot valve is damaged.

Machine does not slew. The hydraulic motor (rotation) is not working or the rotation gear is damaged.

The rotation speed is slow.

REMEDY

Repair or replace.

Repair or replace.

Pilot valve is not working.

Repair or replace.

The rotation gear is damaged.

Repair or replace.

Solenoid valve is not working.

Repair or replace.

The control valve is not working.

Repair or replace.

Lock solenoid valve is not working.

Repair or replace.

The control valve is not working.

Repair or replace.

The hydraulic motor (rotation) 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 upper structure slewing ring and bearings.

Grease.

Pilot valve is not working.

Repair or replace.

The control valve is not working.

Repair or replace.

8-3

8. TROUBLESHOOTING PROBLEM

TRAVEL

Machine does not travel smoothly.

TRAVEL

Travelling power is insufficient.

POSSIBLE CAUSE Too much crawler tension.

Adjust crawler tension.

Dirty or clogged crawlers.

Clean crawlers.

Brake valve is not working.

Repair or replace.

Travel reduction unit is damaged.

Repair or replace.

The control valve is not working.

Repair or replace.

Travel motor damaged.

Repair or replace.

Main relief valve pressure is set incorrectly.

Adjust or replace.

Damaged swivel joint.

Repair or replace.

Hydraulic pump is damaged.

Repair or replace.

Poor engine performance.

Repair or replace.

Main relief valve pressure is set incorrectly.

Adjust or replace.

Low hydraulic oil level.

Fill to proper level.

The hydraulic motor (travel) is not working.

Repair or replace.

Brake valve is not working.

Repair or replace.

Seal in swivel joint is scored or oil is leaking.

Repair or replace.

Machine does not Unequal tensions on crawlers. travel in a straight line. Set pressures of main relief valves unbalanced.

Adjust tension.

Adjusting.

One of the travel motors loses power.

Repair or replace.

Unbalanced oil flow from the control valve.

Repair or replace.

Unbalanced discharge from hydraulic pump.

Repair or replace.

Unbalanced flow from brake valve.

Repair or replace.

Unbalanced flow between right swivel joints.

HYDRAULIC SYSTEM

REMEDY

Temperature rise of the Oil cooler core clogged. hydraulic oil.

Engine fan belt slipping.

Repair or replace.

Cleaning.

Adjust or replace.

Low hydraulic oil level.

Fill oil to specified level.

Wrong type hydraulic oil used.

Replace with correct oil.

Hydraulic pump is not working.

Repair or replace.

8-4

8. TROUBLESHOOTING PROBLEM

INSTRUMENT PANEL DISPLAY

Engine oil pressure low.

Abnormal rise in the coolant temperature.

Battery charge.

POSSIBLE CAUSE Engine oil level low.

Fill oil to specified level.

Oil leaking.

Repair and fill as recommended.

Wrong oil viscosity.

Replace with proper oil.

Insufficient coolant.

Fill to proper level.

Coolant leaking.

Repair and fill as recommended.

Loose radiator cap.

Tighten.

Clogged radiator.

Clean the cooling system.

V-belt loose or damaged.

Tighten to proper tension.

Rust or scale in coolant.

Flush system / fill to level.

Faulty thermostat.

Replacing.

Battery terminals disconnected, loose or corroded.

Clean and connect.

Low battery electrolyte level.

Refill.

V-belt loose or damaged.

Adjust or replace.

Battery service life has run down.

The starter does not Battery disconnected. turn or turns too slowly Battery discharged. to start the engine.

Battery terminals disconnected, loose or corroded.

ENGINE

The starter turns but the engine does not start.

Replacing.

Connect.

Charge.

Clean and connect.

Ground cable disconnected.

Connect.

Engine oil viscosity too thick (Cold Weather).

Replace with correct oil.

Insufficient fuel.

Refill.

Improper starting procedure.

Refer to section “1.

SAFETY INSTRUCTIONS”.

Air in fuel line.

Bleed air.

Fuel filter clogged.

Replace element.

Clogged air filter.

