New Holland EW160 Wheeled Excavator Operator's Manual 73183099 - PDF DOWNLOAD

OPERATOR'S MANUAL EW160 WHEELED EXCAVATOR

CONSTRUCTION 73183099

OPERATOR’S MANUAL EW 160

The NEW HOLLAND CONSTRUCTION operator’s manual is in 5 sections; the sections are designed for different target groups: 2801377

Operating manual

Target group Operating personnel + Inspection and servicing personnel

Part 1 INTRODUCTION + FUNDAMENTAL SAFETY INSTRUCTIONS Repair personnel

Operating personnel

Part 2 OPERATION

The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Inspection and servicing personnel

Part 3 INSPECTION AND SERVICING

The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

Repair personnel

Part 4 REPAIR WORK

Part 5 ANNEX

73183099

The repair personnel must have know-how and experience relevant to the repair of this or comparable machines.

Operating personnel + Inspection and servicing personnel + Repair personnel

NOTES

PART 1 - INTRODUCTION PREFACE .................................................................................................................................................. 3 Warnings and symbols ............................................................................................................................ 4 DESIGNATED USE .................................................................................................................................... 4 Organizational measures ........................................................................................................................ 5 Selection and qualification of personnel - basic responsibilities ........................................................ 6 Safety instructions governing specific operational phases Standard operation .................................................................................................................................. 6 Special work in conjunction with utilization of the machine - maintenance and repairs during operation disposal of parts and consumables ........................................................................................................ 7 Warning of special dangers Electric energy ........................................................................................................................................ 8 Gas, dust, steam and smoke .................................................................................................................. 8 Hydraulic and pneumatic equipment ...................................................................................................... 9 Noise ...................................................................................................................................................... 9 Oil, grease and other chemical substances ............................................................................................ 9 Transporting and towing - recommissioning ........................................................................................ 9 California, Proposition 65 Warning ........................................................................................................ 9 SAFETY PRECAUTIONS FOR OPERATION .......................................................................................... 10 General .................................................................................................................................................... 10 Before Operation .................................................................................................................................... 12

PART 2 - OPERATION Operation - safety instructions .............................................................................................................. 21 DESCRIPTION OF THE MACHINE Machine layout ...................................................................................................................................... 25 Undercarriage........................................................................................................................................ 25 Superstructure ...................................................................................................................................... 25 Hydraulic system .................................................................................................................................. 25 Steering ................................................................................................................................................ 25 Service brake ........................................................................................................................................ 25 Parking brake ........................................................................................................................................ 25 Floating axle .......................................................................................................................................... 25 Electrical system .................................................................................................................................. 25 Working equipment .............................................................................................................................. 25 SIGNS Warning and instruction signs .............................................................................................................. 27 Machine number.................................................................................................................................... 29 Engine number ...................................................................................................................................... 29 Component numbers ............................................................................................................................ 29 DRIVER’S CAB Climbing Up and Down .......................................................................................................................... 30 Opening / Closing the Driver’s Cab Door .............................................................................................. 31 Opening the Door from Outside ............................................................................................................ 31 Opening the Door from Inside .............................................................................................................. 31 Closing the Door.................................................................................................................................... 31 Adjustment of driver’s seat .................................................................................................................... 32 Adjustment of seat suspension ............................................................................................................ 32 Fore and aft adjustment of seat ............................................................................................................ 32 Adjustment of seat position .................................................................................................................. 32 Adjustment of backrest inclination ........................................................................................................ 32 Adjustment of armrests ........................................................................................................................ 32 Adjusting the control console position Adjusting the Mirrors ............................................................................................................................ 34 Opening and Closing the Windscreen .................................................................................................. 34 Front window - Removing the lower part .............................................................................................. 35 Opening / closing side window .............................................................................................................. 35 Emergency exit...................................................................................................................................... 35 Using the Sunshade .............................................................................................................................. 36 Cab interior lamp - switching on and off ................................................................................................ 37 Socket outlet in cab .............................................................................................................................. 37

MONITORING-, WARNING- AND CONTROL ELEMENTS Description of control panel .................................................................................................................. 38 Control panel operating instructions ...................................................................................................... 39 Control panel .......................................................................................................................................... 40 Supplementary control panel ................................................................................................................ 48 Control elements (SAE-control) ............................................................................................................ 52 STARTING UP THE MACHINE ................................................................................................................ 56 Refuelling Refuelling, safety instructions ................................................................................................................ 56 Refuelling .............................................................................................................................................. 56 Switching the electrical system on and off .......................................................................................... 57 Immobilizer, entering the code .............................................................................................................. 58 Starting and stopping the engine Starting the engine ................................................................................................................................ 59 Starting the engine with cold-starting aid .............................................................................................. 60 Engine does not start ............................................................................................................................ 61 Shutting off the engine .......................................................................................................................... 61 Ventilation and heating Ventilation.............................................................................................................................................. 62 Heating .................................................................................................................................................. 62 Adjusting the heating performance ........................................................................................................ 62 Defrosting the front and rear screens .................................................................................................... 63 Switching the windscreen wiper / washer on and off ............................................................................ 63 DRIVING .................................................................................................................................................. 64 Driving - Safety instructions .................................................................................................................. 64 Fastening the retaining belt .................................................................................................................. 65 Braking system Applying the service brake .................................................................................................................... 66 Applying the parking brake .................................................................................................................... 67 Releasing the parking brake .................................................................................................................. 67 Travel gear selection ............................................................................................................................ 68 Adjustment of steering column Steering column - Safety instructions .................................................................................................... 69 Adjusting the steering column .............................................................................................................. 69

First-aid kit Warning triangle .................................................................................................................................... 70 Fire-extinguisher .................................................................................................................................... 70 Blocking the swing axle ........................................................................................................................ 71 Bringing the machine into its basic position ...................................................................................... 71 Travelling Driving on and off the road .................................................................................................................... 73 Braking and stopping ............................................................................................................................ 73 Driving on slopes and gradients ............................................................................................................ 74 Driving with a load on the hook ............................................................................................................ 75 Recovery and towing - Safety instructions ............................................................................................ 76 Recovering / towing the machine .......................................................................................................... 76 During recovery / towing ........................................................................................................................ 77 After recovery / towing .......................................................................................................................... 77 Releasing the parking brake with the emergency unlocking device ...................................................... 77 Transporting of the machine Transport - Safety instructions .............................................................................................................. 78 Driving in case of PCS failure ................................................................................................................ 79 After travel operation .............................................................................................................................. 79 WORKING OPERATION .......................................................................................................................... 80 Working operation - Safety instructions Extreme positioning of working equipment - Instructions ...................................................................... 81 Before beginning work .......................................................................................................................... 81 Switching on floodlamps........................................................................................................................ 82 Speed reset function ............................................................................................................................ 83 Selecting the PCS output stage ............................................................................................................ 84 Activating the servo control .................................................................................................................. 85 Switching off the pilot control ................................................................................................................ 85 Swinging and braking the superstructure Locking the superstructure .................................................................................................................... 86 Unlocking the superstructure ................................................................................................................ 86 Swinging the superstructure .................................................................................................................. 86 Braking the superstructure .................................................................................................................... 87 Swinging - changing the mode of operation .......................................................................................... 87 Superstructure retaining brake - function .............................................................................................. 88 Applying the superstructure retaining brake .......................................................................................... 88 Releasing the superstructure retaining brake ........................................................................................ 89 Superstructure holding brake - emergency operation .......................................................................... 89

Machine in working position .................................................................................................................. 90 Stabilization of the machine .................................................................................................................. 91 Working with backhoe or grab equipment (SAE-control) Slewing superstructure .......................................................................................................................... 93 Raising and lowering the boom ............................................................................................................ 93 Extending and retracting the stick ........................................................................................................ 93 Filling and emptying the bucket ............................................................................................................ 93 Opening and closing the grab .............................................................................................................. 93 Turning the grab .................................................................................................................................... 93 Activate the Power Assist function ........................................................................................................ 93 Activate the Power Boost function ........................................................................................................ 93 Activate the horn .................................................................................................................................. 93 Power assist, function .......................................................................................................................... 94 Power Boost, function .......................................................................................................................... 95 Operating methods ................................................................................................................................ 96 Working operation in case of PCS failure Switching the proportional valve over to emergency operation ............................................................ 98 After daily operation Shutting off the machine ........................................................................................................................ 99 WORKING EQUIPMENT ........................................................................................................................ 100 Assembling working equipment - safety instructions Protective roof against falling objects .................................................................................................. 101 Securing the machine .......................................................................................................................... 101 QUICK-CHANGE DEVICE Quick-change device - safety instructions .......................................................................................... 102 Quick-change device - detaching the excavator bucket ...................................................................... 102 Quick-change device - remounting the excavator bucket.................................................................... 103 Attaching and detaching the grab equipment Attaching and detaching the grab equipment - Safety instructions...................................................... 104 Attaching the grab .............................................................................................................................. 104 Detaching the grab .............................................................................................................................. 105 Selecting the backhoe / grab equipment ............................................................................................ 106 Detaching / attaching the backhoe bucket ........................................................................................ 107 Corrosion protection for pins and bearings (bushings and hubs) Part nos. for Voler A.C......................................................................................................................... 108 Application of Voler A.C. .................................................................................................................... 108

Multi-position boom Description of multi-position boom ...................................................................................................... 109 Working with the multi-position boom .................................................................................................. 109 Lowering boom upper section ............................................................................................................ 109 Raising boom upper section ................................................................................................................ 109 Transporting the machine with multi-position boom ............................................................................ 109 HYDRAULIC HAMMER .......................................................................................................................... 110 Working with the hydraulic hammer, safety instructions ................................................................ 110 Working with a hydraulic hammer Switching on the hydraulic hammer .................................................................................................... 111 Switching off the hydraulic hammer .................................................................................................... 111 SCRAP SHEARS .................................................................................................................................. 112 Working with scrap shears, safety instructions ................................................................................ 112 Working with scrap shears Switching on the scrap shears ............................................................................................................ 113 Switching off the scrap shears ............................................................................................................ 113 LIFTING-GEAR OPERATION ................................................................................................................ 114 Lifting-gear operation - safety instructions ........................................................................................ 114 Loading hooks on backhoe buckets and couplers Loading hook capacity ........................................................................................................................ 115 Excavator load capacity ...................................................................................................................... 115 Overload warning system Function of overload warning system .................................................................................................. 116 Activating the overload warning system .............................................................................................. 116 Testing the overload warning system .................................................................................................. 117 Putting the overload warning system out of operation ........................................................................ 117 Pipe-fracture safety system, function .................................................................................................. 118 OPTIONAL EQUIPMENT Rotary beacon .................................................................................................................................... 119 Switching on the floodlamps at the rear of the cab .............................................................................. 120 Radio .................................................................................................................................................. 121 Refuelling system Refuelling with the refuelling system, safety instructions .................................................................... 122 Refuelling with the refuelling system .................................................................................................. 123 Driver’s seat - adjusting the lumbar support Adjusting the lumbar support .............................................................................................................. 124

Driver’s seat with pneumatic suspension and integrated heating Adjusting the pneumatic suspension .................................................................................................. 125 Fore-and-aft adjustment ...................................................................................................................... 125 Adjusting the seat cushion .................................................................................................................. 125 Adjusting the backrest ........................................................................................................................ 125 Adjusting the armrests ........................................................................................................................ 125 Adjusting the lumbar support .............................................................................................................. 126 Switching on the seat heating ............................................................................................................ 126 To switch on the seat heating: ............................................................................................................ 126 To switch off the seat heating: ............................................................................................................ 126 Air conditioner, switching on / off ...................................................................................................... 127 KEYBOARD, FURTHER FUNCTIONS Service (key 16), function .................................................................................................................... 128 Display (key 18), function .................................................................................................................... 129 To indicate the engine revolutions ...................................................................................................... 129 To indicate the time of day .................................................................................................................. 129 Display, setting the contrast ................................................................................................................ 130 Setting the time .................................................................................................................................. 131 Immobilizer, deactivate / activate ........................................................................................................ 132

PART 3 - INSPECTION AND SERVICING Inspection and servicing - safety instructions .................................................................................. 135 Inspection and servicing plans - instructions Further servicing work ........................................................................................................................ 139 Plan V - Once before first commissioning .......................................................................................... 140 Plan N - After first commissioning ...................................................................................................... 142 Plan T - Every 10 OH or per working shift .......................................................................................... 143 Plan W - Every 50 OH or weekly ........................................................................................................ 143 Plan A - After every 250 OH ................................................................................................................ 145 Plan B - After every 500 OH ................................................................................................................ 145 Plan C - After every 1000 OH .............................................................................................................. 145 Plan D - After every 3000 OH .............................................................................................................. 145 LUBRICATING CHART - GREASE Lubricating chart - Grease Working equipment .................................................................................. 149 Lubricating chart - Grease Undercarriage .......................................................................................... 151 Filling quantities - grease .................................................................................................................... 151 Joints and hinges ................................................................................................................................ 151 OIL INSPECTION PLAN Oil inspection plan .............................................................................................................................. 153 Refilling quantities - oil ........................................................................................................................ 153 Refilling quantities - other .................................................................................................................... 153 LUBRICANTS ........................................................................................................................................ 154 Oils for internal combustion engines.................................................................................................. 154 Oils for hydraulic system, mineral ...................................................................................................... 155 Oils for axles and gearboxes (selection) ............................................................................................ 156 Greases for bearings and swing rings ................................................................................................ 157 SERVICING Draining hose for oil changes .............................................................................................................. 158 ENGINE Engine, safety instructions for inspection and servicing ...................................................................... 159 Checking the engine oil level / topping up with oil .............................................................................. 159 Checking the drive belts ...................................................................................................................... 160 Checking the coolant level .................................................................................................................. 160 AIR-INTAKE SYSTEM Emptying the dust collector ................................................................................................................ 161

Removing, checking, and cleaning the main filter element ................................................................ 162 Checking / replacing the safety filter element ...................................................................................... 163 Checking air intake lines .................................................................................................................... 163 FUEL SYSTEM Fuel system - Safety instructions ........................................................................................................ 164 Cleaning the fuel tank .......................................................................................................................... 165 ELECTRICAL SYSTEM Electrical system - Safety instructions ................................................................................................ 166 Alternator - instructions ...................................................................................................................... 166 Battery main switch .............................................................................................................................. 167 Battery, checking Battery - checking the fluid level .......................................................................................................... 167 Battery - checking the charge .............................................................................................................. 167 Removing and installing the battery .................................................................................................... 168 HYDRAULIC SYSTEM Hydraulic system - safety instructions ................................................................................................ 169 Depressurizing the hydraulic system .................................................................................................. 169 Checking the hydraulic oil level .......................................................................................................... 170 Topping up with hydraulic oil .............................................................................................................. 170 Changing the hydraulic oil return-flow filter ........................................................................................ 171 Replacing the breather valve .............................................................................................................. 171 Changing line filters ............................................................................................................................ 172 Changing the hydraulic oil .................................................................................................................. 173 Draining hydraulic oil .......................................................................................................................... 173 Cleaning the hydraulic oil reservoir .................................................................................................... 174 Renew sealing cord ............................................................................................................................ 174 Filling with hydraulic oil ........................................................................................................................ 174 Venting the hydraulic system .............................................................................................................. 175 Bleeding the supporting cylinder of the full-floating axle Cleaning the hydraulic oil cooler.......................................................................................................... 177 Cleaning the engine cooler .................................................................................................................. 178 SWING GEAR Swing gear - checking oil level ............................................................................................................ 179 Swing gear - changing oil .................................................................................................................... 179 Superstructure holding brake - Function checking .............................................................................. 180 Axles and travel gearbox Rigid axle and travel gearbox - checking the oil level .......................................................................... 181 Rigid axle and travel gearbox - changing the oil.................................................................................. 183 Steering axle gearbox - checking the oil level .................................................................................... 185

Steering axles wheel hub gears - checking the oil level ...................................................................... 186 Steering axle gearbox - changing the oil ............................................................................................ 187 Steering axles wheel hub gears - changing the oil .............................................................................. 188 BRAKING .............................................................................................................................................. 189 Working on brakes - Safety instructions ............................................................................................ 189 Service brake Checking the lining thickness of multiple-disk brakes ........................................................................ 189 Bleeding the multiple-disk brakes ........................................................................................................ 191 Swing axle cylinder - lubricating the contact surfaces .................................................................... 192 WHEELS AND TYRES Tyre inflation pressure - Safety instructions ........................................................................................ 193 Checking the tyre inflation pressure - Refilling the tyre ...................................................................... 194 Table of tyre inflation pressures .......................................................................................................... 194 Tyres and wheels, safety instructions.................................................................................................. 195 Changing a wheel................................................................................................................................ 196 Tread pattern arrangement ................................................................................................................ 196 SWING RING Swing ring - Instructions ...................................................................................................................... 197 Swing ring - checking grease filling .................................................................................................... 197 Swing ring - filling grease .................................................................................................................... 198 Swing ring - greasing the bearing ........................................................................................................ 198 Swing ring - checking tightness of screws .......................................................................................... 199 Lubricating the greasing nipples .......................................................................................................... 199 Greasing the pedal valve tappets ........................................................................................................ 200 Greasing the control valve tappets ...................................................................................................... 200 WINDSCREEN WASHER Topping up the wash fluid .................................................................................................................. 201 HEATING Cleaning the filter mat ........................................................................................................................ 201 AIR CONDITIONER................................................................................................................................ 202 Air conditioner - Inspection and servicing work Location of components in the machine .............................................................................................. 203 Work to be carried out every month .................................................................................................... 203 Work to be performed every 6 months ................................................................................................ 206 Work to be performed every 2 years .................................................................................................. 206 Air conditioner - Checking / retensioning the compressor V-belt .................................................... 207

Air conditioner - Troubleshooting ...................................................................................................... 208 Putting the machine out of operation Battery storage .................................................................................................................................... 212 Recommissioning ................................................................................................................................ 212

PART 4 - REPAIR WORK Repair work - safety instructions ........................................................................................................ 215 Accumulators, safety instructions ...................................................................................................... 216 ENGINE Engine, repair instructions .................................................................................................................. 217 Assisted starting (with jump-leads) - Safety instructions Assisted starting (with jump-leads) ...................................................................................................... 218 Prior to assisted starting ...................................................................................................................... 218 Connecting the jumper cables ............................................................................................................ 218 Starting up the engines ...................................................................................................................... 218 FUSES Checking / replacing the fuses ............................................................................................................ 219 Fuse table............................................................................................................................................ 220 BULBS Replacing the bulbs - Notes ................................................................................................................ 221 Bulbs - Table ...................................................................................................................................... 221 Replacing the headlamp bulb .............................................................................................................. 221 Replacing the front turn signal lamp .................................................................................................... 222 Replacing the bulb in the cab interior lamp ........................................................................................ 222 Replacing the tail-lamp bulb ................................................................................................................ 223 Replacing the bulb of the floodlamp on driver’s cab ............................................................................ 223 Replacing the bulb of the boom floodlamp .......................................................................................... 224 Working equipment - replacing a tooth .............................................................................................. 225 Clamshell, Wear Limits ........................................................................................................................ 226

PART 5 - ANNEX TROUBLESHOOTING .......................................................................................................................... 229 Instructions on troubleshooting .......................................................................................................... 229 Layout of the fault table Fault .................................................................................................................................................... 229 Possible causes .................................................................................................................................... 229 Measure ................................................................................................................................................ 229 Section .................................................................................................................................................. 229 FAULT TABLES Combustion engine fault table ............................................................................................................ 230 Steering system fault table .................................................................................................................. 231 Service brake and parking brake, fault table ...................................................................................... 232 Working hydraulics (incl. boom-adjusting and grab cylinder) fault table .............................................. 233 Transmission fault table ...................................................................................................................... 234 Swing system fault table ...................................................................................................................... 235 Floating-axle blocking fault table ........................................................................................................ 236 Stabilizer system (PLA - A 2) fault table .............................................................................................. 237 Hammer operation (optional equipment) fault table ............................................................................ 238 Grab rotation circuit (optional equipment) fault table .......................................................................... 239 Table of fault codes ............................................................................................................................ 240 Tightening torques - Table .................................................................................................................. 241 ABBREVIATIONS .................................................................................................................................. 243 INDEX .................................................................................................................................................... 245

NOTES

OPERATOR’S MANUAL EW 160 PART 1 - INTRODUCTION

Operating manual

2261176

Target group Operating personnel + Inspection and servicing personnel

Part 1 INTRODUCTION + FUNDAMENTAL SAFETY INSTRUCTIONS Repair personnel

Operating personnel

Part 2 OPERATION

The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Inspection and servicing personnel

Part 3 INSPECTION AND SERVICING

The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

Repair personnel

Part 4 REPAIR WORK

Part 5 ANNEX

73183099

The repair personnel must have know-how and experience relevant to the repair of this or comparable machines.

Operating personnel + Inspection and servicing personnel + Repair personnel

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OPERATOR’S MANUAL EW 160

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OPERATOR’S MANUAL EW 160 PREFACE These operating instructions are designed to familiarize the operator with the machine and its designated use.

The instruction manual contains important information on how to operate the machine safely, properly and with maximum efficiency. Observing these instructions helps to prevent hazardous situations, to reduce repair costs and downtimes and to increase the reliability and service life of the machine.

The instruction manual must be supplemented by the respective national rules and regulations for accident prevention and environmental protection.

The operating instructions must always be available in the operator’s cab of the machine.

The operating instructions must be read and put into practice by any person in charge of carrying out work with or on the machine, such as - operation, including setting-up, troubleshooting in the course of work, care, evacuation of production waste and disposal of fuels and consumables.

- maintenance (inspection, servicing, repair) and / or - transport.