Replace elements.

Air heater circuit malfunctioning.

Check circuit.

Engine tends to stop at Low idling rpm. low speed.

Fuel filter clogged.

No power.

REMEDY

Serviceman.

Replace element.

Clogged air filter.

Replace elements.

Improper valve clearance.

Serviceman.

Fuel filter clogged.

Replace element.

Clogged air filter.

Replace element.

Improper valve clearance.

Serviceman.

Loose clamps on the air inlet hose.

Tighten clamps.

Cracked air inlet hose.

Replace.

8-5

8. TROUBLESHOOTING PROBLEM

ENGINE

Engine overheats.

POSSIBLE CAUSE

REMEDY

Insufficient coolant.

Top up coolant.

Clogged radiator.

Clean the cooling system.

V-belt loose or damaged.

Adjust or replace belt.

Faulty thermostat.

Replacing.

Engine exhaust is black.

Clogged air filter.

Replace elements.

Improper valve clearance.

Serviceman.

Excessive fuel consumption.

Fuel leak.

Serviceman.

Clogged air filter.

Replace elements.

Loose clamps on the air inlet hose.

Tighten clamps.

Excessive oil consumption.

Cracked air inlet hose.

Replace with new hose.

Engine oil level is too high.

Reduce to specified level.

Improper oil.

Replace with correct oil.

Oil leaking.

Serviceman.

Improper oil replacement intervals.

Change at correct interval.

Improper preheating.

Refer to 3-12.

The engine oil pressure Oil level too low. does not rise.

Oil leaking.

Battery dies often.

Fill oil to specified level.

Serviceman.

Improper oil viscosity.

Replace with proper oil.

Battery terminals disconnected, loose or corroded.

Clean and tighten terminals.

Low battery electrolyte level.

Fill cells with distilled water.

V-belt loose or damaged.

Adjust or replace belt.

Defective battery.

Replace batteries.

8-6

9. ELECTRICAL SYSTEM

9-1

9. ELECTRICAL SYSTEM

9-2

9. ELECTRICAL SYSTEM

9.1

GENERALITIES

S WARNING

IMPORTANT: • The electrical system of this machine operates with 24 V and is powered by two batteries connected in series.

• EXCLUSIVELY USE GROUNDED ELECTRICAL POWER SOURCES FOR HEATERS, BATTERY CHARGERS, PUMPS AND SIMILAR DEVICES, SO AS TO MINIMISE ELECTRICAL SHOCK HAZARDS.

• The machine is equipped with complex electric and electronic components which can be handled exclusively by qualified personnel.

• MAKE SURE TO CONNECT THE CABLES TO THE CORRECT POLES (+ TO +) AND (- TO -) AT BOTH ENDS.

• 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 -).

• DO NOT SHORT-CIRCUIT THE TERMINALS. • IF BATTERIES ARE TO BE RECHARGED OR IF BOOSTER CABLES ARE NEEDED FOR STARTING, REMOVE BATTERY CELL PLUGS.

• This norm should be observed also when the engine is to be started using slave batteries.

• FLAMMABLE VAPOURS. EXTINGUISH ALL SMOKING MATERIALS AND NAKED FLAMES BEFORE CHECKING, FILLING OR CHARGING THE 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.

• AVOID CAUSING SPARKS WHILE TESTING BATTERIES. IMPORTANT: • Improper radio-communications equipment and associated parts and/or improper assembly of radio-communications equipment affects machine electronic components with consequent unexpected machine movement. Consult an authorized Dealer when installing radio-communication equipment or any additional electronic component or when replacing an electric part.

• Do not disassemble or change electric or electronic components.

• If a replacement or change of such components is required, consult an authorized Dealer.