In addition to the operating instructions and the mandatory rules and regulations for accident prevention and environmental protection in the user’s country and at place where the machine is to be used, the generally recognized technical rules for safe and proper working must be observed.

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The operating instructions are directed to the construction-machine specialist. They cannot provide basic know-how. This can be acquired, for example, in several days’ instruction by a qualified NEW HOLLAND CONSTRUCTION mechanic or by attending an NEW HOLLAND CONSTRUCTION training course for operators or maintenance personnel.

The NEW HOLLAND CONSTRUCTION aftersales service will be pleased to deal with any queries you may have after reading through the operating instructions.

This operating manuals are issued in German and then translated. Even a good translation may give rise to questions which NEW HOLLAND CONSTRUCTION will be pleased to answer.

The operating instructions are not work instructions for carrying out major repairs. Such work is willingly done for you by the NEW HOLLAND CONSTRUCTION after-sales service.

The documentation relating to the machine is listed according to scope, quantity and language in the shipping note of the machine or in the covering letter if supplied separately. The operating instructions and spare-parts list are marked with the serial number of the machine.

On taking receipt of the consignment, please check that the documentation is complete and in the language requested by you.

This information is valid at the moment of printing. As the manufacturer constantly improves his products, some information may result as not updated. In case of differences, always ask your Service Center.

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OPERATOR’S MANUAL EW 160

Warnings and symbols

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The following signs are used in the manual to designate instructions of particular importance:

Fitted with other attachments, the excavator can also be used as a special-purpose machine, e.g. for drilling, with lifting tackle or with a hydraulic hammer.

Imminent danger involving the risk of death or of severe injuries.

Operating the machine within the limits of its designated use also involves observing the instructions set out in the operating manual and complying with the inspection and maintenance directives.

Precautionary rules and measures designed to protect the machine operator and other persons from life-threatening danger or injuries and to prevent extensive damage.

Information and precautionary measures designed to prevent damage to the machine or other property.

DESIGNATED USE

2732687

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

The machine must be used only in technically perfect condition in accordance with its designated use and the instructions set out in the operating manual, and only by safety-conscious persons who are fully aware of the risks involved in operating the machine. Any functional disorders, especially those affecting the safety of the machine, should therefore be rectified immediately.

The excavator with dipper shovel, grab or scoop attachment is designed solely for excavating and loading: - excavatable soils, sand, gravel, blasted rock, ore, coal and other raw materials.

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Using the excavator or its attachments for purposes other than or extending beyond those stated above, e.g.: - for lifting or transporting persons, - as a working platform, - for lifting crane loads without the equipment being approved for this purpose, - for towing trailer-mounted loads, - for driving in posts, supports, sheet piles etc. without the equipment being approved for this purpose, is considered contrary to the designated use.

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

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

Noise emission specification in acc. with the 3rd Ordinance of the Machine Safety Act of 18th January 1991 resp. with EC Machine Directive, Annex I, para. 1.7.4 f.

If the earth-moving machine is operated in accordance with its designated use, the installation of driver’s seats complying with ISO 7096 ensures that the considered vibration accelerations azw (measured as per ISO 2631, Part 1) fulfil the requirements of protecting the driver against wholebody vibration.

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OPERATOR’S MANUAL EW 160

Organizational measures The operating instructions must always be at hand at the place of use of the machine, e.g. by stowing them in the tool compartment or tool-box provided for such purpose.

In addition to the operating instructions, observe and instruct the user in all other generally applicable legal and other mandatory regulations relevant to accident prevention and environmental protection.

These compulsory regulations may also deal with the handling of hazardous substances, issuing and/or wearing of personal protective equipment or traffic regulations.

The operating instructions must be supplemented by instructions covering the duties involved in supervising and notifying special organizational features, such as job organization, working sequences or the personnel entrusted with the work.

Personnel entrusted with work on the machine must have read the operating instructions and in particular the chapter on safety before beginning work. Reading the instructions after work has begun is too late. This applies especially to persons working only occasionally on the machine, e.g. during setting up or maintenance.

Check - at least from time to time - whether the personnel is carrying out the work in compliance with the operating instructions and paying attention to risks and safety factors.

For reasons of security, long hair must be tied back or otherwise secured, garments must be close-fitting and no jewellery, such as rings, may be worn. Injury may result from being caught up in the machinery or from rings catching on moving parts.

2261965

Observe all safety instructions and warnings attached to the machine.

See to it that safety instructions and warnings attached to the machine are always complete and perfectly legible.

In the event of safety-relevant modifications or changes in the behaviour of the machine during operation, stop the machine immediately and report the malfunction to the competent authority/person.

Never make any modifications, additions or conversions which might affect safety without the supplier’s approval. This also applies to the installation and adjustment of safety devices and valves as well as to welding work on load-bearing elements.

Spare parts must comply with the technical requirements specified by the manufacturer. Spare parts from original equipment manufacturers can be relied to do so.

Replace hydraulic hoses within stipulated and appropriate intervals, even if no safety-relevant defects have been detected.

Adhere to prescribed intervals or those specified in the operating instructions for routine checks and inspections.

For the execution of maintenance work, tools and workshop equipment adapted to the task on hand are absolutely indispensable.

The personnel must be familiar with the location and operation of fire extinguishers.

Observe all fire-warning and fire-fighting procedures.

Use protective equipment wherever required by the circumstances or by law.

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OPERATOR’S MANUAL EW 160

Selection and qualification of personnel - basic responsibilities

Safety instructions governing specific operational phases

Any work on and with the machine must be executed by reliable personnel only. Statutory minimum age limits must be observed.

Standard operation

Employ only trained or instructed staff and set out clearly the individual responsibilities of the personnel for operation, set-up, maintenance and repair.

Make sure that only authorized personnel works on or with the machine.

Define the machine operator’s responsibilities also with regard to observing traffic regulations giving the operator the authority to refuse instructions by third parties that are contrary to safety.

Do not allow persons to be trained or instructed or persons taking part in a general training course to work on or with the machine without being permanently supervised by an experienced person.

Work on the electrical system and equipment of the machine must be carried out only by a skilled electrician or by instructed persons under the supervision and guidance of a skilled electrician and in accordance with electrical engineering rules and regulations.

Work on chassis, brake and steering systems must be performed by skilled personnel only, which has been specially trained for such work.

Work on the hydraulic system must be carried out only by personnel with special knowledge and experience of hydraulic equipment.

Avoid any operational mode that might be prejudicial to safety.

Before beginning work, familiarize yourself with the surroundings and circumstances of the site, such as obstacles in the working and travelling area, the soil bearing capacity and any barriers separating the construction site from public roads.

Take the necessary precautions to ensure that the machine is used only when in a safe and reliable state.

Operate the machine only if all protective and safety-oriented devices, such as removable safety devices, emergency shut-off equipment, soundproofing elements and exhausters, are in place and fully functional.

Check the machine at least once per working shift for obvious damage and defects. Report any changes (incl. changes in the machine’s working behaviour) to the competent organization/person immediately. If necessary, stop the machine immediately and lock it.

In the event of malfunctions, stop the machine immediately and lock it. Have any defects rectified immediately.

Start the machine from the driver’s seat only.

During start-up and shut-down procedures always watch the indicators in accordance with the operating instructions.

Before setting the machine in motion, make sure that nobody is at risk.

Before starting work or travelling with the machine, check that the braking, steering, signalling and lighting systems are fully functional.

Before setting the machine in motion always check that the accessories have been safely stowed away.

When travelling on public roads, ways and places always observe the valid traffic regulations and, if necessary, make sure beforehand that the machine is in a condition compatible with these regulations.

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In conditions of poor visibility and after dark always switch on the lighting system.

Persons accompanying the driver must be seated on the passenger seats provided for this purpose.

When crossing underpasses, bridges and tunnels or when passing under overhead lines always make sure that there is is sufficient clearance.

Always keep at a distance from the edges of building pits and slopes.

Avoid any operation that might be a risk to machine stability.

Never travel across slopes; always keep the working equipment and the load close to the ground, especially when travelling downhill.

On sloping terrain always adapt your travelling speed to the prevailing ground conditions. Never change to a lower gear on a slope but always before reaching it.

Before leaving the driver’s seat always secure the machine against inadvertent movement and unauthorized use.

Special work in conjunction with utilization of the machine - maintenance and repairs during operation - disposal of parts and consumables Observe the adjusting, maintenance and inspection activities and intervals set out in the operating instructions, including information on the replacement of parts and equipment. These activities may be executed by skilled personnel only.

Brief operating personnel before beginning special operations and maintenance work, and appoint a person to supervise the activities.

In any work concerning the operation, conversion or adjustment of the machine and its safety-oriented devices or any work related to maintenance, inspection and repair, always observe the start-up and shut-down procedures set out in the operating instructions and the information on maintenance work.

Ensure that the maintenance area is adequately secured.

If the machine is completely shut down for maintenance and repair work, it must be secured against inadvertent starting by: - removing the ignition key and - attaching a warning sign.

Carry out maintenance and repair work only if the machine is positioned on stable and level ground and has been secured against inadvertent movement and buckling.

To avoid the risk of accidents, individual parts and large assemblies being moved for replacement purposes should be carefully attached to lifting tackle and secured. Use only suitable and technically perfect lifting gear and suspension systems with adequate lifting capacity. Never work or stand under suspended loads.

The fastening of loads and the instructing of crane operators should be entrusted to experienced persons only. The marshaller giving the instructions must be within sight or sound of the operator.

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OPERATOR’S MANUAL EW 160

For carrying out overhead assembly work always use specially designed or otherwise safety-oriented ladders and working platforms. Never use machine parts as a climbing aid.

Wear a safety harness when carrying out maintenance work at greater heights.

Keep all handles, steps, handrails, platforms, landings and ladders free from dirt, snow and ice.

Clean the machine, especially connections and threaded unions, of any traces of oil, fuel or preservatives before carrying out maintenance/repair. Never use aggressive detergents. Use lintfree cleaning rags.

Before cleaning the machine with water, steam jet (high-pressure cleaning) or detergents, cover or tape up all openings which - for safety and functional reasons - must be protected against water, steam or detergent penetration. Special care must be taken with electric motors and switchgear cabinets.

Ensure during cleaning of the machine that the temperature sensors of the fire-warning and firefighting systems do not come into contact with hot cleaning agents as this might activate the fire-fighting system.

After cleaning, remove all covers and tapes applied for that purpose.

After cleaning, examine all fuel, lubricant, and hydraulic fluid lines for leaks, loose connections, chafe marks and damage. Any defects found must be rectified without delay.

Always tighten any screwed connections that have been loosened during maintenance and repair.

Any safety devices removed for set-up, maintenance or repair purposes must be refitted and checked immediately upon completion of the maintenance and repair work.

Ensure that all consumables and replaced parts are disposed of safely and with minimum environmental impact.

Warning of special dangers Electric energy Use only original fuses with the specified current rating. Switch off the machine immediately if trouble occurs in the electrical system.

When working with the machine, maintain a safe distance from overhead electric lines. If work is to be carried out close to overhead lines, the working equipment must be kept well away from them.

Caution, danger! Check out the prescribed safety distances.

If your machine comes into contact with a live wire - do not leave the machine - drive the machine out of the hazard zone - warn others against approaching and touching the machine - have the live wire de-energized - do not leave the machine until the damaged line has been safely de-energized.

The electrical equipment of machines is to be inspected and checked at regular intervals. Defects such as loose connections or scorched cables must be rectified immediately.

Gas, dust, steam and smoke Operate internal combustion engines and fueloperated heating systems only on adequately ventilated premises. Before starting the machine on enclosed premises, make sure that there is sufficient ventilation.

Observe the regulations in force at the respective site.

Carry out welding, flame-cutting and grinding work on the machine only if this has been expressly authorized, as there may be a risk of explosion and fire.

Before carrying out welding, flame-cutting and grinding operations, clean the machine and its surroundings from dust and other inflammable substances and make sure that the premises are adequately ventilated (risk of explosion).

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Hydraulic and pneumatic equipment Check all lines, hoses and screwed connections regularly for leaks and obvious damage. Repair damage immediately. Splashed oil may cause injury and fire.

Transporting and towing - recommissioning The machine must be towed, loaded and transported only in accordance with the operating instructions.

Depressurize all system sections and pressure pipes (hydraulic system, compressed-air system) to be removed in accordance with the specific instructions for the unit concerned before carrying out any repair work.

For towing the machine observe the prescribed transport position, admissible speed and itinerary.

Hydraulic and compressed-air lines must be laid and fitted properly. Ensure that no connections are interchanged. The fittings, lengths and quality of the hoses must comply with the technical requirements.

The recommissioning procedure must be strictly in accordance with the operating instructions.

Noise During operation, all sound baffles of the machine must be closed.

Always wear the prescribed ear protectors.

Use only appropriate means of transport and lifting gear of adequate capacity.

California, Proposition 65 Warning 2732686

Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects, and other reproductive harm.

Oil, grease and other chemical substances When handling oil, grease and other chemical substances, observe the product-related safety regulations.

Be careful when handling hot consumables (risk of burning or scalding).

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OPERATOR’S MANUAL EW 160

SAFETY PRECAUTIONS FOR OPERATION General • Be prepared • Do not operate this machine unless you have read and understood the instructions in this manual. Improper operation is dangerous and could result in injury or death.

• Learn how to use the safety devices on your machine.

• Be sure you understand the meaning of the caution decals.

2801383

if a fire starts by having a fire extinguisher handy (Fig. 2).

Keep a first aid kit handy.

• Keep emergency numbers for doctors, ambulance service, hospital and fire department near your telephone.

• Learn the prohibitions, cautions and rules about work procedures in the work site.

• Establish a means of communication for accidents and fires and take measures against them.

Learn the location of fire extinguishers and first aid kits; learn how to use them.

Fig. 1

• Wear a hard hat, protective glasses, and other protective equipment as required by job conditions (Fig. 1).

• Do not wear loose clothing that can catch on controls or other parts of the machine.

Fig. 3

• Take care of your health, Do not operate when tired, after drinking, or while on medication that could cause drowsiness.

• Fuel or oil are dangerous substances.

Never handle fuel, oil, grease or oily rags in places where there is any fire or flame (Fig. 3).

• Never use diesel fuel or gasoline as cleaning solvents since they are highly flammable (Fig. 3)!

• Inspect the inside of the engine room and remove any dead leaves, wood chips, or papers.

Dead leaves, papers, wood chips, are highly flammable and can cause fires.

• Carry out checks before starting the machine. If any problem is found, do not start the engine, but inform the foreman immediately. Always keep the machine in good condition.

Fig. 2

10

• Keep engine compartment free of accumulated fuel or oil leaks. Clean any oil or fuel that leaks or spills immediately.

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OPERATOR’S MANUAL EW 160

Fig. 4

Fig. 5

• Examine the lay of the land and the kind of soil at the work site to determine the dangerous points and the best method of opreation.

Proceed with the work only after making safety arrangements about the dangerous points (Fig. 4).

• Fasten the seat belt securely (Fig. 5), if equipped with Roll-Over Protective Structure (ROPS).

• Clear obstacles from path of machine. Beware of hazards such as wires and ditches.

• Keep machine, especially deck and steps, free of foreign material.

Secure all loose items such as lunch boxes, tools, etc. Clean steps, grab irons and operator’s platform.

• Inspect the seat belt, buckle and mounting hardware. Replace the belt or any damaged hardware.

Tighten any loose mounting hardware.

• Adjust the seat so that full brake pedal travel can be obtained with operator’s back against the seat back.

• Do not start the machine or move any of the controls if there is a warning tag attached to the controls or starter switch.

• Structural damage, an overturn, modification, alteration, or improper repair can impair this structure’s protection capability thereby voiding this certification. Consult a NEW HOLLAND CONSTRUCTION dealer to determine this structure’s limitations without voiding its certifications.

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OPERATOR’S MANUAL EW 160

Before Operation • Start and operate the engine only in a well ventilated area. In an enclosed area, vent the engine exhaust to the outside.

• The front window of the cab serves as an emergency exit. Use it only if left hand door is blocked.

• Clean windows. Secure door and windows in either open or shut position.

• Climb on and off the machine only where steps and/or grab irons are provided (Fig. 6 and 7).

• Climb on and off the machine only where steps and/or grab irons are provided (Fig. 6 and 7).

• Use both hands and face the machine when mounting and dismounting.

• Never get on or off a moving machine.

• Never jump off a machine.

• Do not try to climb onto the machine while carrying tools or supplies.

• In dangerous places, always work in teams of two; one man to operate the machine, and the other to give instructions.

• Keep all personnel and objects clear of the swing range. Always be aware of your surroundings when operating. Be especially careful when swinging in confined areas not to bump the rear of the machine into something (Fig. 8).

Fig. 6

Fig. 8

• Know the hand signals and who gives them.

Accept signals from one person only.

• Confirm that all gauges and warning devices are functioning correctly, and that the gauge readings are within the prescribed range.

Fig. 7

• Test all of the controls, before starting to work.

• Test the right and left steering before moving the machine.

• Be sure that all brakes are operating properly before moving the machine.

• Make sure the horn, backup buzzer, etc., are working properly.

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OPERATOR’S MANUAL EW 160

• Check for proper operation of all controls and protective devices while moving slowly in an open area.

• Make sure no one is working on, underneath, or close to the machine before starting the engine, or beginning to move the machine.

• Lower the bucket and move controls to NEUTRAL before starting the engine.

• Operate the controls only while seated. Operate the controls only with the engine running except during the engine starting procedure.

• Do not allow riders on the machine unless additional seat, seat belt and rollover protection are provided.

• Always sit in the operator’s seat when operating the machine.

• Do not allow unauthorized persons into the work area.

• It is extremely dangerous to allow yourself to be distracted or to think of other things when operating a machine.

• Do not operate the machine in an overload condition.

• When the uppercarriage is swung beside, be sure in which direction the machine will travel, before start travelling with speed (see also: "Driving the machine into its basic position").

• Do not travel without the help of a flagman preceding the machine. Do not travel near the edge of a ditch, gully, trench or excavation.

Proceed with much care where room is limited, over rough or sloping grounds.

• Be particularly careful to check that the rear is clear before backing the machine.

• Keep work site flat. By continually grading the work site, work efficiency will be improved and machines will be able to drive smoothly over the site.

Make sure that the worksite footing has sufficient strength to firmly support the machine (Fig. 10).

• Never attempt to put the machine to use other than specified.

• Do not use the bucket as a hammer or pile driver.

Such operation will damage the bucket and other front attachments parts (Fig. 9).

Fig. 10

Fig. 9

• Do not use the bucket as a brake except in emergencies.

• Keep the machine under control - do not try to work it over its capacity.

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OPERATOR’S MANUAL EW 160

• Before crossing bridges or other structures, confirm that they are strong enough to hold the machine.

• When reaching an area that appears dangerous or where visibility is poor, get off your machine to check for safety before starting work.

• Make sure the worksite footing has sufficient strength to firmly support the machine. When working close to an excavation, stabilize your machine with the stabilizers/blade (Fig. 12).

• Do not operate the machine under or near an overhanging ledge.

• To climb over obstacles such as rocks, move slowly while checking machine stability; never move diagonally or at high speed or the machine might tip over.

Fig. 13

• When you operate, move or hault the excavator, avoid contact between boom or arm and overhead obstacles (Fig. 13).

Before you dig, check the location of cables, gas lines and water mains. Do not dig under the machine. If engine stops during operation on a hillside, lower the bucket to ground. Start engine immediatly.

Fig. 11

• Serious injury or death can result from contact with electric lines (Fig. 11).

Never move any part of the machine or load closer to electric line than 3m (10 ft) plus twice the line insulator length.

Fig. 12

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• Do not travel the machine with the bucket thrust into the ground or dig by using the machine’s weight.

These operations applay excessive stresses on the machine (Fig. 14).

• When operating at night, remember the follwing points: - Be sure to arrange an adequate lighting system.

- Make sure lights are working properly.

- At night is very easy to make mistakes in assuming the distance and height of objects and land.

• Stop the machine frequently at night-walk around and inspect the machine-stay alert.

Fig. 14

• When loading trucks or hoppers, be careful not to hit the truck or hopper with the bucket. Do not bring the bucket over people’s heads or over the cab of the truck.

• On windy days, always load downwind.

• Check clearance prior to entering areas with limited clearance such as tunnels, overpasses, power cables, and garages.

• Do not work when visibility is reduced by smoke, fog or dust. If the jobsite is dark, install lighting as necessary.

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Fig. 15

• Carry the bucket low at all times, especially when you work on a hillside or travel. Carry the bucket high enough to clear obstacles. Do not let anyone ride in the bucket (Fig. 15).

• Stay a safe distance from the edge of cliffs, overhangs, slides areas and from other machines.

• In a narrow or enclosed area, take care not to let your machine contact surrounding or overhead objects.

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OPERATOR’S MANUAL EW 160

Fig. 16

Fig. 17

• Care to be exercised when working on a slope (Fig. 16).

• When you operate on a slope, do not swing the bucket down-hill if possible. When you swing heavy loads to the side of the tracks, avoid tipping the excavator. When the bucket is loaded, be careful when you swing or lift the boom.

Machine operation on a slope involves danger. Step down speed, using care so the machine does not turn over and slide sideways.

• Do not change directions on a slope as it causes the machine to turn over or slide sideways. In case you must change direction on a slope for an unavoidable reason, do it on a mild slope with solid ground.

• Avoid crossing a slope as it may cause the machine to slip sideways.

• When working on a slope, do not swing the machine torward the vally as if the side of the machine is loaded, it may turn over. Perform swing and boom actions carefully at low speed (Fig. 17).

16

• If you notice any abnormal noise, vibration, heat, odor, or gauge reading, immediately drive your machine to a safe area and stop it.

Locate the cause of the problem and take proper measures.

• Report needed repairs immediately.

• Always stop the engine when adding fuel. After adding fuel, tighten the fuel cap properly.

• Be sure hitch points and tow cable are adequate.

• Connect the trailing equipment to a drawbar or hitch only.

• Personnel should not be between the machine and the trailing equipment while maneuvering to connect. Block tongue or hitch of trailing equipment to align it with the drawbar or hitch.

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OPERATOR’S MANUAL EW 160

Fig. 18

Fig. 19

• If the excavator needs to be towed, or is used to tow another vehicle, attach the tow ropes as shown (Fig. 18).

Only designated towing or pulling attachment points are to be used for towing or pulling. Do not start suddenly at full throttle against a tow chain or cable. Take up slack carefully.

• When a river bed is flat and water current is slow, the machine may be operated in a water depth to the middle of the axles (Fig. 19).

Where river bed condition is poor or water current is fast, pay full attention so the swing bearing, swing pinion, gear and swivel joint are not immersed in water, sand and oil.

• Operating the machine in water and on soft ground.

• On a soft ground, the machine body sinks little by little in some cases. Therfore, pay full attention the under body of the machine at all times during operation.

If the machine is operated after the swing bearing, swing pinion, gears and swivel joint are immersed in water, sand or soil, the swing bearing and others may be worn abnormally.

Immediate replacement of grease or overhaul of the swing bearing is required. Suspend operation and get in touch with your nearby servicing dealer.

Fig. 20

• Before you leave the cab: Lower bucket to ground stop engine. Shift control lever to neutral. When the excavator is parked on slopes, lock the wheels with suitable blocks. Never park or stand wheels pointing downhill. Do not leave the lock switch key in cab: take key with you (Fig. 20).

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OPERATOR’S MANUAL EW 160

Fig. 21

Fig. 23

• Be sure to stop the engine.

Place the machine on level ground. Lower the bucket to the ground (Fig. 21).

• Place a sign "Under inspection and maintenance" on the cab door or control lever (Fig. 23).

Never get under the machine when it is self jacked by the boom and arm.

When inspecting or servicing the machine with raised boom and arm always use safety blocks, props, stands etc.

Fig. 22

• Avoid dangerous situations.

Never attempt to get on or off the machine while it is operating. When getting on or off the machine, use handles and stepping points (Fig. 22).

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OPERATOR’S MANUAL EW 160 PART 2 - OPERATION

Operating manual

2261177

Target group Operating personnel + Inspection and servicing personnel

Part 1 INTRODUCTION + FUNDAMENTAL SAFETY INSTRUCTIONS Repair personnel

Operating personnel

Part 2 OPERATION

The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Inspection and servicing personnel

Part 3 INSPECTION AND SERVICING

The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

Repair personnel

Part 4 REPAIR WORK

Part 5 ANNEX

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The repair personnel must have know-how and experience relevant to the repair of this or comparable machines.

Operating personnel + Inspection and servicing personnel + Repair personnel

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OPERATOR’S MANUAL EW 160

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OPERATOR’S MANUAL EW 160 Operation - safety instructions

2801341

Operating instructions

Safety belt

Never operate the machine before having read and understood the operating instructions.

For machines with a safety belt for operating personnel:

Pay special attention to: "Fundamental Safety Instructions" and all warnings and safety instructions attached to the machine.

Familiarize yourself with the layout, the functioning and the activating devices of the control elements prior to starting up the machine.

Activate the control elements from the driver’s seat only.

Check safety belt attached to driver’s seat. In the event of damage or after an accident, have it replaced immediately.

Apply safety belt before starting work.

State of the machine Operate the machine only in a safe state and only in accordance with its designated use. Always observe the safety instructions.

Keep the operating instructions with the machine at all times.

Always have inspection and maintenance work carried out on schedule.

Note: The operating instructions should be secured to the seat in the cab.

Operate the machine only with the equipment and component combinations approved by NEW HOLLAND CONSTRUCTION. Clear-cut data are given in the technical specifications.

Operating personnel The operating personnel must be fully informed of the operation and application of this or comparable machines.

Never install and commission other equipment and component combinations without NEW HOLLAND CONSTRUCTION having first inspected and approved the project.

Personal protective gear and working clothing

Before starting work or travelling with the machine, check that the braking, steering, signalling and lighting systems are fully functional.

Wear a safety helmet and working footwear with non-slip soles. Smooth soles may slip from steps and pedals, resulting in injury or incorrect operation.

Wear closely fitting working clothing when operating the machine. Loose, wide garments may result in the control lever being inadvertently activated.

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Poor visibility may result in accidents. Always clean the windows and the glass covers of all lights before starting up the machine.

Check that all warnings and safety instructions attached to the machine are present and legible.

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OPERATOR’S MANUAL EW 160

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OPERATOR’S MANUAL EW 160

Entering and leaving the machine

Marshallers

Always face the machine when entering and leaving.

The marshall must keep outside the hazard zone.

Use only the steps, platforms and handrails provided when entering and leaving the machine.

Have a marshall to assist you: - when you have no clear overview over the hazard zone of the machine, - when reversing, - when shunting.

Always keep steps, platforms, handles and handrails in a non-slip, safe state and remove any oil, grease, soil, clay, snow, ice and other foreign matter immediately.

Hazard range The hazard range is that zone around the machine in which persons are within reach of falling loads or falling attachments due to operational movements by the machine, to its equipment and attachments or to swinging loads.

Use only those communication signals which you and the marshall understand, or use aids for communication (e.g. walkie-talkie / camera). Calls cannot be understood by the marshaller because of the noise made by the machine during operation.

Keep in constant contact with the marshaller.

Stop the machine immediately if you lose contact with the marshaller.

Persons within the hazard zone Always use the horn to warn persons in the immediate vicinity of the machine before starting up the machine.

Ensure that no one sets foot in the hazard zone of the machine. Interrupt work until such persons have left the hazard zone.

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Securing the machine Secure the machine as described in the section "Securing the Machine" before: - mounting or dismantling the attachment, - parking the machine after daily operation, - carrying out any servicing or repair work.

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OPERATOR’S MANUAL EW 160 DESCRIPTION OF THE MACHINE

2801385

Fig. 1

24

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OPERATOR’S MANUAL EW 160 Machine layout (Fig. 1) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

-

Air intake system Batteries Cooling system Engine Counterweight Cooling system hydraulic oil Fuel reservoir Hydraulic oil reservoir Swing gearbox Rotor Cab Backhoe Toggle link Toggle lever Backhoe cylinder Stick Stick cylinder Boom Boom cylinder Stabilizer feet Rigid axle with transmission Swing ring Cardan shaft Steering axle Levelling blade

Hydraulic system All working and travel movements are executed hydraulically. The working commands are triggered manually and transmitted via control circuits. The oil flow from the superstructure to the undercarriage passes through the rotor. The hydraulic system is protected against overloading by pressure relief valves.

Steering The machine is equipped with a hydrostatic power steering system enabling the machine to be steered manually by applying increased force if the engine is stationary or in case of hydraulic steering pump failure.

Service brake The machine is braked by hydraulically operated multiple-disk brakes on all four pairs of wheels.

The service brake can be blocked in braked position.

Parking brake The parking brake is formed by spring-pressureblocked disk assemblies.

The parking brake is integrated into the travel gearbox and therefore acts on all wheels.

Floating axle The steering axle is of the fully floating type. This axle can be blocked hydraulically by means of two cylinders during excavator operation.

Undercarriage

Electrical system

The undercarriage of the hydraulic excavator serves as a stable base when the excavator is stationary and for travelling.

The undercarriage also carries the components used for stabilizing and supporting of the machine during working operations such as the levelling blade or the stabilizers.

The undercarriage is hydraulically driven with oil motor and transmission.

Undercarriage and superstructure are linked by a swing ring.

The electrical system operates on 24 volts.

An electronic voltage regulator moreover supplies a voltage of 12 V. Electronic modules (Power Control System) ensure that the available engine power is converted in an optimal way into hydraulic power.

Superstructure The drive motor and part of the hydraulic and electrical systems are housed in the superstructure.

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Working equipment The working equipment comprises the monoblock boom, the stick, the toggle lever with toggle link and the backhoe bucket (multi-position-boom with lower and upper section is optional equipment). Further excavating or working tools can be attached.

25

OPERATOR’S MANUAL EW 160 SIGNS

2796498

Fig. 1

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OPERATOR’S MANUAL EW 160 SIGNS

Warning and instruction signs

2801342

Fig. 1 and 2 shows the location of warning and instruction signs on the machine.

Always observe the warning and instruction signs attached to the machine.

Keep signs clean and legible.

Replace signs immediately if they have become illegible.

New warning and instruction signs can be ordered from the NEW HOLLAND CONSTRUCTION Spare-Parts Service. The Part nos. required for orders can be found in the spare-parts list of your machine.

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OPERATOR’S MANUAL EW 160

Fig. 2

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OPERATOR’S MANUAL EW 160 Machine number

2472323

Engine number

2472058

The nameplate with the machine number is attached on the righthand side in front of the undercarriage (Fig. 3).

The nameplate (Fig. 4) with the engine number is attached to the engine.

Fig. 3

Fig. 4

Component numbers

2732688

Other larger components such as hydraulic pumps and -motors, gears and axles also have nameplates where, amongst other things, their serial number is indicated.

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OPERATOR’S MANUAL EW 160 DRIVER’S CAB Climbing Up and Down

2796954

Hazard of Injuries You may slip off soiled grab handles and foot steps.

Clean grab handles, foot steps and your shoes of oil, grease, soil, loam, snow, ice and other substances.

Keep foot steps and platforms in safeto-step and handles in safe-to-grip condition.

Fig. 1

• Always face the machine when entering or leaving it.

• Always use the foot steps, platforms and grab handles provided for entering or leaving the machine (refer to the illustrations).

• When leaving the driver’s cab, never use operating or control levers as grab handles.

These are not designed for such load.

Fig. 2

Fig. 3

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OPERATOR’S MANUAL EW 160 Opening / Closing the Driver’s Cab Door

2796610

Opening the Door from Outside • Unlock the door (Fig. 4).

• Withdraw the flap on the door lock (arrow, Fig. 4).

The door can now be opened.

• Fully opened, the door can be locked into place.

Opening the Door from Inside To open the driver’s cab door from inside, press forward the lever (Fig. 5).

Fig. 4

Closing the Door • Unlock the opened, locked-in door by pushing down the lever (Fig. 6). Grab the handle on the upper side of the door frame and close the door.

Fig. 5

Fig. 6

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OPERATOR’S MANUAL EW 160 Adjustment of driver’s seat

Adjustment of seat suspension

The seat permits adjustment of backrest inclination, height and position. The suspension of the seat can be adjusted to suit the driver’s weight.

• Adjust seat to the driver’s weight using knob (3, Fig. 7) to adapt the suspension accordingly.

2796523

Fore and aft adjustment of seat

Risk of accidents Never adjust the seat while driving, but concentrate on the road.

Before adjusting the seat: - Stop machine.

- Switch steering column switch to neutral position.

- Apply parking brake.

• Pull lever (4) upwards, move seat forwards or backwards to the desired position and allow lever to engage in the corresponding locking notch.

Adjustment of seat position • Height and inclination forwards/backwards: - pull handle (2) upwards, adjust seat and engage handle (2).

Adjustment of backrest inclination • Pull lever (5) upwards, adjust backrest and allow lever (7) to engage.

Adjustment of armrests • The armrests can be raised backwards. Their inclination can be adjusted with knobs (1).

The driver’s seat can be equipped with: - lumbar support or - pneumatic suspension and - integrated heating (see: "Optional equipment").

Fig. 7

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OPERATOR’S MANUAL EW 160 Adjusting the control console position

2796499

Risk of accidents Never move control consoles while driving, but concentrate on the road.

Never move control consoles when the hydraulic servo control is activated.

The control levers may be actuated inadvertently, initiating movements by the working equipment.

Before changing the position of the control consoles: - stop the machine - stand working equipment on the ground - set the travel selector lever (61, Fig. 8) to the middle position (neutral).

- Apply parking brake by switching rocker switch (44) in such a way that the switch surface with the symbol is up (the switch is locked).

- Deactivate servo control with rocker switch (43); the switch surface with the STOP symbol must be pressed down.

- shut off engine.

Fig. 9

The control consoles on the right and on the left of the driver’s seat can be shifted forwards and backwards parallel to the seat by approximately 16 cm to enable the operator to choose his individual position for fatigue-free working.

Adjusting the righthand control console: • Push lever (72, Fig. 9) forwards against the spring resistance and maintain while shifting the console into the desired position.

Release lever and check that the console is locked firmly in place.

Adjusting the lefthand control console: • Push lever (75) forwards against the spring resistance and maintain while shifting the console into the desired position.

Release lever and check that the console is locked firmly in place.

The lever for switching the hydraulic pilot control (77) on and off is attached to the lefthand control console.

The control console swings up when the pilot control is switched off.

Fig. 8

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For switching the pilot control on, the control console is pushed downwards until it engages (cf. "Switching the pilot control on and off").

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OPERATOR’S MANUAL EW 160 Adjusting the Mirrors

Opening and Closing the Windscreen 2716646

2796933

The outside mirrors of the machine (Fig. 10) must be adjusted so that as wide a part of the working area as possible can be overlooked.

The windscreen can be pushed under the roof of the driver’s cab.

• Sit down on the driver’s seat.

• Grab the right and left handles of the windscreen and press down the locks (Fig. 11).

• Have the outside mirrors adjusted by an assistant.

• Roll sunshade up.

• Tilt the windscreen inwards and pull it fully back in upward direction.

• Release the locks, they will engage.

• Make sure both locks are properly engaged.

If the locks are not properly engaged, the windscreen may move forward under high vibration.

Fig. 10

Fig. 11

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OPERATOR’S MANUAL EW 160 Front window - Removing the lower 2904038 part The lower part of the front window can be removed. To do so: • open both latches on the right and left side of the window by swinging the levers (Fig. 12) away from the front window.

Opening / closing side window 2472067

• Release locking device (Fig. 14) and push pane to front and lock it at the desired position.

To close, pull the pane backwards until the locking device engages.

• Take out the pane and place into the supports in front of the rear window (1, Fig. 13).

• Allow both latches to engage in the supports (2) on the right and left of the rear window swinging the levers in the direction of the front pane.

Fig. 14

Emergency exit

Fig. 12

2472065

The front window can be used as an emergency exit if the cab door cannot be opened after it has been damaged in an accident, for instance.

Fig. 13

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OPERATOR’S MANUAL EW 160 Using the Sunshade

2796934

The sunshade is fitted to a holder above the windscreen.

It can be pulled in front of the windscreen (Fig. 15) or the roof window (Fig. 16).

Rolling out the Sunshade • Grip end strip, roll blind down against spring tension, and fix in brackets to right and left of screen (arrows, Figs. 15 and 16).

Rolling up the Sunshade • Take the end strip, unhang the sunshade from its holders and allow it to slowly roll up by the spring work. Do not abruptly release the unrolled sunshade for it could get damaged.

Fig. 15

Fig. 16

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OPERATOR’S MANUAL EW 160 Cab interior lamp - switching on and2800862 off The interior lamp is switched on and off with the switch (Fig. 17).

Important: The lamp can be switched on even if the keyswitch for the electrical system is in OFF position and the key is withdrawn.

If the light is left on inadvertently for a longer period (e.g. a weekend), the batteries may be discharged.

So always check that the interior lamp is switched off before leaving the machine.

Fig. 17

Socket outlet in cab 2904422

A socket outlet is installed in the panelling on the left behind the operator’s seat (Fig. 18).

This provides the output voltage of the voltage transformer (12V) for connection of the cool-box (option). Other electrical consumers can also be connected as long as the maximum output of the voltage transformer is not exceeded.

Important: The voltage transformer installed at the factory is designed so as to supply not only a cassette radio but also the cool-box (option); the maximum output is 90 W. In the event of overloading, the temperature of the transformer increases and causes the built-in overload protection to switch off leaving the connected appliance without current. In this case, pull the plug out of the socket (Fig. 18). After 5 10 minutes, the overload protection has cooled down and switches the transformer back into the circuit. If the overload condition persists, the thermal overload shut-off does not work anymore and the fuse in the electrical supply cable blows. To replace it, the panelling below the radio must be removed.

The socket is still live when the key-switch for the electrical system is in OFF position and the key is withdrawn.

If a connected consumer is left on inadvertently for a longer period (e.g. a weekend), the batteries may be discharged.

So always check that the connected consumer is switched off before leaving the machine.

Fig. 18

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OPERATOR’S MANUAL EW 160 MONITORING-, WARNING- AND CONTROL ELEMENTS The tables on the following pages inform you about the functions of - the control panel, - the supplementary control panel and - all control elements.

More information on the different functions can be found in other chapters of these operating instructions.

If you want to find information on a specific subject please refer to the table of contents and the index.

2801386

At low winter temperatures (approx. below -20oC / -4oF), the multi-functional display (A, Fig. 1) may be difficult to read or not readable at all. This is not a malfunction but rather a phenomenon due to the liquid crystal technique used.

After a short time of operation, the display can again be read in full contrast.

The control panel layout is identical for excavators of the EC and EW series. For this reason, functions and elements required for wheel-mounted ecxavators are not used for crawler-trackmounted machines such as, for instance, the steering pressure warning lamp (no. 7).

The control panel is subdivided into four functional groups of elements:

Some of the keyboard functions are options. They can only be used if the machine is equipped correspondingly and if the function has been validated on the PCS electronic unit board, e.g.:

- the multi-functional display (A, Fig. 1),

- hydraulic hammer (key 19),

- indicator and warning lamps (B),

- overload warning system (key 29).

- the keyboard (C) and

Not all of the functions indicated on the control panel are available for each type of machine. If you have questions, please contact your nearest NEW HOLLAND CONSTRUCTION dealer-service.

Description of control panel

- the supplementary control panel (D, Fig. 2).

The whole control panel is automatically illuminated as soon as the key-switch is turned to position 1 (ignition ON).

Fig. 1

Fig. 2

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OPERATOR’S MANUAL EW 160 Control panel operating instructions The keyboard is a membrane-type keyboard with symbols printed on the membrane describing the function of the key below.

2732897

Example (Fig. 3): Key (15), fan

The keys are depressed to activate or de-activate the corresponding functions. The keys are shortstroke tactile touch types telling the operator by a click that the key has been successfully depressed.

Light-emitting diodes (LEDs) are located above the keys under transparent sections of the keyboard membrane to indicate the control state of the key. Depressing the key repeatedly permits to select all possible control states sequentially (see example opposite).

Fig. 3

The keyboard membrane may be damaged by pointed objects.

Use your fingers only to depress the keys.

Never use ball-point pens, pencils, nails or similar pointed objects.

Possible control states: - none of the LEDs lit = fan OFF. - key (15) depressed once: = fan in range 1, LED above 1 on.

- key (15) depressed twice: = fan in range 2, LED above 2 on.

After shutting off the machine (ignition OFF), the last switching state of the keys "Fan" (15), "Hydraulic Hammer" (19), "PCS-range (20), "AutoIdle" (22), "Swing mode" (26), "Gearshift" (27) and "Overload warning system" (29) remain stored and are being displayed when the machine is started next time.

All other activated functions are reset to zero.

The following rule applies to the rocker switches on supplementary control panel (D, Fig. 2): A function is activated when the switch face bearing the function symbol / the description is depressed.

- key (15) depressed three times: = fan in range 3, LED above 3 on.

- Depress key (15) four times: = fan in stage 2, LED above 2 lit up.

- Depress key (15) five times: = fan in stage 1, LED above 1 lit up.

- If the key is depressed again: = fan OFF, LED extinguished.

It is not possible to pass directly into the OFF position from a selected range. This means that if the operator wants to switch off the fan running in range 1 he has to depress the key five times.

The other keys are operated the same way.

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39

OPERATOR’S MANUAL EW 160 Control panel

1946501

Fig. 4

40

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OPERATOR’S MANUAL EW 160 Control panel (Fig. 4) No. Element

Page 1 of 4

Function

1

Bar-graph display

Coolant temperature

indicates the temperature of the coolant: indicator bar in light segment = ok indicator bar in dark segment = working speeds reduced by PCS to lower the engine temperature.

(C = cool - H = hot)

2

Indicator

PCS range

indicates the actual PCS power mode.

HEAVY ECO LIFT

Symbol

Display while travelling: 1.G / 2.G (see: "Travel gearbox shifting") 3

Multi-functional display

standard display: time in hours : minutes alternatively: engine revs (RPM = min-1) travel speed in km/h (see: "Display (key 18), function" )

4

Bar-graph display

indicates the fuel reserve. indicator bar in light segment = ok indicator bar in dark segment = refuelling required (F = full - E =empty)

5

Operating-hours meter

- adds up the hours run of the machine - Indicates the next service interval (see: "Service (key 16) function") - indicates fault codes (see: "Table of fault codes")

6

Warning lamp

Brake pressure

Lights up if braking pressure is too low.

Stop machine. Wait until warning light goes out before continuing operation.

7

Warning lamp

Steering pressure

lit up when the steering pressure is too low: shut off machine.

8

Indicator lamp

Hazard warning

lit up when the hazard warning system is activated.

9

Warning lamp

Engine oil pressure

lit up when the engine oil pressure is too low: shut off engine.

10

Warning lamp

Hydraulic oil temperature

lit up when the hydraulic oil temperature is too high: working speed reduced by PCS to allow the hydraulic oil to cool off.