9-3

9. ELECTRICAL SYSTEM

9.2

BATTERIES

INSPECTION

S WARNING • BATTERY GAS MAY EXPLODE. KEEP AWAY SPARKS AND FLAMES. • TO AVOID DANGERS: WHEN STARTING THE MACHINE WITH BOOSTER BATTERIES, OBSERVE THE PROCEDURES DETAILED IN CHAPTER “MEASURES AFTER AN EMERGENCY STOP OF ENGINE”. MAKE SURE TO CONNECT THE CABLES TO THE CORRECT POLES (+ TO +) AND (- TO -) AT BOTH ENDS. DO NOT SHORTCIRCUIT THE TERMINALS. The battery installed to this type of machine are maintenance-free, therefore is do not require topups with distilled water.

S CAUTION Always disconnect the negative (-) ground terminal first and reconnect it last.

Open the engine guard (1).

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

Remove cover (3).

Keep the terminals and plugs located on top of the battery clean at all times to prevent battery from discharging. Check battery terminals, clamps should not be loose and should not show signs of rust or oxidation. Apply petroleum jelly to the terminals to prevent corrosion.

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.

9-4

9. ELECTRICAL SYSTEM Observe the following norms to preserve battery efficiency: • with the engine stopped, remove the starter key to prevent a progressive battery discharge; • do not keep the lights switched on for a long time with the engine stopped or idling.

Close the cooler bay access panel.

NOTE: handle and dispose of batteries according to current legislation. Only use authorised disposal procedures; in case of doubt, contact the authorities concerned.

9-5

9. ELECTRICAL SYSTEM

9.3

FUSE BOX

S CAUTION Stop the machine before replacing the fuses (starter key set to OFF).

The fuses protect the electrical system from excessive current. If operation is irregular, a fuse may be blown. Replace blown or faulty fuses with the spare fuses as follows.

Replace any fuse generating white powder on it or in case that some looseness exists between the fuse and fuse holder.

NOTE: • When replacing a fuse, replace it with one of the same capacity.

• The spare fuses are stored in the back side of fuse box cover.

1. Wiper, heater - 30A 2. Relay, solenoid - 30A 3. Work lights - 30A 4. Horn, dome light - 10A 5. Engine stop solenoid - 30A 6. Battery relay, gauge cluster - 10A FUSIBLE FOR STARTER In case power does not come when the starter switch is turned “ON”, a disconnection of the fusible (1) link is suspected.

Inspect and replace the fusible link.

NOTE: the fusible link is of a fuse wiring of big size provided in the electric wiring for large current. It protects the electrical equipment and wiring from abnormal current just like an ordinary fuse.

9-6

ATTACHMENT 1 - “EC” DECLARATION OF CONFORMITY On the following pages, a facsimile copy of the “EC” Declaration of Conformity (EC DoC) is provided.

The EC DoC is the manufacturer’s declaration about equipment compliance to relevant EU provisions.

Please keep the original document in a safe place.

Local authorities may require you to show this document in order to assure compliance of your equipment.

IMPORTANT: an original of this “EC” declaration is supplied with each machine and must be kept carefully by the owner.

IMPORTANT: the official documents supplied with the machine must be kept by the owner so as to be able to present them to any inspecting authority which may request them.

1. Under point 1.2 those options or variants are listed which have safety related functions. Some of them are standard provided, like FOPS or TOPS (please refer to page 0-6 for other detail).

Others, like object handling kit required to lift loose objects, are available upon Customer request.

Please address to your Dealer to know the availability of variants/optionals provided for your machine.

2. Under point 2 all information required by EU “Outdoor Noise” Directive 2000/14/EC is given.

Please refer to your own original EC DoC for specific machine information. Other information about equipment guaranteed sound power level (LWA) can be found on page 0-4. On the same page, information about operator’s station noise level (LpA) is given, which is not matter of above-mentioned EU Directive and therefore not indicated on it.

3. Generic serial number for this machine type.

The sequence of letters and numbers may vary depending on machine configuration.

4. EC DoC serial number. Please make reference to this number when requiring information or support to New Holland about EC DoC. 5. Signature of a person authorised to sign the document on behalf of the company.

Attachment-1

Reduced scale. Original is A4 format.

Reduced scale. Original is A4 format.

Reduced scale. Original is A4 format.

xx

CONSTRUCTION

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