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Fuel reserve

41

OPERATOR’S MANUAL EW 160 Control panel

Fig. 5

42

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OPERATOR’S MANUAL EW 160 Control panel (Fig. 5) No. Element

Page 2 of 4

Function

11

Warning lamp

Overload warning system (optional equipment)

lights up with the activated overload warning system on when the load lifted is too big and the stability of the machine is endangered. In this case, the load must be reduced.

12

Warning lamp

Hydraulic oil filter

lit up when the return-flow filters in the hydraulic system are contaminated: replace return-flow filter.

13

Indicator lamp

Direction indictor right

lit up when the right-hand direction indicator is on.

14

Warning lamp

15

Key

Fan

switches the fan to: OFF, ranges 1, 2, and 3.

16

Key

Service

When the button is pressed, the display (5) shows after how many operating hours the next servicing will be due. For further functions, see: "Service (key 16) function".

17

Key

Buzzer

switches off the acoustic warning (buzzer) of all functions, except the overload warning system.

(LED lit up when the buzzer is off).

The buzzer is automatically re-activated for the next warning.

18

Key

Display mode

selects the following indications of the multi-functional display: - time - engine speed see: "Display (key 18), function"

19

Key

Hydraulic hammer (optional equipment)

switches the "hydraulic hammer" function on/off.

20

Key

PCS range

PCS (Power Control System) - preselection of the maximum engine speed and hydraulic performance in three steps: H = HEAVY, 100% performance E = ECO, 90% performance L = LIFT, 65% performance

21

Key

Power assist

switches increased hydraulic pressure for the working functions and the travelling drive, engine speed is reduced to the PCS-stage LIFT.

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Symbol

not used on this machine

43

OPERATOR’S MANUAL EW 160 Control panel

Fig. 6

44

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OPERATOR’S MANUAL EW 160 Control panel (Fig. 6) No. Element

Page 3 of 4

Function

Symbol

22

Key

Auto Idle

switches the automatic speed reduction function on/off.

23

Key

Hazard warning

switches the hazard warning system on/off

24

Key

Direction indicator

switches the right-hand direction indicator on/off.

25

Key

Direction indicator

switches the left-hand direction indicator on/off.

26

Key

Swing mode

LED OFF = higher swinging performance LED ON = normal swinging performance

27

Key

Gearshift

LED off = 2nd gear, driving on roads LED on = 1st gear, driving off roads (see: "Travel gearbox shifting")

28

Key

Superstructure holding brake

LED off =

29

Key

Overload warning system (optional equipment)

LED on =

30

Key

Floodlamps

LED off = floodlamps OFF LED 1 on = floodlamp on working equipment ON (sidelights or headlamps ON) LED 1+2 = f l o o d l a m p s o n w o r k i n g equipment and auxiliary floodlamp ON (option) LED 3 = not used on this machine.

31

Key

Automatic wipe/wash

activates the screen washer and the wiper as long as the key is held down.

32

Key

Lighting

LED off = LED 1 on LED 2 on

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holding brake released, superstructure free to turn LED I on = holding brake applied, superstructure braked LED A on = automatic mode, holding brake applied and released automatically overload warning system OFF LED 1 on = overload warning system ON (machine without additional stabilisation) LED 2 on = overload warning system ON (machine with additional stabilsation).

lighting OFF sidelamp ON dipped-beam headlamps ON 45

OPERATOR’S MANUAL EW 160 Control panel

Fig. 7

46

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OPERATOR’S MANUAL EW 160 Control panel (Fig. 7) No. Element

Page 4 of 4

Function

33

Key

Screen wiper

34

Indicator lamp

35

Indicator lamp

36

Indicator lamp

37

Warning lamp

Coolant level

lit up when the coolant level is too low: shut off engine.

38

Warning lamp

Coolant temperature

lit up when the temperature of the coolant is too high: shut off engine.

39

Warning lamp

40

Indicator lamp

Alternator

lit up when the alternator supplies no current.

41

Indicator lamp

Superstructure holding brake

lit up when the superstructure holding brake is applied for longer than 10 seconds

42

Indicator lamp

Parking brake

lit up when the parking brake or service brake is applied.

LED off = wiper OFF LED J on = intermittent wiping LED 2 on = wiper ON not used on this machine.

Direction indicator left

lit up when the left-hand direction indicator is on. not used on this machine.

not used on this machine

Buzzer (inside the control panel)

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Symbol

sounds acoustic warnings: Short tone if: - the alternator does not supply power - the return-flow filter of the hydraulic system is contaminated - the parking brake is applied - the hydraulic oil temperature is too high - the "raising / lowering of the stabilizers / levelling blade" function is activated - during self-test Continuous tone when: - the braking pressure is too low.

- the oil pressure in the engine is too low - the temperature of the cooling liquid is too high - the level of the cooling liquid is too low - when the admissible load moment is exceeded (optional overload warning system installed)

47

OPERATOR’S MANUAL EW 160 Supplementary control panel

2905204

Fig. 8

48

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OPERATOR’S MANUAL EW 160 Supplementary control panel (Fig. 8) No. Element

Page 1 of 2

Function

43

Rocker switch

Hydraulic servo control

Activate hydraulic servo control press switch surface without symbol Deactivate hydraulic servo control press switch surface with symbol

44

Rocker switch with lock

Parking brake

Apply parking brake (activate only when machine is stationary) Press switch surface without symbol (this also locks the rocker switch; the pilot lamp (42) lights up, the swing axle is blocked)

Symbol

Release parking brake Unlock switch and press switch surface with symbol (pilot lamp (42) goes out; the swing axle is free unless blocked with switch (52)) 45

Potentiometer

Engine speed control

knob turned counter-clockwise - idling knob turned clockwise - max. engine speed

46

Key-switch

Electrical system

activation and deactivation of the electrical system / preheating and starting of the engine, stopping of the engine

47

Rocker switch

Air conditioning system (Option)

symbol side up air conditioning system OFF symbol side down air conditioning system ON (see: "Air conditioner, switching on / off")

48

Not used on this machine.

49

Rocker switch

Scrap shears (Option)

switches between hammer and scraper shears operation symbol side up - hammer operation ON symbol side down - scrap shears ON

50

Rocker switch with lock

Refuelling system (Option)

switching on the refuelling system set symbol face of rocker switch to middle position, unlock and depress symbol face briefly. (switch returns to middle position after releasing) switching off the refuelling system depress switch face with slide lock.

51

Rocker switch

Floodlights rear (Option)

symbol side up floodlights rear OFF. symbol side down floodlights rear ON.

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49

OPERATOR’S MANUAL EW 160 Supplementary control panel

Fig. 9

50

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OPERATOR’S MANUAL EW 160 Supplementary control panel (Fig. 9) No. Element 52

Rocker switch

Page 2 of 2

Function Floating-axle blocking

53

Symbol

symbol side up - axle free to float symbol side down - axle blocked Not used on this machine.

54

Rocker switch

Rotary beacon (Option)

symbol side up - rotary beacon OFF symbol side down - rotary beacon ON

55

Rocker switch

Stabilizer feet (Option)

switches between levelling blade / stabilizer feet symbol side up - levelling blade ON symbol side down - stabilizer feet ON

56

Rocker switch

Stabilizer feet left/right (Option)

switches between right/left stabilizer feet symbol side up - left stabilizer feet ON symbol side down - right stabilizer feet ON

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51

OPERATOR’S MANUAL EW 160 Control elements (SAE-control)

1946492

Fig. 10

52

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OPERATOR’S MANUAL EW 160 Control elements (SAE-control) (Fig. 10) No. Element

Page 1 of 2

Function

60

Steering column and steering wheel

transfer of steering movements to steering axle.

61

Steering column travel selector

Selection of travel direction: Forwards - forwards Middle - neutral Back - reverse Activate crawling speed function: Upwards - crawling speed OFF Downwards - crawling speed ON (switch only when the machine is stationary)

62

Control panel

control and monitoring of machine functions

63

Pedal

Service brake

Brakes the travel movement of the machine.

The locking lever blocks the service brake in braked position.

64

Pedal

Travelling

initiating of machine travelling function

65

Push-button

Power Boost

Brief working at higher engine speed and higher pressure, (see: "Power Boost function").

66

Push-button

Horn

acoustic warning signals

67

free for optional equipment

68

Lock-bolt

Superstructure locking

locking of superstructure and undercarriage

69

Momentarycontact rocker switch

Grab rotation (optional equipment)

pressing down right-hand contact - grab rotation to the right pressing down left-hand contact - grab rotation to the left

70

Control lever

Boom

Press forwards - lower boom Pull back - raise boom

Bucket

Press to right - empty bucket Press to left - fill bucket

Grab

With grab (option): Press to right - open grab Press to left - close grab

71

Supplementary control panel

controlling and monitoring of machine functions

72

Lever

Locking of right-hand console

lever in vertical position - console locked in position lever forwards - console unlocked and free to slide

73

Knob

Heating

heating performance control: fully counter-clockwise - min. heating performance fully clockwise - max. heating performance

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53

OPERATOR’S MANUAL EW 160 Control elements (SAE-control)

Fig. 11

54

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OPERATOR’S MANUAL EW 160 Control elements (SAE-control) (Fig. 11) No. Element 74

Socket outlet

75

Lever

Page 2 of 2

Function To connect cool-box (option) and other electrical consumers to 12V supply (cf.: "Socket outlet in cab").

Locking of left-hand console

76

lever in vertical position - console locked in position lever forwards - console unlocked and free to slide Free for optional equipment

77

Lever

Hydraulik servo control

Pull upwards hydraulic servo control OFF. Press downwards hydraulic servo control ON. (cf.: "Activating the servo control")

78

Control lever

Slewing

Press to right superstructure slews clockwise.

Press to left superstructure slews counter-clockwise.

Stick bullgrader / stabilizers

Press forward extend stick lower bullgrader / stabilizers.

Press back retract stick lift bullgrader / stabilizers. (cf. no. 80).

79

Lever

80

Momentary-contact rocker switch, lefthand contact

switching over between the stabilizers / levelling blade stick functions (the buzzer sounds when the function "Raising / lowering of stabilizers / levelling blade" is activated).

81

Push-button

free for optional equipment

82

Push-button

83

Foot rest

84

Pedal (optional equipment)

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Steering column locking

Hydraulic hammer (optional equipment)

Locks steering column in required inclination: Press forward - steering column can be adjusted.

Release lever - steering column locked.

activation of hydraulic hammer

Examples - boom adjusting equipment: extension/retraction of adjusting cylinder - hydraulic hammer: hammer control

55

OPERATOR’S MANUAL EW 160 STARTING UP THE MACHINE 2413786

Prior to starting up the machine each day, do jobs listed in the maintenance schedule T (cf.

Section 3 of these operating instructions "Inspection and Servicing").

Refuelling

2413658

Refuelling, safety instructions

Refuelling

2472072

Explosion hazard No smoking, no use of naked flames! Fuels and fuel gases are inflammable. Fire hazard.

Fuel may damage the skin, so wear protective gloves or use a barrier cream.

Lower the attachment to the ground.

Switch off the engine. Switch off fuel-operated ancillary heating systems and air conditioning systems.

Avoid spilling fuel and allowing it to seep into the ground: environmental hazard!

Soak up any overflowing fuel immediately with cloths or binding agents. Then dispose of these correctly to avoid pollution.

Fig. 1

• Unscrew cap of filler neck (Fig. 1).

• Fill in fuel through the filter gauze in the filler neck. Do not remove gauze.

Report any accidents involving fuels to the user or his authorized agent without delay.

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OPERATOR’S MANUAL EW 160 Switching the electrical system on and off

Fig. 2

2904040

Fig. 3

• Switch the main battery switch to position ON. (The battery main switch is installed in the battery compartment beside the batteries).

The key-switch (46, Fig. 2) is used to switch the following functions: 0 = All electrical consumers except the interior light, turn signals, outlet in cab, hazard warning system, refuelling system and illuminating systems are without voltage, engine off.

I = Electrical system ON. If the immobilizer is active, the system now requests entering of the code (see: "Immobilizer, entering the code").

If the immobilizer is not active, the electronics will perform a self-test.

All monitoring and warning lamps will light up for a few seconds and the buzzer sounds briefly.

Then, warning lamps (7, 9, 40, 42, Fig. 3) will light up and the buzzer will sound again.

All indicators will be shown at the display.

The following functions are now activated by the electronics: - The PCS is switched to the mode that was active during the preceding engine shut-off, - Superstructure holding brake in AUTOMATIC mode.

II = Start the engine. All warning and pilot lamps must cease when the engine is running.

(Indicator lamp (42) goes out after the parking brake is released).

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OPERATOR’S MANUAL EW 160 Immobilizer, entering the code This machine is equipped with an electronic immobilizer system preventing the machine from being put into operation by unauthorized persons.

The immobilizer function is not enabled when the machine is delivered ex factory. On request of the customer, it can, however, be activated by the service mechanic when the machine is handed over.

When the electrical system is switched on by turning the key-operated switch, the electronic central unit requests entering of a code (Fig. 4).

The engine can be started up only after the code has been entered correctly.

During the work, the immobilizer can be deactivated (see also: "Immobilizer, deactivating / activating").

2904030

Fig. 4

Entering the code (f. ex. "5"): • Turn keyswitch to I. • Depress key (24, Fig. 5) five times: the display (A) moves on by one unit after each depression of the key.

• Depress key (25) five times: the display (A) moves back by one unit after each depression of the key.

The start inhibit function is now cancelled. The machine can be put into operation.

• After an incorrect entry, the procedure can be interrupted and restarted by setting the keyswitch to "0" and by repeating the procedure from the beginning. (cf. "Immobilizer, deactivating / activating").

Fig. 5

N.B.: The code preset at the factory can be changed.

This requires, however, a specially equipped tester.

Contact your NEW HOLLAND CONSTRUCTION dealer if you want to have the code changed.

The new code must be entered as described above.

Make sure the information on the new codes is not accessible to unauthorized persons.

You can thus be sure that your machine can only be put into operation by duly authorized persons.

58

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OPERATOR’S MANUAL EW 160 Starting and stopping the engine

2801390

Starting the engine

Engine exhaust can endanger health.

Start the engine only outdoors or in premises equipped with an exhaust removal system.

Fig. 7

Fig. 6

If the warning lights fail to go out when the engine is running, the engine may suffer substantial damage. Stop the engine immediately.

Locate cause of fault and rectify. Only then may the engine be started up again.

• Set travel selector switch (61, Fig. 6) to the middle position (neutral).

• Turn engine speed potentiometer (45) to the left. During starting, the amount of fuel injected is automatically increased.

• Turn key in key-switch (46) to position II. The engine starts.

• Release key. Key goes back to position I. Warning lamps for steering pressure (7, Fig. 7), engine oil pressure (9) and charge monitor (40) go out.

Monitoring lamp (42) goes out, after the parking brake is released with rocker switch (44, Fig. 6).

If the engine doesn’t easily starts at temperatures below 0˚C (32˚F) try to start it using the cold-starting aid (see: "Starting the engine with cold-starting aid").

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If the engine is cold, a warm-up phase now starts automatically. During this time, "WARMUP" is displayed alternately with the set PCS power stage. The engine speed corresponds to the programmed speed for the PCS power stage LIFT. After the WARMUP phase, the engine is brought to the speed set on the engine speed potentiometer (45, Fig. 6). If the potentiometer is at the left limit stop, the engine is brought to the speed programmed for the selected PCS power stage.

Do not allow the engine to operate for too long at idling speed.

Excessive idling periods (over 10 minutes) can cause damage to the engine.

If the coolant temperature is too low, the fuel flushes the lubricating oil from the cylinder walls and dilutes the engine oil in the crankcase. This leads to insufficient lubrication of moving parts of the engine.

59

OPERATOR’S MANUAL EW 160 Starting the engine with cold-starting aid

The engine is equipped with a cold-starting aid.

2904436

• Turn key to position II and depress "cold starting aid" button (48, Fig. 9) two to three times.

Each press of the button injects approx.

1,5 cm3 of starting liquid to the air intake line of the engine.

The starter fluid contains ether and is therefore harmful to health.

It is also extremely flammable.

Incorrect use can lead to explosions and uncontrolled combustion.

Therefore: - do not breathe in fumes - do not use additional starting devices, such as preheaters, glow plugs, flame devices or other electrical starting aids - avoid the vicinity of naked flames.

Fig. 9

The cold-starting aid is only active while starting the engine.

It is automatically switched off when the engine stands still and when the engine is running.

• The engine starts.

• Release key, it returns to position I.

• Turn potentiometer (45, Fig. 8) as far as possible to the left (idling position).

Excessive use of starter fluid leads to inadmissibly high pressure in the cylinders and can cause the engine to race.

Further information on starting at low outside temperatures or after engine malfunctions can be found in the "Engine operating and maintenance instructions".

Fig. 8

• Turn key in key switch (46) to position I. Wait until the buzzer sounds a second time and all indicators are fully visible on the display.

(The self-test of the central electronic unit is then terminated).

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OPERATOR’S MANUAL EW 160 Engine does not start

2732246

If the engine does not start, return the key switch (46, Fig. 10) to position 0 (mechanical start-repeating lock). Only restart after completing this procedure.

Starting without interruption should not be performed for longer than 20 seconds. Allow a break of two minutes between starting procedures.

Use the fault table to determine and rectify (have rectified) the cause of the malfunction.

When starting in winter observe the guidelines given in the engine operation instructions.

Shutting off the engine

2796509

Never shut off the engine out of full load, but continue running for ca. three - five minutes at idling speed to cool down.

• Set working equipment down on the ground.

• Switch travel selector (61, Fig. 10) to the middle position (neutral).

• Apply parking brake with rocker switch (44). To do so depress the switch surface with the locking bar. Monitoring lamp (42, Fig. 11) lits up.

The rocker switch is locked.

• Turn speed-change potentiometer (45, Fig. 10) counter-clockwise to the limit stop.

The engine is brought to idling speed.

• Switch key-switch (46) to 0. The engine is shut off and is stationary.

• Withdraw the key from the key-switch (46).

Fig. 10

Fig. 11

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61

OPERATOR’S MANUAL EW 160 Ventilation and heating

2716622

Ventilation (fresh air)

Heating

Fig. 12

Fig. 14

While the engine is running:

The heat exchanger of the heating system is heated by the cooling liquid flowing through it.

Therefore, the heating power is also dependent on engine temperature. The full heating power can only be obtained when the engine has reached its operating temperature.

• Turn heating control knob (73, Fig. 12) to "min" (heating performance = 0).

(If the engine is not running, switch key in key-switch (46, Fig. 8) to position I. This is necessary to activate the fan).

• Select the desired fan speed with key (15, Fig. 13) (ranges 1 - 3).

2800853

Even if the heating is not used for prolonged times, it must be switched on once a week for abt. 5 minutes to mix the cooling liquid in the engine and in the heating system.

(When auxiliary heating system (option) is installed, cf.: "Activating the auxiliary heating system").

(When air condition system (option) is installed, cf.: "Air conditioner, switching on / off").

Adjusting the heating performance 2472788

Fig. 13

• Turn knob (73, Fig. 12) clockwise to increase the desired amount of heat.

• Depending on the amount of warm air desired, switch the fan with key (15, Fig. 13) into stages 1 to 3.

• The slats of the outlet nozzles (Fig. 14, 15 and 16) are variable. The air flow can be directed to the side and up and down.

62

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OPERATOR’S MANUAL EW 160 Defrosting the front and rear screens 2796936

Switching the windscreen wiper / washer on and off

2461482

To activate intermittent wiping Screens that are steamed or iced up obstruct the operator’s view of the hazard zone.

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

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

• Close the air-flow vents under the operator’s seat.

• Open the two air-flow vents for the front screens (Fig. 15) as wide as possible and direct onto the front screens.

• Open the air-flow vents to the right and left of the rear screen (Fig. 16) as wide as possible and direct onto the rear screen.

- depress key (33, Fig. 17) once. LED J lights up.

To activate permanent wiping - depress key (33) twice. LED 1 lights up.

To de-activate the wiper - depress key (33) until the LEDs are no longer lit up.

To activate the wipe / wash function - depress key (31). LED I lights up.

The washer pump starts up and the wiper begins to move at the same time.

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

• Set heating output to max.

• Switch blower to stage 3.

Fig. 17

Fig. 15

Fig. 16

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63

OPERATOR’S MANUAL EW 160 DRIVING Driving - Safety instructions

2904033

Before starting to drive

Contact with overhead power lines

Clean off any earth, mud, snow, ice, grease and oil ahering to your working footwear before operating the machine.

There is otherwise the risk of slipping off the pedals and steps and initiating inadvertent movements.

Raise the working equipment only in so far as required to pass under such lines without any risk.

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

If this is not possible: - Do not leave the driver’s cab.

- Inform persons outside the hazard zone to keep away from the machine and to take the necessary steps to have the power line shut off.

Close the front window and the cab door.

If the machine is equipped with a safety belt for the driver, put on the belt.

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

If a power line has been contacted, drive the machine out of the hazard range or lower the working equipment.

Allow no other persons to accompany you on the machine during driving.

Driving on slopes Watch position of working equipment Do not drive with the working equipment stretched out. The machine may loose its stability. Retract the working equipment as far as possible towards the machine.

Do not pull trailers The machine is not suited for the towing of trailers or other vehicles over greater distances. Towing over greater distances would result in damage to axles and gearboxes. The coupling is intended for recovering or towing the machine out of the hazard range after an accident or for attaching the fixing ropes on transport vehicles. See "Recovering and towing the machine".

64

Do not drive across slopes.

Do not turn round on slopes to prevent the machine from slipping or overturning.

Be extremely careful on muddy and icy ground.

Pay attention to sufficient adherence of the wheels on the ground to ensure the machine’s maneuvrability and braking capability.

Reversing During reversing, your view of the hazard zone is restricted. You should therefore seek the assistance of experienced banksmen. Instruct the banksman to ensure that you understand his signals correctly.

During reversing the acoustic Travel Alarm is automatically switched on.

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OPERATOR’S MANUAL EW 160 Fastening the retaining belt 2904035

Parking the machine Machines parked on sloping terrain may move inadvertently.

The machine must therefore be parked on level and horizontal ground, lower the working equipment and all stabilizers to the ground.

Information on the engine At low temperatures, the engine starts up with the "WARMUP" phase.

Only when this phase is completed may the engine be fully loaded.

Long-distance driving Before driving long distances: - Lift working equipment, but only so far that obstacles on or above the ground are avoided.

- lock the superstructure, - apply the superstructure holding brake and - install the transport safety devices.

The machine is then in its basic position.

Before driving on public roads: Observe your national road traffic regulations before driving on public roads.

Check the belt and its fasteners regularly.

If the belt or its fasteners are damaged or if parts are missing, have them repaired or replaced immediately.

Belts damaged or overstrained in an accident must be replaced.

The inlet opening of the belt lock must not be obstructed, for instance, by paper, since the locking tongue will otherwise not engage in the lock.

Do not run the belt over solid or fragile objects such as bunches of keys or spectacles to prevent injuries to the body in the event of an accident.

The driver’s seat is equipped with a lap belt (Fig. 1).

Always put on the retaining belt before setting off.

Attaching the retaining belt • Introduce the locking tongue (1, Fig. 1) into the belt lock (2). Check for proper locking by pulling the belt at the locking tongue.

• Adjust the length of the belt so that it runs flat and firm over the body. The belt must not be jamming or twisted.

Detaching the retaining belt • Lift the flap of the belt lock (2) and pull out the locking tongue (1).

Fig. 1

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OPERATOR’S MANUAL EW 160 Braking system

1946490

Applying the service brake Four multiple-disk brakes installed in the wheel hubs form the service brake. The brake is hydraulically actuated.

The hydraulic accumulators of the service brake are subject to continuous monitoring. If the pressure falls below a set minimum pressure, the warning lamp (6, Fig. 2) in the console lights up and the buzzer sound continuously. (The buzzer is switched off if the parking brake is applied in this situation).

If the warning lamp (6) lights up during operation: - stop the machine immediately, - apply the parking brake and - secure the machine.

Fig. 1

Do not start the machine up again until the fault has been rectified.

• To brake the machine, depress the pedal (63, Fig. 1).

• During working operation the service brake can be blocked in braked position by depressing the pedal (63). The pedal is locked in depressed position by the locking lever (arrow, Fig. 3).

The swing axle is blocked simultaneously (irrespective of the position of the rocker switch for blocking the swing axle).

Fig. 2

• To release the service brake, depress the locking lever to the left of the pedal (63). This releases the pedal and thus the brake.

This releases at the same time the blocking of the swing axle if it has not been blocked beforehand with the respective rocker switch (52) (see: "Blocking the swing axle").

Fig. 3

Under certain circumstances, this condition may endanger the stability of the machine, for instance, when the machine is to be driven after a load has been lifted with the superstructure out of basic position.

In these cases see: "Driving with a load on the hook".

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OPERATOR’S MANUAL EW 160 Applying the parking brake

2796512

Do not apply the parking brake unless the machine is stationary.

Only in an emergency may the parking brake be applied when the machine is moving, e.g. if the service brake fails.

The braking action is then abrupt.

A disk assembly is installed in the travel gearbox.

It is blocked by spring pressure when the parking brake is applied.

Applying the parking brake

Fig. 4

• The parking brake is actuated with the rocker switch (44, Fig. 4) by depressing the switch surface with the locking bar. The rocker switch is then locked against inadvertent actuation.

The pilot lamp (42, Fig. 5) lights up.

The swing axle is blocked simultaneously (irrespective of the position of the rocker switch for blocking the swing axle).

The direction indicator switch (61, Fig. 4) now has no function. This prevents the machine being driven against the applied parking brake.

Releasing the parking brake • Unlock rocker switch (44, Fig. 4) by pushing locking bar in direction indicated by arrow.

Fig. 5

• Then depress switch surface with symbol. The parking brake is now released, the pilot lamp (42, Fig. 5) goes out.

This releases at the same time the blocking of the swing axle if it has not been blocked beforehand with the respective rocker switch (52) (see: "Blocking the swing axle").

Under certain circumstances, this condition may endanger the stability of the machine, for instance, when the machine is to be driven after a load has been lifted with the superstructure out of basic position.

In these cases see: "Driving with a load on the hook".

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OPERATOR’S MANUAL EW 160 Travel gear selection

1946491

Depending on the required travelling speed, two gears can be selected in the travel gearbox: 1st gear for slow travel, e.g. off the road.

(LED above button 27 lights up) 2nd gear for travel on the public highway.

(LED above button 27 does not light up) The display shows the selected gear (1st (1.G) or 2nd (2.G), Fig. 6) as soon as the accelerator is depressed.

The powershift transmission can be shifted with key (27, Fig. 7).

The following situations must be taken into account:

Fig. 6

Machine stationary or rolling at a speed of less than 1 km/h, "Travel" pedal not depressed: The transmission can be shifted from 1st into 2nd gear and also from 2nd gear back into 1st gear Machine accelerating, "Travel" pedal depressed: • When the speed is below 3 km/h, the transmission can be shifted from 1st into 2nd gear • When the speed is above 3 km/h, the shifting instruction is stored by the central electronic control for the 2nd gear. Transmission shifting occurs, however, only after the speed has dropped to below 3 km/h

Fig. 7

Machine braking, "Travel" pedal depressed: When the speed is above 1 km/h, the shifting instruction is stored by the central electronic control for the 1st gear. Transmission shifting occurs, however, only after the speed has dropped to below 1 km/h and when the "Travel" pedal is not depressed.

Important: The transmission cannot be shifted when the machine is travelling faster than 3 km/h in 1st or 2nd gear and when the "Travel" pedal is not depressed.

The creep speed range can be activated at any time with steering column lever (61), actvate only when the machine is stationary.

68

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OPERATOR’S MANUAL EW 160 Adjustment of steering column 2281250

Steering column - Safety instructions

Risk of accidents Do not adjust the steering column while driving. Concentrate on the road to avoid accidents.

Before adjusting the steering column: - Stop the machine - Set travel selector lever to "0" - Apply parking brake.

Adjusting the steering column

2716627

Read and observe: "Steering column Safety instructions".

The angle of the steering column can be adjusted to suit the height and posture of the operator: - Press lever (79, Fig. 8) with toe cap towards front screen and keep in position to unlock steering column.

- Tilt steering column into required position.

- Release lever (79) to lock steering column.

- Check that steering column is locked.

Fig. 8

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OPERATOR’S MANUAL EW 160 First-aid kit

2472199

Fire-extinguisher

2472216

Fig. 9

Fig. 10

The first-aid kit can be stowed away in the compartment behind the driver’s seat (Fig. 9).

The fire-extinguisher can be stowed away in the tool-kit box (Fig. 10).

Check the contents of the first-aid kit and replace removed or unusable material regularly.

Have the fire-extinguisher checked at the prescribed intervals by authorized testing institutions.

Warning triangle The warning triangle can be stowed away in the compartment behind the driver’s seat (Fig. 9) or in the tool-box (Fig. 10).

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OPERATOR’S MANUAL EW 160 Blocking the swing axle

2904835

The steering axle is suspended on the undercarriage in such a way that it can swing transversely to the longitudinal axle of the machine (swing axle). This is advantageous when driving over uneven terrain. When working however, this swinging motion has to be prevented by disabling the oil exchange between two hydraulic cylinders which are supported on the axle. This blocks the swing axle so that the stability of the machine is substantially increased.

Before travelling again with the machine, the swing axle must be released again (exception: see "Driving with a load on the hook").

Blocking the swing axle • Switch rocker switch (52, Fig. 11) downwards; the surface with the symbol is pressed down.

Releasing the swing axle • Switch rocker switch (52) upwards; the surface with no symbol is pressed down.

Important: If the swing axle is released (rocker switch (52) surface without symbol pressed down), the swing axle is automatically blocked when the parking brake is applied or when the service brake is blocked.

The swing axle is automatically released again when the parking brake or the service brake is released.

Bringing the machine into its basic position

2801585

Read and observe the chapter: "Driving - safety instructions".

The machine is in its basic position when the driver’s cab (1, Fig. 12) is over the left pair of wheels of the steering axle (2).

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

If the superstructure is turned by more than 90o from its basic position (Fig. 13), the excavator travels in the opposite direction to that selected.

If the position of the superstructure in relation to the undercarriage is not exactly known, touch the accelerator lightly to see which direction the machine takes before initiating the full driving operation.

Fig. 12

Fig. 11

Fig. 13

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OPERATOR’S MANUAL EW 160 Travelling

1946493

Fig. 14

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OPERATOR’S MANUAL EW 160 Driving on and off the road

Braking and stopping

2801394

The numbers in the text refer to the diagram on the opposite page.

Read and observe: "Driving - Safety instructions".

Observe your national road traffic regulations before driving on public roads.

The numbers in the text refer to the diagram on the opposite page.

• Lift bullgrader and claws as high as possible.

• Before longer journeys: - Lock superstructure with bolt (68).

- Apply superstructure retaining brake by pressing button (28) until LED I lights up.

• Switch off hydraulic servo control with rocker switch (43) by pressing down switch surface STOP. • Select gear with button (27): (cf.: "Travel gear selection").

- LED not lit up = 2nd gear, travel on roads - LED I lit up = 1st gear, travel off road

• Release accelerator pedal (64).

• Apply service brake pedal (63) until machine stops.

• Turn engine speed potentiometer (45) clockwise to the limit stop; the engine is brought to idling speed.

• Switch steering column switch (61) to neutral position.

If travelling is not to be continued after stopping, secure the machine against inadvertent movement: • Park machine on level surfaces only; set working equipment and stabilizers down on the ground.

• Apply parking brake with rocker switch (44) by pressing down switch surface with locking bar.

The switch is now secured against inadvertent actuation.

• Shut off engine.

• Select direction of travel with steering column switch (61): - Switch forward = forwards - Switch back = reverse (If an exceptionally low travel speed is required, switch steering column switch downwards = crawling speed ON. Switch only, when the machine is stationary.)

• Release parking brake by unlocking rocker switch (44) and pressing switch surface with symbol.

(The blocking of the swing axle is released simultaneously, the selected direction of travel is enabled) • Release blocking of service brake by depressing locking lever to left of pedal (63); release pedal gradually.

• Press accelerator pedal (64) to start machine movement.

Regulate travelling speed with accelerator pedal (64).

Engine speed and hydraulic output are increased in 2nd gear.

The display (3) shows the selected gear (1.G or 2. G) and the travel speed when it is higher than 2 km/h.

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OPERATOR’S MANUAL EW 160 Driving on slopes and gradients

During long drives on steep downhill slopes with high speeds the driver may lose control over the machine and not be able to stop the machine anymore. Therefore, - do not drive on slopes with a gradient of more than 30˚. Look for another less steep route (Fig. 2).

- Never drive downhill for a long time with the foot permanently on the service brake. This may lead to extreme wearing of the braking disks and in the worst case to complete failure of the service brake.

- To prevent the driving speed from getting too high, shift the steering wheel lever down to the "creep speed" position before reaching the slope (Fig. 1).

2904034

Fig. 1

Read and observe the section "Driving Safety instructions".

• Drive the machine only in basic position and forwards. In this case, the steering wheel is above the steered axle.

• Do not drive across slopes and do not turn on the slope to prevent the machine from toppling over.

Fig. 2

• Always shift into lower gear before reaching the slope / gradient.

For downhill drives, always select the same gear as you would for driving up the hill.

This increases the braking action of the drive engine and prevents inadmissibly high driving speeds.

• Bring the engine to maximum speed.

Control the driving speed with the travel pedal (64).

74

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OPERATOR’S MANUAL EW 160 Driving with a load on the hook

2904161

Read and observe "Driving - Safety instructions".

• Swing load into direction of travel.

• Keep load as close as possible to the ground and to the machine.

• Lock superstructure.

• Apply superstructure retaining brake.

• Release swing axle blocking with rocker switch (52, Fig. 1). (The switch surface with the symbol is up).

Fig. 1

• Drive slowly and carefully.

When driving on smooth ground and with the superstructure swung:

Avoid this situation whenever possible.

The stability of the machine is reduced.

• Block swing axle with rocker switch (52). (The switch surface with the symbol is pressed down).

The swing axle is then blocked without the parking brake being affected.

• After completing the journey and setting down the load: Release blocking of swing axle.

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OPERATOR’S MANUAL EW 160 Recovery and towing - Safety instructions

2904037

Recovering / towing the machine

2796531

Tow the machine with a tow rod or tow cable only.

Observe the valid accident prevention regulations.

The tow rod or cable must not be damaged. Their dimensioning must ensure that their theoretical breaking load is equal to three times the tractive power of the towing machine.

Read and observe "Recovery and towing Safety instructions".

The towing vehicle must have adequate tractive power.

Drive slowly and carefully.

• Connect a tow rod to the traction vehicle and to the towing lug (Fig. 1).

All persons must keep clear of the tow rod or cable.

Tow away only if the braking and steering systems of the machine are working and the machine cannot be transported in any other way.

Tow non-functioning machines only as far as necessary for recovery from hazard zones.

After recovery, secure the machine against inadvertent movements and unauthorized starting.

For long-distance machine transport, repair the machine or load it onto a transport vehicle.

The machine is not suited for the towing of trailers or other vehicles over greater distances. Towing over greater distances would result in damage to axles and gearboxes. The coupling (see picture) is intended for recovering or towing the machine out of the hazard range after an accident or for attaching the fixing ropes on transport vehicles. See "Recovering and towing the machine".

Fig. 1

• Disconnect drive at travel gearbox by turning hex (Fig. 2) clockwise or counter-clockwise by ca. 180 degrees until the built-in indexing ball is felt to engage.

The connection between travel gearbox and axles is now disconnected.

Fig. 2

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OPERATOR’S MANUAL EW 160 Releasing the parking brake with the 2801565 emergency unlocking device

Fig. 3

• Release parking brake with rocker switch (44, Fig. 3).

• Switch steering column switch (61) to neutral position.

During recovery / towing • Keep all persons well clear of the hazard zone.

• Drive slowly and carefully.

• When the drive motor is running: the service brake is fully functional.

• When the drive motor is not running: the service brake is not fully functional.

The legal requirements are fulfilled: When the braking pressure accumulators are filled, eight braking actions can be performed until the machine is stationary even when the engine is not running.

Secure the machine against inadvertent movements before working under the machine to release the parking brake with the emergency unlocking device: - press the bucket into the ground, shut off the engine, - prevent others from putting the machine into operation: Attach a sign with the following warning: "Do not use the machine, brake is out of order" to the machine.

- lock up the driver’s cab, block the wheels with chocks.

After the following steps, the parking brake is inactivated and can no longer be used.

To avoid risks and dangers, the emergency unlocking device is to be used only in exceptional cases when the applied parking brake has to be released.

Have any faults of the parking brake rectified immediately.

The servo pressure required for releasing the parking brake is routed to the brake via a solenoid valve. In the event of solenoid valve malfunctions or electrical power supply failure, the parking brake can be released with the emergency unlocking device. The solenoid valve is located in the chassis frame above the travel gearbox (Fig. 4).

After recovery / towing • Secure machine against inadvertent movement by - setting working equipment down on the ground, - pressing trencher bucket into the ground.

• Secure machine against unauthorized starting.

• Connect drive at travel gearbox by turning hex (Fig. 2) clockwise or counter-clockwise by ca.

180 degrees until the built-in indexing ball is felt to engage.

The connection between travel gearbox and axles is now reconnected.

Fig. 4

• Turn grub screw (1) fully down using an Allan key size SW 3. The parking brake is now released.

• Turn grub screw completely back out when the fault has been rectified.

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OPERATOR’S MANUAL EW 160 Transporting of the machine Transport - Safety instructions

The machine must only be transported and loaded if all safety regulations are complied with.

Entrust loading and transporting of the machine only to a company experienced in the transport of heavy equipment.

The responsibility for loading and transporting lies with the transport company or their representative.

Remove oil, grease, soil, mud, snow, ice and other materials from the machine’s wheels and from ramps and loading platforms of the transport vehicle to minimize slipping.

Secure transport vehicle against inadvertent movements.

2801586

For transport on public roads apply to the competent traffic authority for a transport permit.

In case of rail transport, arrange for loading and transport of the excavator with the competent railway authority to obtain a corresponding approval.

Depending on the size of the low-bed trailer or railway waggon, the working equipment must be partially or completely detached. Dimensions and weights for loading are set out in the "Technical data".

Drive the machine carefully onto the transport vehicle.

Have a marshaller assist you in this operation.

Secure the machine against unintentional movements (Fig. 1):

Use only tying equipment of sufficient strength (the weights of the machine are set out in the "Technical data").

Fig. 1

• Apply parking brake with rocker switch (44, Fig. 2).

• Block service brake (63).

• Lock superstructure with bolt (68).

• Stand working equipment on the loading platform of the transport vehicle.

• Switch off pilot control with lever (77).

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OPERATOR’S MANUAL EW 160 Driving in case of PCS failure

2732724

Read and observe the section on "Driving - Safety instructions".

If the engine speed drops suddenly during working or during travelling (engine choking) or if the engine even stalls, the cause may be a fault in the electronic module of the PCS (load limit regulator GLR).

Fig. 2

In case of PCS malfunctions, the display shows a fault code (see "fault codes table").

• Shut off engine.

The superstructure holding brake is now automatically applied.

• Withdraw key from key-switch.

The measures to be taken in case of a PCS failure (load limit regulator module) are described in the section "Working operation in case of PCS failure".

• Close doors and windows.

• Tie down the machine safety placing the tying chains or cables at the marked positions (Fig. 3) at the towing lug and dozerblade/stabilizer crossbeam.

After travel operation

2486236

If machine operation is to be ended, proceed according to section "Shutting off the machine".

Never place tying chains or cables over steering cylinder and braking or hydraulic lines.

Fig. 3

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OPERATOR’S MANUAL EW 160 WORKING OPERATION Working operation - Safety instructions

2281256

Before starting work

Contact with overhead power lines

Read and observe the sections "Fundamental safety instructions" and "Operation - Safety instructions"

Make sure the clearance between working equipment and overhead power lines and other structures is sufficient.

Inspect the site for underground gas, power and water lines before starting work.

If a power line has been contacted, drive the machine out of the hazard zone or lower the working equipment. If this is not possible: - Do not leave the driver’s cab - Inform persons outside the hazard zone to keep away from the machine and to take the necessary steps to have the power line shut off.

Any damage to such lines is a risk to life.

Clean off any earth, mud, snow, ice, grease and oil adhering to your working footwear before operating the machine.

There is otherwise a risk of slipping off the pedals and steps and initiating inadvertent movements.

Warn persons in the immediate vicinity by sounding the horn before starting work.

Work with the machine only in its basic position and when it is standing on level and - if possible - horizontal ground.

There is otherwise a risk of affecting the machine’s working stability.

Bear the load capacity of the machine in mind (cf. "Technical data").

Persons in the machine’s hazard range

Notes on engine operation At low temperatures, bring the engine to medium speed, then activate all hydraulic functions for abt. 10 minutes (bring to service temperature). For further instructions, see section "Lubricants".

Lower the working equipment and shut off the engine as soon as the warning lamps for engine operation or filter monitoring light up with the hydraulic oil being at service temperature.

Stop work if anyone is in the hazard range of the machine.

Make sure such persons have left the hazard range before resuming work.

Trenches and building pits Trenches and building pits may give way.

Keep well clear of them.

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OPERATOR’S MANUAL EW 160 Extreme positioning of working equipment - Instructions

Before beginning work 2411342

Parts of the working equipment may damage the machine if moved into extreme positions (see Fig. 1).

Work with due care and attention, avoiding such extreme positions.

Fig. 1

2472205

Read and observe the section "Working operation - Safety instructions".

Before daily operation carry out all works in accordance with servicing plan T (cf. Part 3 "Inspection and servicing").

Fig. 2

• Sit down on the driver’s seat.

• Start the engine as described.

Set the speed of the warm engine with potentiometer (45, Fig. 2) to the maximum number of revolutions.

Depending on the type of work executed, the speed may also be reduced.

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OPERATOR’S MANUAL EW 160 Switching on floodlamps

2800854

Switching on the floodlamps The floodlamp on the boom is supplied with power via the plug and the external socket outlet (Fig. 3) at the righthand wall of the cab.

• Press button (30, Fig. 4) once; LED 1 lights up.

The floodlamp on the working equipment is switched on.

• Press button (30) twice; LEDs 1 and 2 light up.

The floodlamps on the working equipment and the supplementary floodlamps (option) are switched on.

Switching off floodlamps

Fig. 3

• Press button (30) until LEDs are no longer lit up; the floodlamps are switched off.

The function for LED 3 is not assigned in this machine.

Fig. 4

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OPERATOR’S MANUAL EW 160 Speed reset function

2801398

Never activate the speed reset function while using lifting gear or travelling.

This might result in unpredictable fluctuations in output.

The speed reset function (Auto Idle) automatically activates two different stages: First stage: The engine speed is automatically reduced during load-free working phases (by 100 - 200 min-1, depending on the set PCS power stage).

Fig. 5

Second stage: The engine is set to idling speed if the working equipment is not used for more than 4 seconds.

This reduces fuel consumption as well as noise and exhaust emissions.

(This period, which is set at the factory, can be changed. However, this requires a specially equipped test unit.

So consult your NEW HOLLAND CONSTRUCTION dealer-service if the period is to be changed).

If the operator activates a hydraulic function, the engine is brought back to the previously set speed.

The switch position of the Auto Idle function (ON / OFF) is stored when the engine is shut off.

Activating the speed reset function • Press button (22, Fig. 5); LED I lights up.

Deactivating the speed reset function • Press button (22); the LED goes out.

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OPERATOR’S MANUAL EW 160 Selecting the PCS output stage

2904438

• Select output stage with button (20, Fig. 6): LED above H (HEAVY) lights up = 100 % maximum motor speed and pump output.

LED above E (ECONOMIC) lights up = 90 % reduced motor speed and pump output for work in the economic range of the motor. Slightly lower working speed.

LED above L (LIFT) lights up = 65 % further reduced motor speed and pump output for exceptionally sensitive operations, e.g. for operations with lifting gear.

The set power stage is shown in addition in the display.

Fig. 6

After machine start-up the PCS switches to the stage that was active during the preceding engine shut-off.

(Exception: warming-up phase) The PCS controls the hydraulic pumps depending on the required output.

84

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OPERATOR’S MANUAL EW 160 Activating the servo control

Switching off the pilot control

2796535

2796534

• Move lever (77, Fig. 7) to position I , while pressing the left control console down until it engages in the lower position.

The hydraulic servo control is then activated; the control levers (70 and 78, Fig. 8) and pedal (84, option) are fully functional.

Before leaving the driver’s seat set lever (77, Fig. 9) to position "0" to prevent working functions, such as swinging of the superstructure, from being inadvertently activated by touching one of the control levers or pedals.

• Set lever (77, Fig. 9) to position 0. The lefthand control console swings upwards and the hydraulic pilot control is off.

Before driving off, the servo control must be deactivated with rocker switch (43). The left control console then remains in the lower position (see: "Travelling").

Fig. 7

Fig. 9

Fig. 8

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OPERATOR’S MANUAL EW 160 Swinging and braking the superstructure

2801399

Locking the superstructure

Swinging the superstructure

• Bring machine to basic position.

• Switch retaining brake of superstructure to Automatic operation by pressing button (28, Fig. 11) repeatedly until LED A lights up (This mode is activated automatically when the engine is started; cf.: "Applying / releasing the superstructure retaining brake").

The bolt (68, Fig. 10) is then located above a cutout in the undercarriage.

• Lift bolt (68), turn away from seat and press downwards.

The bolt engages in the cutout in the undercarriage.

If the bolt can be moved only with difficulty or not at all, swing the superstructure carefully clockwise or counter-clockwise while pressing the bolt downwards.

Unlocking the superstructure • Pull bolt (68, Fig. 10) up. Turn towards seat and engage.

If the bolt can be moved only with difficulty or not at all, swing the superstructure carefully clockwise or counter-clockwise while pulling the bolt upwards.

• Activate servo control with lever (77, Fig. 12).

• Unlock the superstructure (68, Fig. 10).

• Swinging the superstructure clockwise: - Press control lever (78, Fig. 12) to the right • Swinging the superstructure counter-clockwise: - Press control lever (78) to the left The swing speed increases the further the control lever is moved to the right or left.

Fig. 11

Fig. 10

Fig. 12

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OPERATOR’S MANUAL EW 160 Braking the superstructure The swing movement of the superstructure is braked when the swing control lever (78, Fig. 12) returns to position 0.

Adjustable swing brake valves determine the delay in braking. The period from the releasing of the swing control lever until the superstructure is stationary can thus be adapted to meet individual requirements.

Consult your NEW HOLLAND CONSTRUCTION dealer-service.

The braking action is reinforced by countering (i.e. by pressing the swing control lever in the opposite direction).

Swinging - changing the mode of operation

2800880

The swinging drive can be switched between two different modes of operation with key (26, Fig. 13).

Changing the mode has an effect on the "boom lift" function.

- LED I above key (26) on = normal hydraulic power for swinging movements.

At the same time, more hydraulic power is available for the "boom lift" function.

This mode of operation should be selected whenever there is only a small amount of swinging to be performed during the work.

- LED I above key (26) off = increased hydraulic power available for swing movements. There is no influence on working equipment functions.

Fig. 13

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OPERATOR’S MANUAL EW 160 Superstructure retaining brake function

2800866

A multi-disc brake is fitted in the swing gear. It is applied by spring pressure and released by hydraulic pilot control pressure.

The retaining brake is not applied until the swing control lever is in 0 position and the swing motion of the superstructure is terminated. Therefore it cannot be used to brake the swing movement.

With the keyswitch in the OFF position, the engine stationary or in case of machine voltage failure, the superstructure holding brake is applied. and the superstructure is braked.

Applying the superstructure retaining 2732896 brake The superstructure retaining brake can be used in three modes of operation: • Key (28, Fig. 15) not depressed, LEDs extinguished: holding brake released, superstructure free to swing.

• Key (28) depressed once, LED I lit up: holding brake applied, superstructure braked.

The pilot lamp (41, Fig. 16) lights up.

• Key (28, Fig. 15) depressed twice, LED A lit up: automatic mode, the holding brake is being applied automatically when the superstructure is stationary and released when a swing movement is initiated. This mode is activated automatically when the engine is started.

The pilot lamp (41, Fig. 16) lights up if the superstructure holding brake is aplied for longer than 10 seconds.

Fig. 14

Fig. 15

Fig. 16

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OPERATOR’S MANUAL EW 160 Releasing the superstructure retaining brake • Depress key (28, Fig. 15) until the LEDs above the key are extinguished. The holding brake is released and the superstructure is free to swing.

In the "Automatic" mode of operation with LED A lit up, the holding brake is released as soon as the swing control lever is deflected.

This mode is activated automatically when the engine is started.

Superstructure holding brake emergency operation

2904409

The superstructure may be swung freely if the superstructure holding brake is released using emergency operation!

Then the superstructure is not braked automatically after a swing movement.

When working on a slope or if the machine is in a sloping position the superstructure can continue swing independently if the swing movement is not countered.

To avoid dangerous situations, emergency operation should only be used in exceptional circumstances.

Rectify superstructure holding brake malfunctions immediately (or have them rectified).

The pilot control pressure to release the superstructure holding brake is controlled by a solenoid valve.

If a malfunction occurs at the solenoid valve the superstructure holding brake can be released using emergency operation.

The solenoid valve is attached in the frame behind the driver’s cab (Fig. 17).

• Turn grub screw (Fig. 17) fully down using an Allan key size SW 3. The superstructure holding brake is released, the superstructure swings freely.

• Rectify solenoid valve malfunctions immediately (or have them rectified).

• Turn grub screw completely back out when the fault has been rectified.

Fig. 17

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OPERATOR’S MANUAL EW 160 Machine in working position

2801587

• Bring machine to basic position.

This is the best position for working as it provides the greatest stability.

• Stop the machine.

• Apply parking brake with rocker switch (44, Fig. 18) by pressing down the switch surface with the locking bar.

• Block service brake by depressing pedal (63).

The pedal is locked in depressed position.

• Extend the stabilizers.

The machine can be equipped with various stabilizers (options). Instructions are given on the next page.

Fig. 19

Fig. 18

Fig. 20

Before moving the machine: - Lift all stabilizers.

- Release parking brake with rocker switch (44) by pushing the locking bar in the direction indicated by the arrow and pressing the switch surface with the symbol.

- Release the blocking of the service brake by depressing the locking lever at the left side of the pedal (63). Release the pedal slowly.

Fig. 21

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OPERATOR’S MANUAL EW 160 Stabilization of the machine

2801513

Bring control lever (78, Fig. 20) to 0 position. With left button of momentary-contact rocker (80, Fig. 19) switch over to "Stabilizers / levelling blade" function. The buzzer sounds intermittently as long as the function is activated.

Stabilizing elements

Stabilizer feet

Levelling blade Lowering: push control lever (78, Fig. 20) forwards

Raising: pull control lever (78) backwards

PLA Lowering: push control lever (78) forwards

Raising: pull control lever (78) backwards

A2 Lowering: switch rocker switch (55, Fig. 21) symbol side down push control lever (78, Fig. 20) forwards

Lowering: switch rocker switch (55, Fig. 21) symbol side up push control lever (78, Fig. 20) forwards

Raising: switch rocker switch (55, Fig. 21) symbol side down push control lever (78, Fig. 20) backwards

Raising: switch rocker switch (55, Fig. 21) symbol side up push control lever (78, Fig. 20) backwards

PLA / A2 Select right/left stabilizer feet (optional equipment): Left foot: - switch rocker switch (55) symbol side down Right foot: - switch rocker switches (55) and (56) symbol side down

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OPERATOR’S MANUAL EW 160 Working with backhoe or grab equipment (SAE-control)

2904840

Fig. 22

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OPERATOR’S MANUAL EW 160 Extending and retracting the stick Before starting work Read and observe: "Working operation Safety instructions".

Persons in the hazard zone Stop work if there are any persons in the hazard zone. Warn them with the hooter.

Do not continue work until all persons are well clear of the hazard zone.

At first, switch over to the "stick" function by actuating the lefthand contact of the rocker switch (80).

• To extend the stick - push control lever (78) forwards.

• To retract the stick - pull control lever (78) backwards.

Filling and emptying the bucket • To fill the bucket - push control lever (70) to the left.

If levelling work is to be carried out with the machine, the equipment must be used in the direction of digging only.

Never use the excavating tool for "sweeping or beating" (e.g. during demolition work).

The working equipment is not designed to withstand great forces acting from the side. Such forces would damage the equipment.

• To empty the bucket - push control lever (70) to the right.

Opening and closing the grab (optional equipment) • To open the grab - push control lever (70) to the right.

• To close the grab - push control lever (70) to the left.

All control levers and pedals for the working functions return automatically to 0 position on being released.

Turning the grab

Before starting work:

• To turn the grab to the right

- Block service brake by depressing pedal (63).

The pedal is locked in depressed position.

- Activate pilot control with lever (77, Fig. 22).

Slewing superstructure • Slewing superstructure to right - push control lever (78) to the right.

• Slewing superstructure to left

(optional equipment)

- press rocker switch (69) in control lever (70) to the right.

• To turn grab to the left - press rocker switch (69) in control lever (70) to the left.

Activate the Power Assist function • Depress key (21) in the control panel. (cf. "Power Assist, function").

- push control lever (78) to the left.

Activate the Power Boost function Raising and lowering the boom • To raise the boom - pull control lever (70) backwards.

• To lower the boom - push control lever (70) forwards.

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• Depress key (65) in the control lever (70). (cf. "Power Boost, function")

Activate the horn • Depress key (66) in the control lever (70).

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OPERATOR’S MANUAL EW 160 Power assist, function

2800299

Activation of the power assist function increases the hydraulic pressure for the working functions and the travel drive. The engine runs at the speed programmed for the PCS power stage LIFT. This means increased - lifting force, - tearing force, - breaking force, - traction force and - more sensible control operation Fig. 23

at reduced working speed (cf. "Technical data").

Switching the power assist on • depress key (21, Fig. 23) once, LED I lit up.

Switching the power assist off • depress key (21) a second time, the LED is extinguished.

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OPERATOR’S MANUAL EW 160 Power Boost, function

2800298

Do not switch on the "Power Boost" function for lifting and driving operations.

Risk of unexpected and sudden losses of power.

Activation of the "Power Boost" function increases the engine speed and hydraulic pressure (PCS power stage HEAVY). This function can be used if maximum power and speed and required briefly for a working movement (e.g. increased breakaway force). The activation time is limited to ca. 8 seconds.

Fig. 24

This function is only active - if the ECO or HEAVY modes are selected and - if the ON time has not been exceeded.

Switching the Power Boost function on • Depress key (65, Fig. 24).

The increased hydraulic power is available for a period of approximately 8 seconds. Thereafter the PCS switches back to the economic range.

To use the function once again, release key (65) and press again.

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OPERATOR’S MANUAL EW 160 Operating methods

2801516

Read and observe the section: "Working operation - Safety instructions".

• Use arm pull action often. When digging, use the arm pulling force and operate the bucket using shallow teeth cuts.

Deep teeth cuts will decrease efficiency (Fig. 1).

• Point the bucket teeth in the direction of digging. This will decrease digging resistance and possible damage to the teeth (Fig. 3).

Fig. 1

Fig. 3

• Operate boom smoothly. When moving the boom up and down, begin and end the operation very slowly and smoothly. When the boom is stopped suddenly, strong shocks are exerted upon the machine body, causing excessive wear and possible damage (Fig. 2).

• Maximum digging force is obtained with 90˚ ~110˚ angles. When maximum digging force is needed, dig earth slowly having the boom and the arm at nearly 90˚ ~110˚ (Fig. 4).

Fig. 2

Fig. 4

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OPERATOR’S MANUAL EW 160 • How to shake off sand and soil on the bucket.

Push the arm to near level position and bring the bucket to a dumping position. If sand and soil do not fall out, move the bucket lever back and forth a few times. Avoid shaking out soil using shocks at the end of the bucket cylinder stroke (Fig. 5).

Fig. 7

• Land leveling work. For back filling and leveling work after digging, move the bucket back and forth horizontally (Fig. 7).

Fig. 5

• Stop swing motion early. To stop swing action, release the swing lever before you get to your final point of digging or dumping (Fig. 6). (cf.: "Swinging and braking the superstructure")

Do not push and pull earth by the bucket like a bulldozer, while the machine is leveling earth, off. Use the levelling blade.

In leveling ground toward yourself, pull the arm gently, lift the boom a little and when the arm has passed the vertical point, lower the boom gently and manipulate the machine so the bucket moves horizontally.

For leveling ground away from yourself, reverse the steps described above.

In the above operation, bucket motion may be used together. By controlling the action of the boom work lever, you can dig a slope like slope facing operation.

Never travel with attachment touching the ground. Severe structural damage could occur.

Fig. 6

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OPERATOR’S MANUAL EW 160 Working operation in case of PCS failure

2801515

If the engine speed drops abruptly during working or during driving (engine choking) or if the engine even stalls, a failure of the electronic system of the PCS (load limit regulator module) may be the cause. In the event of PCS malfunctions, the display shows a fault code (cf. "Fault code table") and the buzzer sounds.

Switching the proportional valve over to emergency operation

If it is not possible to rectify the fault on site, the proportional valve can be switched over to emergency operation.

• Carry out the following work on the proportional valve:

In such case, working or driving can be carried on at reduced speed.

The proportional valve (1, Fig. 1) is installed in the frame behind the driver’s cab.

• Unscrew the cover plate below the frame.

- Turn out the fixing screw of the electrical connector.

- Withdraw connector.

- Remove protective cap over adjusting screw.

- Slacken counter-nut (2).

- Retract stick cylinder to the limit stop and hold.

- Turn in adjusting screw (3) until swinging is possible without the engine being choked.

Have the PCS checked and re-adjusted by the NEW HOLLAND CONSTRUCTION dealer Service.

Fig. 1

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OPERATOR’S MANUAL EW 160 After daily operation

2801563

Shutting off the machine • Park machine on level and firm ground.

• Place chocks under the wheels.

• Lock superstructure.

• Clean off gross dirt adhering to the machine.

• Stand working equipment on the ground.

• Fill up fuel tank.

• Apply parking brake.

• Inspect the machine visually for leaks in the hydraulic system, axles and gearboxes.

Never shut off the engine out of full load, but continue running for ca. three - five minutes at idling speed to cool down.

Escaping oil constitutes a risk to the environment.

• Shut off engine.

Repair leaks immediately (or have them repaired).

• Turn key switch to position I (Ignition ON).

Report oil accidents to the user of the machine.

• Move both control levers to all directions to depressurize the hydraulic cylinders.

• Shut off pilot control.

• Withdraw key from key switch of electrical system.

• Check superstructure, under-carriage and working equipment for damage and all steel components for cracks and fractures.

Report any damage detected immediately to the user of the machine.

• Close cab windows.

• Switch the battery main switch off and withdraw the key lever.

• Lock cab door and all lockable trap doors and covers of the machine.

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OPERATOR’S MANUAL EW 160 WORKING EQUIPMENT Assembling working equipment - safety instructions

2801353

Personnel

Tools and auxiliaries

Assembly work may be carried out only by operating or maintenance personnel who have the necessary know-how at their disposal.

Tools, hoists, slings, chocks and other devices must be in a reliable, safe state.

If such know-how is lacking, meticulous instruction must be given by experienced personnel, e.g. from NEW HOLLAND CONSTRUCTION. The operating manual, and in particular the section headed "Fundamental Safety Instructions", must have been read and understood.

Only such persons may start up the machine during assembly work in order to adjust the attachments.

Incorrect operation of the machine or the attachments may give rise to life-threatening situations.

Personal protective gear and working clothing Wear closely fitting working clothing when working on the machine. Loose, wide garments may catch on machine parts and result in injury.

Wear a safety helmet, safety footwear and gloves.

Metal spinters may cause injury when accessory bolts are being driven in or out. A brass or copper mandrel should therefore be used for this purpose, and goggles must be worn.

Use steps and handrails when climbing onto or off the machine.

Always keep steps and platforms in a non-slip state. Remove any oil, grease, earth, clay, snow, ice and other foreign matter immediately.

Securing working equipment Stand working equipment on the ground in such a way that no movements can be made if mechanical or hydraulic connections become detached.

When working in jointed areas, block off the joints. Remove the blocks on finishing work.

Secure any equipment or component which is to be mounted or dismantled, or whose position is to be changed, with hoists or appropriate slinging/supporting devices to prevent them from moving, slipping or falling inadvertently.

Securing the machine Carry out work on the attachment only if the machine is secured as decribed in the section "Securing the Machine".

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OPERATOR’S MANUAL EW 160 Securing the machine

2904441

Selecting the attachments

Risk of injury

The machine can be equipped with various attachments. The components of the attachments are assembled with hydraulic cylinders and connectors. Components can be combined in various ways for optimum adaptation of the attachments to the specific application.

The machine must not be started by unauthorized persons.

Operate the machine only with the equipment and component combinations expressly approved by NEW HOLLAND CONSTRUCTION.

Therefore, the machine must be secured.

The machine must be secured as described below: - before fitting or changing the working equipment, and - before carrying out any servicing or repair work on the machine.

• Park machine on level and firm ground.

• Lock superstructure.

Protective roof against falling objects 2801518

If the machine is used in areas where there is a risk of heavy objects falling, e.g. for - work on earth or rock faces, - demolition or forestry work, it must be equipped with a protective roof (FOPS) and with a NEW HOLLAND CONSTRUCTION approved front guard.

• Stand working equipment on the ground.

• Apply parking brake.

Never shut off the engine out of full load, but continue running for ca. three - five minutes at idling speed to cool down.

• Shut off engine.

• Turn key switch to position I (ignition ON).

• Depressurize the hydraulic system.

• Withdraw key from key switch of the electrical system.

• Switch off pilot control.

• Switch the battery main switch off and withdraw the key lever.

• Before carrying out work on the electrical system or welding work on the machine, the batteries must be disconnected.

Insulate connecting clamps.

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OPERATOR’S MANUAL EW 160 QUICK-CHANGE DEVICE (Option)

2486243

Quick-change device - safety instructions

Read and observe the section on "Fitting of working equipment - safety instructions".

Wear protective footwear and protective gloves.

Align the quick-change device and the attachment only by moving the machine and working equipment towards each other.

Never attempt to change the position of the attachment manually when the working equipment is being moved: Risk of crushing.

Stand aside from the working equipment.

Fig. 2

• Withdraw the retaining wedge (Fig. 2).

Leave the hazard range when the working equipment is being moved.

Quick-change device - detaching the excavator bucket

Fig. 3

• Retract the bucket cylinder slightly and lower the boom slowly (Fig. 3).

The excavator bucket is released.

Fig. 1

• Position the excavator bucket on the ground in such a way that the bucket contacts the ground over as large an area as possible.

• Loosen the lock nut (Fig. 1) and slacken the bolt by some turns.

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OPERATOR’S MANUAL EW 160 Quick-change device - remounting the excavator bucket

Fig. 4

Fig. 5

• Clean the contact surfaces on the quick-change device and excavator bucket (Fig. 4) and grease them lightly.

• Move the machine up to the excavator bucket (Fig. 5).

- Align the quick-change excavator bucket.

device and

the

• Pick up the excavator bucket, making sure that all contact surfaces are flush with one another (Fig. 2).

• Push in the retaining wedge to the limit stop.

• Tighten the bolt (Fig. 1) and secure it with the lock nut.

Before beginning work, check that the working equipment is safely locked with the adaptor.

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OPERATOR’S MANUAL EW 160 Attaching and detaching the grab equipment (optional equipment) Attaching and detaching the grab equipment - Safety instructions

Movements of working or grab equipment involve a risk of injury.

So never attempt to change position of grab or grab suspension by hand.

2905644

Attaching the grab

Read and observe: "Attaching and detaching the grab equipment, safety instructions".

Keep away from grab when working equipment is being moved.

• Detach backhoe bucket as described in section "Detaching and attaching the backhoe bucket".

This description applies to machines with cabinet terminal block control according to SAE (see section "Control elements").

• Retract bucket cylinder and mount locking pin for linking element and toggle lever (1, Fig. 1).

If the machine is equipped with a different control, activities "Depressurize hydraulic lines to grab" must be adapted to the control.

• Shut off engine.

• Turn key switch to position I. • Depressurize hydraulic lines to grab:

The linking element must not be used for lifting loads when in a secured state.

- push control lever (70, Fig. 2) to left and hold in place,

The locking pin might bend or break.

- depress "Rotate grab" rocker button (69) to the right and to the left,

Use the load hooks/lugs on the grab or remove the locking pin as long as loads have to be lifted.

Read and observe: "Fitting of working equipment, safety instructions".

- push control lever to right, - release rocker button and control lever.

• Turn key switch to position 0, shut off pilot control with lever (77).

Before fitting, check that grab and machine are filled with identical or mixable hydraulic oil.

If this is not the case, drain oil out of hydraulic system of grab.

Conventional hydraulic oil and biodegradable hydraulic fluid should not be mixed, as this affects biodegradability.

Fig. 1

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OPERATOR’S MANUAL EW 160

Fig. 2

Fig. 4

• The marker grooves on the valves’ squares (arrows, Fig. 3) must be in vertical position.

Detaching the grab • Open grab shells completely and set grab down on level surface.

• Shut off engine, turn key switch to position I. • Depressurize hydraulic lines to grab: - push control lever (70, Fig. 2) to left and hold in place, - depress "Rotate grab" rocker button (69) to the right and to the left, - push control lever to right, - release rocker button and control lever.

Fig. 3

• Turn key switch to position 0, shut off pilot control with lever (77).

• Clean and grease bearing pins and bushings.

• Drive machine towards grab.

• Disconnect hydraulic hoses (1 and 2, Fig. 4) from express couplings.

• Insert stick into grab bearing, push bearing pin home and secure (2, Fig. 1).

• Protect express couplings at grab and stick from soiling by fitting dust caps.

• Shut off engine and depressurize hydraulic lines to grab as described.

• Unscrew safety device of bearing pin (2, Fig. 1) and withdraw pin.

• Clean express couplings on grab and stick.

• Start up engine.

• Connect hydraulic hoses to grab cylinder (1, Fig. 4) and grab rotation motor (2).

Check that the express couplings are perfectly engaged.

• Lift working equipment carefully to release grab.

• Grease all nipples on grab and gearing of grab rotating mechanism.

• Start up engine and lift grab clear of ground.

• Bleed grab hydraulic system by opening and closing grab repeatedly and turning clockwise and counter-clockwise.

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OPERATOR’S MANUAL EW 160 Selecting the backhoe / grab equipment (Option)

2905642

To switch the working equipment over from backhoe bucket to grab operation, two valves (Fig. 5 and 6) must be switched over at the stick cylinder.

Switch the valves only when the hydraulic system is depressurized to avoid damaging seals.

(See: "Depressurizing the hydraulic system").

Backhoe bucket operations • The marker grooves on the valves’ squares (arrows, Fig. 5) must be in horizontal position.

Grab operation

Fig. 5

• The marker grooves on the valves’ squares (arrows, Fig. 6) must be in vertical position.

Fig. 6

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OPERATOR’S MANUAL EW 160 Detaching / attaching the backhoe bucket

2411343

Danger of injury Risk of crushing when working equipment or backhoe is moved.

Therfore, do not attempt to alter the position of the backhoe manually.

Stand back from the backhoe when the working equipment is moved.

Read and observe: "Fitting of working equipment - Safety instructions".

Fig. 1

• Stand working equipment on the ground.

• Place safety wedges under the backhoe bucket (arrow, Fig. 1).

The bucket may otherwise overturn as soon as the linkage pins have been driven out.

• Turn out screws (2 and 4).

• Drive out pins (1 and 3).

• Raise working equipment cautiously (Fig. 2).

The bucket stands now freely on the ground.

• Clean linkage pins and bearing bushes before refitting and protect them against corrosion as described in the section "Corrosion protection for pins and bearings (bushings and hubs)".

Fig. 2

• Attach another backhoe bucket by proceeding in reverse order.

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OPERATOR’S MANUAL EW 160 Corrosion protection for pins and bearings (bushings and hubs)

2801355

Application of Voler A.C. Use Voler A.C. anti-corrosive agent only.

Other agents are not approved by NEW HOLLAND CONSTRUCTION. All pins and bearings (bushings and hubs) of the working equipment or in equipment components must be treated with Voler A.C. anti-corrosive agent before fitting.

Voler A.C.: • permits easy fitting and dismantling • protects against rust, oxidation and similar wear • prevents seizing and fretting corrosion in nonmoving parts of bearings.

This is achieved by aluminium and copper particles forming a protective layer on the metal. This layer removes surface irregularities and does not sweat, seize or harden.

Part nos. for Voler A.C. P/N 73171461 - 0,5 l spray can (CFC-free)

• Clean off grease, oil, dirt and corrosion protection agents from pins and bearings using white spirit or diesel fuel.

Rust patches must be thoroughly removed, if any.

All parts must present a dry, bright metal surface.

• Apply a thin layer of Voler A.C. on pins and all bearings using a brush or a spray can. Pin shafts and bearings must be completely covered by the protective layer.

If the protective layer of a pin already treated with Voler A.C. is damaged, these areas must be touched up before fitting the part.

• Fitting and securing of pins If the pin is too heavy to be fitted manually, apply Voler A.C. at first only on abt. a quarter of the pin’s length Then position pin by means of a lifting gear ready for fitting.

Apply Voler A.C. on the remaining length of pin shaft, fit pin and secure.

P/N 73171462 - 0,5 kg tin P/N 73171463 - 4,5 kg bucket Available from the NEW HOLLAND CONSTRUCTION Spare-Parts Service

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OPERATOR’S MANUAL EW 160 Multi-position boom (optional equipment)

2905207

Description of multi-position boom

Working with the multi-position boom

Fig. 1

Fig. 2

With this version there is an additional joint (2, Fig. 1) between the boom lower section (3) and the boom upper section (1). An additional hydraulic cylinder (4) (adjusting cylinder) makes it possible to adjust the boom upper section.

Lowering boom upper section

The multi-position boom has the following advantages for travelling and working: • Extended working area,

• Operate pedal (84, Fig. 2) forwards. The adjusting cylinder extends.

Raising boom upper section • Operate pedal (84) to rear. The adjusting cylinder retracts.

• Improved mobility of equipment, • Easier transport of machine on flat-bed trailers.

Transporting the machine with multi-position boom The optimal transport height for loading on a flat-bed trailer is achieved if the • Adjusting cylinder is fully retracted, • Stick cylinder is fully extended, • Backhoe cylinder is fully extended.

• Retract the boom cylinder so that the multiposition boom rests as flat as possible on the loading surface.

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OPERATOR’S MANUAL EW 160 HYDRAULIC HAMMER (Option) Working with the hydraulic hammer, safety instructions

2801519

Keep danger zone clear

Operation with various attachments

All persons must be kept away from the danger zone of the hammer: Risk of flying stone chippings.

If the machine is designed for optional operation with other hydraulically driven attachments (e.g. hydraulic hammer with scrap shears or concrete cruncher), the corresponding sections of these operating instructions must also be observed: "Working with scrap shears, safety instructions" or "Working with a concrete cruncher, safety instructions"

So stop work immediately if anyone enters the danger zone of the hammer or of the machine.

Never resume work until all persons have left the danger zone.

Always close the windscreen of the machine before operating the hammer.

Fit a safety screen for protection from chippings.

Always wear ear protectors.

Never operate the hammer except from the operator’s seat.

Read the operating instructions Also read and note the safety instructions and the instructions for designated use in the operating instructions issued by the manufacturer of the hammer.

Prior to fitting attachments, check that the hydraulic hammer and the machine are filled with the same or compatible hydraulic oil.

If this is not the case, drain the oil out of the hydraulic system of the hammer.

Mineral hydraulic oil and biodegradable hydraulic fluid should never be mixed, as the compound is not biodegradable.

In the event of damage Stop work immediately on detecting damage or loss of oil.

Soak up spilt oil and dispose of it in accordance with local environmental protection regulations.

Rating coordination The machine rating and the rating of the hydraulic hammer must be coordinated.

This prevents the hydraulic hammer from being overloaded.

If in doubt, consult your NEW HOLLAND CONSTRUCTION dealer.

Report any accidents involving oil immediately to the user of the machine or to his agent.

Ensure that any damage and leakages are repaired immediately.

Never adjust pressure relief valves yourself, never remove lead seals.

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OPERATOR’S MANUAL EW 160 Working with a hydraulic hammer

2801520

Switching on the hydraulic hammer Read and observe "Working with a hydraulic hammer, safety instructions".

Before starting work: • Check that the hydraulic hammer is securely locked with the operating equipment and that the hydraulic lines are correctly connected (see operating instructions issued by the manufacturer of the hammer).

• Select the "hydraulic hammer" function by pressing the pushbutton (19, Fig. 2), - the LED above the pushbutton lights up, - the PCS switches to the HEAVY mode, (The hydraulic hammer can also be operated in the ECO mode after corresponding reprogramming; consult your NEW HOLLAND CONSTRUCTION dealer), - the pedal (84, Fig. 3) is switched over to the "hydraulic hammer" function.

If the machine is designed for optional operation with a hydraulic hammer and other hydraulically operated attachments (e.g. scrap shears or concrete cruncher): • Set the lever of the valve on the hydraulic oil tank (Fig. 1) to vertical position.

The return line of the hydraulic hammer is then connected direct with the hydraulic oil tank.

Having the valve (Fig. 1) in a position other than that indicated may result in damage to the seals of the hydraulic hammer.

Fig. 3

Hammer operation with set number of blows per minute • Mount bit, then switch on hammer with pushbutton (82, Fig. 3).

The hammer remains switched on as long as the pushbutton is depressed.

Hammer operation with variable number of blows per minute Fig. 1

• Mount bit, press pedal (84) forwards. The further the pedal is pressed down, the higher the number of blows per minute.

Switching off the hydraulic hammer • Release the pushbutton (82) or pedal (84).

• Press pushbutton (19, Fig. 2), the LED above the pushbutton is extinguished.

• The pedal (84) is switched over to the "adjusting cylinder" function.

Fig. 2

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OPERATOR’S MANUAL EW 160 SCRAP SHEARS (option) Working with scrap shears, safety instructions

2801521

Keep danger zone clear

Operation with various attachments

All persons must be kept away from the danger zone of the scrap shears:

If the machine is designed for optional operation with other hydraulically operated attachments (e.g. scrap shears with a hydraulic hammer or concrete cruncher), the corresponding sections of these operating instructions must also be observed:

Risk of flying or falling scrap.

So stop work immediately if anyone enters the danger zone of the scrap shears or of the machine.

Never resume work until all persons have left the danger zone.

Always close the windscreen of the machine before operating the scrap shears.

Fit a safety screen.

Never operate the scrap shears except from the operator’s seat.

Read the operating instructions Also read and note the safety instructions and the instructions for designated use in the operating instructions for the scrap shears.

"Working with a hydraulic hammer, safety instructions" or "Working with a concrete cruncher, safety instructions" Prior to fitting attachments, check that the attachment and the machine are filled with the same or compatible hydraulic oil.

If this is not the case, drain the oil out of the attachment.

Mineral hydraulic oil and biodegradable hydraulic fluid should never be mixed, as the compound is not biodegradable.

In the event of damage Stop work immediately on detecting damage or loss of oil.

Rating coordination The machine rating and the rating of the scrap shears must be coordinated.

This prevents: - the machine from being overloaded or - the stability from being jeopardized.

Soak up spilt oil and dispose of it in accordance with local environmental protection regulations.

Report any accidents involving oil immediately to the user of the machine or to his agent.

Ensure that any damage and leakages are repaired immediately.

If in doubt, consult your NEW HOLLAND CONSTRUCTION dealer.

Never adjust pressure relief valves yourself, never remove lead seals.

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OPERATOR’S MANUAL EW 160 Working with scrap shears

2801522

Switching on the scrap shears Read and observe "Working with scrap shears, safety instructions".

Before starting work: • Check that the scrap shears are securely locked with the operating equipment and that the hydraulic lines are correctly connected (see operating instructions issued by the manufacturer of the scrap shears).

• Select "scrap shears" function with rocker switch (49, Fig. 2) (The switch area with the symbol must be depressed, the pilot lamp lights up).

The "hydraulic hammer" and "adjusting cylinder" functions are now disabled.

If the machine is designed for optional operation with scrape shears and other hydraulically operated attachments (e.g. hydraulic hammer or concrete cruncher): • Set the lever of the valve on the hydraulic oil tank (Fig. 1) to horizontal position.

Only then is it assured that the scrap shears will work properly.

Fig. 3

Work with the scrap shears can now begin (Fig. 3): - Close scrap shears = press pedal (84) forwards; - Open scrap shears = press pedal (84) to the rear.

Only for swivel-type scrap shears: - Swivel scrap shears clockwise = Press joystick (69) to right; Fig. 1

- Swivel scrap shears counterclockwise = Press joystick (69) to left.

Switching off the scrap shears • Release pedal (84, Fig. 3).

• Switch off rocker switch (49, Fig. 2) (The switch surface with the symbol is raised, the pilot lamp is extinguished).

Fig. 2

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OPERATOR’S MANUAL EW 160 LIFTING-GEAR OPERATION Lifting-gear operation - safety instructions

Never use the machine for lifting-gear operation unless it is equipped and approved for this purpose.

The machine must be equipped with an overload warning system and pipe-fracture safety devices.

Read the sections "Fundamental safety instructions" and "Operation, safety instructions" with care and observe the instructions contained in them.

Switch the overload safety device on before starting work.

Room for slingers Slingers must approach the working gear from the side when the load is slung.

2413662

Sling the load in such a way as to prevent it from slipping or falling while being lifted or transported.

Transporting the load Never move the load above persons. Keep the load as close as possible to the ground.

Prevent the load from swinging.

The machine must never be driven with a slung load unless the road surface is even and the roadway is clearly visible.

Roadway visibility can be improved by adjusting the boom and swinging the superstructure to the right.

Use only tested and efficient lifting gear with an adequate load capacity.

The built-in overload warning device cannot totally exclude accidents due to incorrect operation. This applies in particular to: - inadequate hooking of the load or the load-carrying device, - excessive deceleration or acceleration forces (hard braking or strong swinging with the load to be moved), - loads dropping into the cable, - oblique pull, - driving the excavator into an area with steeply sloping ground, - exposure to strong wind.

Hoist the load only from the hooks provided for that purpose.

Avoid these risks by handling the machine carefully and with discretion.

During the lifting and transporting of loads, slingers or other assistant personnel must stand in a safe position or go beside the machine to ensure that they are outside the hazard zone.

Ensure that slingers and other assistant personnel are always in sight.

Slinging loads

Never use the teeth of backhoe dippers, buckets or grippers.

Cable lugs, thimbles or U-bolts may slip from the teeth, putting the load out of control.

Register the weight of the load. Sling only those loads not exceeding the load capacity of the lifting gear and of the machine (cf. "Technical data").

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OPERATOR’S MANUAL EW 160 Loading hooks on backhoe buckets and couplers

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(optional equipment) To enable hydraulic excavators to be used for lifting purposes too, backhoe buckets and couplers are available with welded loading hooks (Fig. 1 and 2) (option).

Before attaching loads: Read and observe: "Lifting gear operation - Safety instructions".

Switch on the overload warning system before starting work.

Loading hook capacity The maximum capacity of the loading hook is marked on the hook (Fig. 1 and 2).

Excavator load capacity The admissible load capacity depending on working equipment and working radius is given in the "Load capacities" table, cf. "Technical Data".

Attach the load only to the load hook provided for this purpose.

Extra important for load hook on linking element: If a different working attachment (e.g. a grab) is mounted instead of the backhoe, the linking element and toggle lever must be joined with a locking pin.

In this case the load hook must not be used for lifting loads.

The locking pin is not designed for such loads and may bend or suddenly break. In this case the linking element and attached load suddenly start to swing.

Fig. 1

The swinging load may get out of control, resulting in injury or damage. In extreme cases, the stability of the machine may be at risk.

So: Never attach loads to the load hook of a locked linking element.

Always use the load hooks/lugs on the attachment (e.g. grab). If the attachment is not equipped with a load hook but a load has to be moved, the locking pin can be removed from the linking element and toggle lever as long as the load hook on the linking element has to be used.

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Fig. 2

115

OPERATOR’S MANUAL EW 160 Overload warning system

2461493

(optional equipment)

Function of overload warning system

Activating the overload warning system 2461494 The overload warning system can be operated in two modes:

The overload warning system gives only warning signals; it does not prevent overturning.

When the warning signal sounds: - let down load immediately, - reduce working radius or weight of load.

Hydraulic excavators used as lifting devices or for the transport of loads must be equipped with an overload warning system and an pipe-fracture safety system for the lifting cylinders of the working hydraulics.

• Depress key (29, Fig. 4) once, LED 1 lights up = if the machine is used without additional stabilizers for lifting operations.

• Depress key (29) twice, LED 2 lights up = if the machine is used with additional stabilizers (levelling blade/stabilizer feet) for lifting operations.

The overload warning system must be on when such works are carried out.

If the admissible load moment is exceeded, warning lamp (11, Fig. 3) lights up and the buzzer sounds.

Fig. 4

Before the machine is being used for lifting operations, the overload warning system must be activated: • Switch the overload warning system with key (29) into the required mode of operation.

The LED above the key lights up.

Fig. 3

• Checking the overload warning system (cf.

"Checking the overload warning system").

The overload warning system is now ready for operation.

The admissible load moment is exceeded when too heavy a load is being lifted at a great working radius of the working equipment (lifting capacity cf. section "Technical data").

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OPERATOR’S MANUAL EW 160 Testing the overload warning system 2801523

Check correct function of the overload warning system: - daily before starting operation and

Putting the overload warning system 2461496 out of operation If the machine is used exclusively for excavating operations, the overload warning system can be put out of operation:

- before each lifting-gear application.

Fig. 6 Fig. 5

• Activate overload warning system (cf. "Activating overload warning system".

• Depress key (29, Fig. 6) until the LEDs are no longer lit up.

The overload warning system is now out of operation.

• Raise boom to highest position limit stop.

• The warning light (11, Fig. 5) indicates and the buzzer sounds).

If an error occurs have the overload warning system tested and repaired immediately by NEW HOLLAND CONSTRUCTION. The adjustment or inspection is confirmed by a certificate.

Never carry out setting of or repairs to the overload warning system yourself.

Correct function of the overload warning system could be impaired or it could fail completely.

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OPERATOR’S MANUAL EW 160 Pipe-fracture safety system, function (Option) The pipe-fracture safety system prevents the working equipment from being lowered if a hydraulic line to the boom cylinder piston side fractures.

The hydraulic connection at the piston side of the boom cylinder is blocked. hydraulic oil can only flow out here when the "lower boom" function is operated.

With machines with multi-position boom, additionally to the boom cylinders, the adjusting cylinder of the boom upper section is also equipped with a pipe-fracture safety device at the rod side.

2413657

If a hydraulic line is fractured: • Operate the control lever for the "lower boom" function to 0 position.

• Warn people in the vicinity using the horn.

• Secure the range of the working equipment and suspended load, so that persons cannot remain under the working equipment and load or in the vicinity of the fractured hydraulic line.

When the working equipment and the load are lowered to the ground, oil flows out of the hydraulic line at the fracture.

• Carefully lower working equipment and load to the ground.

• Replace fractured hydraulic line (or have it replaced).

Only then resume operation.

• Collect escaped hydraulic oil. Dispose of oilsoaked rags, oil-binding agent, etc. in an environmentally responsible manner.

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OPERATOR’S MANUAL EW 160 OPTIONAL EQUIPMENT

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Rotary beacon The rotary beacon is installed on a mounting post (Fig. 1) and secured with a clamping screw.

The electrical connection is integrated in the mounting post. Additional wiring is not necessary.

The rorary beacon can only switched on, when the key switch electrical system is switched to position I (ignition ON).

Switch rotary beacon ON • Switch rocker switch (54, Fig. 2) symbol side down. (The monitoring lamp inside the switch lits up).

Fig. 1

Switch rotary beacon OFF • Switch rocker switch (54) symbol side up. (The monitoring lamp inside the switch goes out).

Fig. 2

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OPERATOR’S MANUAL EW 160 Switching on the floodlamps at the rear of the cab

2732888

The floodlamps (Fig. 3) can only be switched on when the electrical system key-switch is in position I (ignition ON).

Switching the floodlamps on • Switch on rocker switch (51, Fig. 4). (The symbol face is depressed and the indicator lamp inside the switch lights up.)

Switching the floodlamps off • Switch off rocker switch (51). (The symbol face is up and the indicator lamp inside the switch is off.)

Fig. 3

Fig. 4

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OPERATOR’S MANUAL EW 160 Radio

2796946

The radio is factory-installed at the right side behind the driver’s seat (Fig. 5).

The radio installed may be of different types.

Instructions on how to use the radio can be found in the manufacturer’s instructions.

The electrical system voltage of 24V is stepped down to the operating voltage of the radio (12V) by means of a voltage converter.

The radio remains connected to the power supply even if the key-switch is in the OFF position. Therefore, switch off the radio when leaving the machine.

Fig. 5

If the radio remains in operation for a longer period of time (e.g. during the weekend) without power supply from the machine’s engine, the batteries will be discharged.

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OPERATOR’S MANUAL EW 160 Refuelling system

2716604

Refuelling with the refuelling system, safety instructions

Explosion hazard

Securing the machine

No smoking. Keep away from open flames. Fuels and fuel gases are highly flammable; fire hazard.

While refuelling the machine, secure it against unauthorized starting: - Set working equipment down on the ground - Switch off the engine - Remove the key from the key-operated switch for the electrical system.

Switch off fuel-fired auxiliary heating and air-conditioning systems.

Personal and environmental protection Fuel may damage the skin, so wear protective gloves or apply a barrier cream.

Avoid spillage, ensure that no fuel soaks into the ground; it constitutes an environmental hazard.

Soak up spilt oil immediately with cotton waste or binding agent and dispose of it in accordance with local environmental protection regulations.

Report any accidents involving oil immediately to the user of the machine or to his agent.

122

Increased risk of contamination If the machine is often or regularly refuelled with fuel from cans or barrels, the refuelling system is exposed to an increased risk of contamination.

In this case the preliminary fuel filter must also be drained and cleaned more often than specified in the servicing schedule.

The fuel filter must be changed at shorter intervals.

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OPERATOR’S MANUAL EW 160 Refuelling with the refuelling system

2904439

Read and observe: "Refuelling with the refuelling system, safety instructions".

Fuel can be pumped from a high-capacity tank into the fuel tank of the machine by means of the refuelling system.

The refuelling system is installed beside the fuel tank.

The refuelling system comprises the intake hose, the electrically driven fuel pump and the fuelling hose to the fuel tank.

Fig. 1

• Connect the intake hose to the high-capacity tank.

• Switch on the pump with rocker switch (50, Fig. 1) by - setting the symbol face of the switch to the middle position, - sliding the lock (arrow) rearwards and by depressing the symbol face of the switch briefly to start up the pump.

After releasing, the rocker returns to the middle position.

The pump may be slightly or even irreparably damaged if allowed to run dry during prolonged periods.

Never switch on the pump therefore unless it is needed for refuelling.

The pump is switched off automatically when the fuel tank is filled.

• Set rocker switch (50) back to resting position.

(The symbol face of the switch is up)

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OPERATOR’S MANUAL EW 160 Driver’s seat - adjusting the lumbar support (optional equipment)

2796932

Adjusting the lumbar support

Never adjust the seat while driving, but concentrate on the road.

The lumbar region is supported by air chambers built into the backrest. These chambers can be filled with air or deflated independently of each other. An electrically operated compressor as well as valves are installed in the seat.

Always stop the machine before adjusting the seat.

The amount of air is controlled with switches (1 and 2, Fig. 1):

Risk of accidents

- Switch 1 = lower chamber, - Switch 2 = upper chamber.

The following applies to both switches: - Press switch in direction + = chamber is filled with air.

- Press switch in direction chamber is deflated.

-

=

Fig. 1

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OPERATOR’S MANUAL EW 160 Driver’s seat with pneumatic suspension and integrated heating (optional equipment)

2800297

Adjusting the pneumatic suspension

Risk of accidents Never adjust the seat while driving, but concentrate on the road.

Always stop the machine before adjusting the seat.

The driver’s seat can be adjusted in inclination, height, and fore-and-aft position. It also has an electrical heating system.

The seat has a pneumatic suspension system.

The seat suspension can be adjusted to suit the driver’s weight.

The lumbar region is supported by air chambers integrated into the backrest. These air chambers and the seat suspension are supplied with compressed air by an electrically driven compressor.

The compressor and valves are integrated into the seat.

• The seat suspension can be adjusted with the rocker switch (3, Fig. 1) to suit the operator’s weight: - Press switch in + direction = suspension harder.

-

- Press switch in direction = suspension softer.

Fore-and-aft adjustment • Pull bar (8) upwards, slide seat into desired position and engage bar.

Adjusting the seat cushion • Height and inclination to front / back: Pull handles (9 or 10) upwards. Bring seat cushion into desired position and engage handles.

Adjusting the backrest • Pull lever (7) upwards. Bring backrest into desired position and engage lever (7).

Adjusting the armrests • The armrests can be raised and lowered as required.

The inclination can be adjusted with the knobs (11).

Fig. 1

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OPERATOR’S MANUAL EW 160 Adjusting the lumbar support

Switching on the seat heating

Two air chambers are integrated into the backrest. They can be filled with air or deflated independently of each other. An electrically operated compressor as well as valves are installed in the seat.

The driver’s seat has two integrated heating elements, one in the seat cushion and on in the backrest.

The amount of air is controlled with rocker switches (4 and 5, Fig. 2): - Switch 4 = lower chamber, - Switch 5 = upper chamber.

- Press switch in direction + = chamber is filled with air.

-

The seat heating can be switched on only when the key-switch for the electrical system is set to position 1 (ignition ON).

To switch on the seat heating:

The following applies to both switches:

- Press switch in direction chamber is deflated.

The maximum heating output is fixed; a thermostatic switch prevents the seat from being overheated.

=

• Switch on rocker switch (2, Fig. 2).

The pilot lamp (1) lights up.

To switch off the seat heating: • Switch off rocker switch (2).

The pilot lamp (1) goes out.

Fig. 2

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OPERATOR’S MANUAL EW 160 Air conditioner, switching on / off (option)

2904814

Switching on • Start up the engine (see Operator’s Manual) • Switch on rocker switch (47, Fig. 1) by depressing the switch face with the symbol. The indicator lamp under the symbol lights up.

The fan starts up automatically in stage 1.

If a larger amount of air is needed, the fan can be switched with key (15, Fig. 2) into stages 2 and 3.

Selecting the air temperature • The temperature of the air blown into the cab can be regulated with the heating control knob (73, Fig. 3). Knob positions:

Fig. 1

- fully to the left (min) = cooled air blown into the cab, - fully to the right (max) = heated air blown into the cab.

Between these end positions, the desired temperature is freely variable.

If a higher heating or cooling performance is needed, the fan can be switched into stages 2 and 3.

Best cooling performance can be achieved with the following settings: - Close the air outlets at the bottom and for the front window - Open the outlets on the right and left side of the rear window and turn them in such a way that the outflowing air is blown into the cab and not against the rear pane.

Fig. 2

To obtain a good cooling performance, make sure: - the fresh air intake at the back of the cab is not covered up or contaminated, - the filter mat and the lamellas of the evaporator are clean, and - the door and the windows of the cab are closed.

Important: For more information (e.g. on air outlet adjustment) please refer to the "Ventilation and Heating" chapter in the Operating Manual.

Fig. 3

Switching off • Switch off rocker switch (47, Fig. 1) by depressing the blank face of the rocker.

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OPERATOR’S MANUAL EW 160 KEYBOARD, FURTHER FUNCTIONS

2801358

Service (key 16), function The service key (16, Fig. 1) can be used; - to set the time (cf. "Setting the time"); - to display the operating hours interval after which the next maintenance must be performed If servicing is due, "SERVICE" is automatically displayed when the key-switch is switched on.

After about five seconds, the number of hours run is again displayed.

Key (16) is active immediately after switching the keyswitch on and after the self-test of the central electronic unit is terminated.

To display the next maintenance interval: - Depress key (16) until "NEXT SERVICE" is displayed; LED I above the key is lit up.

Instead of the total number of hours run, the screen displays the operating hours interval after which the next maintenance must be performed.

The maintenance intervals displayed are those requiring the installation of new parts. (At 50 and thereafter every 500 operating hours).

Fig. 1

The following applies to the maintenance intervals: The NEW HOLLAND CONSTRUCTION technician confirms the servicing work carried out with a tester. The electronic unit then calculates the operating hours of the next maintenance interval.

The servicing work in acc. with plans T, W and A must moreover be carried out regularly.

The information is displayed until key (16) is depressed a second time. The screen will then display again the total number of operating hours.

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OPERATOR’S MANUAL EW 160 Display (key 18), function

2732727

The "Display" key (18, Fig. 2) can be used to display the following information: - time of day in hours:minutes (standard indication), - number of engine revolutions in rpm (rpm = min-1), Key (18) is active immediately after switching on the keyswitch and after the end of the self-test of the central electronic unit.

The information is shown on the display (3) until another information is called up with key (18).

To indicate the engine revolutions

Fig. 2

• depress key (18). LED I lit up.

Display (3) shows the number of revolutions of the engine by a four-digit number in rpm (rpm = min-1).

To indicate the time of day • depress key (18) until LED I is no longer lit up.

Display (3) shows once again the time of day in hours and minutes.

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OPERATOR’S MANUAL EW 160 Display, setting the contrast

2800863

Under unfavourable light conditions, in strong sunshine or in extremely cold weather it may be necessary to change the contrast setting of the display to ensure the readability of the characters displayed on the screen.

The actual contrast setting is displayed as a numerical value. The factory-set value is 127 (medium contrast). It can, however be varied between 0 (weak contrast) and 254 (very strong contrast).

The "contrast set" function is activated when: - the key-switch is set to position I (engine not yet started) and

Fig. 3

- the self-test cycle of the central electronic unit is terminated.

Setting the contrast: • Depress key (16, Fig. 3) until "SET" is indicated. LED I above the key is lit.

• Depress key (18) until "CONTRAST" is displayed. LED I above the key is lit.

The screen displays the information shown in Fig. 4.

The contrast can now be set.

To do so, depress key (24) or (25) until the desired contrast is reached: - Key (24) = each depression of the key increases the number by one and the characters on the display are darker.

Fig. 4

- Key (25) = each depression of the key decreases the number one and the characters on the display are lighter.

• Depress key (18) to save the new setting.

The screen displays again the time in hours:minutes.

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OPERATOR’S MANUAL EW 160 Setting the time

2800864

For different reasons it may become necessary to set the time stored in the central electronic unit and displayed on the screen (e.g. summer/winter time change).

The "Setting the time" function is active when: - the keyswitch is turned to position I (the engine must not be started) and when - the self-test of the central electronic unit is terminated.

• Depress key (16, Fig. 5) until "SET TIME" is displayed; LED I above the key is lit up.

• Depress key (18), LED I above the key is lit up.

Fig. 5

The screen displays the information as shown in Fig. 6. The hours can now be set.

To do so, depress key (24) or (25) until the desired hour is reached.

- Key (24) = after each depression of the key, the display is incremented by one hour.

- Key (25) = after each depression of the key, the display is decremented by one hour.

Setting the minutes: • Depress key (18).

The display changes from

Fig. 6

"SET HOUR" to "SET MIN".

Depress key (24) or (25) until the minutes have been set.

• Depress key (18) to store the changed setting.

The screen displays again the time in hours:minutes.

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OPERATOR’S MANUAL EW 160 Immobilizer, deactivate / activate

2904032

After enabling of the immobilizer function, the central electronic unit request the operator to enter the code whenever the machine is being put into operation. To avoid having to enter the code after each break of the work (engine shut off), the immobilizer can be deactivated.

• Set key-switch to I. Wait until the buzzer sounds a second time and the indicators on the display are fully visible (The self-test of the central electronic unit is then terminated).

• Depress key (16, Fig. 7) until the screen displays "SET" and "CODE Y/N" (Fig. 8).

- Then depress key (25) to deactivate the immobilizer.

The display (B) changes from I to 0.

Fig. 7

• Depress key (25) to activate the immobilizer.

The display (B) changes from 0 to I. • Depress key (18) three times to display again the operating hours and the time on the screen.

When the machine is immobilized or at the end of each working shift, the immobilizer should be reenabled.

Fig. 8

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OPERATOR’S MANUAL EW 160 PART 3 - INSPECTION AND SERVICING

Operating manual

2261178

Target group Operating personnel + Inspection and servicing personnel

Part 1 INTRODUCTION + FUNDAMENTAL SAFETY INSTRUCTIONS Repair personnel

Operating personnel

Part 2 OPERATION

The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Inspection and servicing personnel

Part 3 INSPECTION AND SERVICING

The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

Repair personnel

Part 4 REPAIR WORK

Part 5 ANNEX

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The repair personnel must have know-how and experience relevant to the repair of this or comparable machines.

Operating personnel + Inspection and servicing personnel + Repair personnel

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OPERATOR’S MANUAL EW 160

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OPERATOR’S MANUAL EW 160 Inspection and servicing - safety instructions

2732238

Operating manual

Securing working equipment

No inspection and servicing work may be carried out until the operating manual has been read and understood.

Pay special attention to the:

Stand working equipment on the ground in such a way that no movements can be made if mechanical or hydraulic connections become detached.

"Fundamental Safety Instructions" and all warnings and safety instructions attached to the machine.

When working in jointed areas, block off the joints. Remove the blocks on finishing work.

The operating manual lists all jobs to be done. The descriptions of job sequences, however, provide only experienced personnel with the necessary instructions.

Secure any equipment or component which is to be mounted or dismantled, or whose position is to be changed, with hoists or appropriate slinging/supporting devices to prevent them from moving, slipping or falling inadvertently.

The operating manual must be kept with the machine at all times.

Inspection and servicing personnel Inspection and servicing personnel must have the necessary know-how on the inspection and servicing of this or comparable machines.

Securing the machine Carry out servicing work only if the machine is secured as described in the section "Securing the Machine".

Climbing onto and off the machine Personal protective equipment and working clothing Wear closely fitting working clothing when working on the machine. Loose, wide garments may catch on machine parts and result in injury.

Wear a safety helmet, safety goggles, safety footwear, gloves and, in the event of high noise levels, ear protectors.

Use only the steps, platforms and handrails provided when climbing onto or off the machine.

Always keep steps, platforms, handles and handrails in a non-slip, safe state and remove any oil, grease, soil, clay, snow, ice and other foreign matter immediately.

Always face the machine when climbing on and off.

Check state of tools Use only fully functional, reliable tools.

Select the right tool for the job.

Wrenches of the wrong size, for example, may slip and cause injury.

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OPERATOR’S MANUAL EW 160

Cleaning jobs

Fastening and securing elements

Clean the units within the working range before starting work.

Select the cleaning agent according to the material constituting the parts to be cleaned.

Check fastening and securing elements, e.g. bolts, nuts, washers, before using them again.

Replace any damaged parts.

Example: Never clean rubber or electrical parts with solvents or steam jets.

Use lint-free cleaning rags when working on the hydraulic system or the engine.

Cleaning agents and solvents may give off harmful, readily flammable vapours.

Never work with such agents except on well ventilated premises; never inhale the vapours and never smoke.

Prevent solvents and cleaning agents from coming into contact with the skin.

Wear gloves.

Observe the instructions on the packaging.

Handling flammable liquids When handling flammable liquids: - never smoke, - keep away from unshielded light sources and naked flames.

Fuel and other consumables often have low flash points and are readily ignited.

Never attempt to extinguish burning liquids with water. Use - dry powder, - carbon dioxide or - foam extinguishers.

Handling oils and greases Hot lubricant or hydraulic oil emerging uncontrolled from the system may result in severe burns.

Never set foot within reach of the emerging oil jet.

Avoid contact with the skin. Wear gloves and firm protective clothing.

Used oil may be harmful to the skin.

Clean soiled skin thoroughly with warm soapy water and apply a barrier cream.

Never use fuels or solvents for cleaning the skin.

If you have swallowed any oil, avoid vomiting but consult a doctor immediately.

Visible loss of oil Have any visible leakage repaired immediately.

Escaping oil is an environmental hazard.

Soak up any oil that has escaped with a binding agent. Sweep up binding agent and dispose of it separately from other waste.

Water used for extinguishing purposes would vapourize instantaneously on contact with burning substances and spread burning oil, for example, over a wide area.

Water generates short circuits in the electrical system, possibly producing new hazards.

Notify the fire brigade.

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OPERATOR’S MANUAL EW 160

Relieving residual pressure in the hydraulic system

Environmentally compatible disposal

Only unpressurized hydraulic systems may be opened. Even when a machine is parked on a horizontal surface with its attachments supported on the ground and its driving motor switched off, there may still be substantial residual pressure in parts of the hydraulic system, e.g. primary pressure from the last hydraulic movements prior to stopping the machine.

Oils, greases, brake fluids, cleaning agents, solvents and oily components, e.g. filters, cleaning rags, replaced wear parts and unserviceable machine parts, must be disposed of separately in the interests of environmental protection.

Residual pressure is reduced only gradually. If an intervention into the hydraulic system is to be undertaken immediately after stopping, depressurize the system as described in the section "Depressurizing the Hydraulic Plant".

Screwed connections, piping, hydraulic hoses Repair any leakages in the piping and hose system immediately.

A fine, highly pressurized jet of hydraulic oil can penetrate the skin.

Never search for leakages with the fingers, but use a piece of cardboard and always wear goggles.

If oil has penetrated into the skin, consult a doctor immediately.

Never repair damaged piping; always replace it.

Replace hydraulic hoses immediately on detecting any damage or moist areas.

Tighten leaking screw plugs only when the system is depressurized.

Never dispose of such substances with standard household refuse.

Empty substances into the containers provided for this purpose.

Even biodegradable, "environmentally friendly" hydraulic oil has to be disposed of separately like any other oil.

Never allow oils and oily waste to get into the soil or into water: environmental hazard!

Sealing faces Individual spares may contain asbestos.

Such spares or their packaging are marked with: Never process spares containing asbestos mechanically. Inhaling asbestos dust is a health hazard.

Clean sealing faces prior to assembly.

Exhaust gases Exhaust gases are a health hazard: never inhale them.

When working on enclosed premises, draw off exhaust gases with a suction plant and ventilate the premises well.

Escaping oil is an environmental hazard.

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OPERATOR’S MANUAL EW 160

Handling batteries

Selecting oils and greases

Batteries give off explosive gases.

Use the recommended qualitities only, matching viscosities with the temperature level.

Never handle batteries close to naked flames and unshielded light sources, never smoke.

Battery acid is toxic and corrosive.

Avoid any contact with the skin, mouth, eyes and clothing. Avoid spilling battery acid or inhaling the vapours.

Wear gloves, firm protective clothing and goggles when handling batteries.

If the skin is splashed with acid, rinse thoroughly with water and consult a doctor.

If the eyes are splashed with acid, rinse thoroughly with running water and consult a doctor immediately.

Never set tools down on the battery. They may induce a short circuit, causing irreparable damage to the battery and injuring persons.

Never wear metal necklaces, bracelets or watch-straps when working on the battery. The metal parts may induce a short circuit, resulting in burns.

Dispose of used batteries separately from other waste in the interests of environmental protection.

Prior to work on the electrical system Prior to any work on the electrical system involving tools, spares etc. coming into contact with electric cables or contacts, disconnect the battery.

Filters Replace all filter elements or filter cartridges within the specified periods if cleaning is not explicity authorized.

All filters are coordinated carefully with the equipment. Original NEW HOLLAND CONSTRUCTION parts must be used to ensure smooth running and a long service life of the engine and the hydraulic units

Sealing elements When dismantling parts, watch for sealing elements.

Check sealing elements prior to installation and replace any that are even slightly damaged.

When assembling, ensure a perfect fit.

Oil-level check and oil change Position the machine horizontally.

Change the oil when the machine is at operating temperature.

Warm oil flows better and carries suspended particles (carbon or abraded matter) better.

Lubricating Clean the lubricating nipple, then lubricate as scheduled.

Disconnect first the negative pole, then the positive pole.

After work:

After servicing

Connect first the positive pole, then the negative pole.

To prevent corrosion, coat all bright metal parts with a grease film.

On completing work, reinstall all protective devices.

Never start up the drive motor while work is being done on the machine.

Carry out a performance test with the machine.

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OPERATOR’S MANUAL EW 160 Inspection and servicing plans - instructions

1946502

Intervals

Warranty

The inspection and servicing plans list all jobs which have to be done on the machine at regular intervals.

The individual inspection and servicing plans are marked with letters providing a link between the operating hours (Oh) recorded by the hours-run meter of the machine and the inspection and servicing plans.

Meanings:

NHC’s warranty is subject among other things to the following compulsory maintenance works having been performed by the NHC dealer service or by a workshop authorized in writing by NHC to perform such work.

1. Compulsory maintenance N after 30 - 50 operating hours after commissioning.

2. Compulsory maintenance B after 500 operating hours after commissioning.

The execution of the compulsory maintenance works in due course must be documented on the NHC service check-lists.

Plan

Do all jobs...

V

... once prior to initial commissioning.

N

... after initial commissioning

Change of engine oil 1)

T

... every 10 Oh or every working shift .

W

... every 50 Oh or once a week1).

A

... every 250 Oh

B

... every 500 Oh

C

... every 1000 Oh

D

... every 3000 Oh

Additional engine maintenance intervalls are: 250 hours or 3 months1); 500 hours or 6 months1); 1000 hours or 12 months1); 2000 hours or 24 months1); (cf. "Engine operation and maintenance manual").

1)

whichever comes first.

Oh = Operating hour

Regular oil analysis The oil change intervals can be extended and wear in components recognized early if regular oil analyses are carried out.

Please request information from your NEW HOLLAND CONSTRUCTION (NHC) dealer.

Further servicing work For special versions / special equipment, further inspection and servicing work prescribed by the respective manufacturer may be necessary.

These are then listed under the corresponding key word in the table of contents, e.g. "Air-conditioning system, inspection and servicing work" or in a separately attached leaflet.

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The intervals stated for changing the engine oil apply to fuels with a sulphur content < _ 0.5% and a permanent ambient temperature down to -10oC In case of higher sulphur content and/or a permanent ambient temperature of below -10oC, shorter intervals are required (see engine operating instructions).

If the engine oil-change intervals are not reached within one year, the oil must be changed at least once a year.

Oil / Greases The "Lubricants" section quotes the specifications of the oils and greases to be used.

Meanings: I

Oils for combustion engines

II

Oils for hydraulic systems

III

Oils for axles and gearboxes

V

Greases for bearings and swivel connections

Cleaning jobs Cleaning jobs, especially on cooling systems, must be done at shorter intervals if the machine is exposed to severe dust build-up.

Servicing material The servicing material required for regular servicing work can be found in the spare parts list under assembly 92.020.

139

OPERATOR’S MANUAL EW 160 Plan V - Once before first commissioning

1946503

Page 1 of 2 Component designation

Servicing activity

Engine

Check oil level according to oil inspection plan

Cooling system

Check level of cooling liquid

Electrical system Battery Battery Lighting

Check acid level 1) Check charge condition Check operation

Monitoring, warning and control elements

Check operation

Hydraulic system Oil reservoir Operating pressure

Check operation Check oil level according to oil inspection plan Check pressure (NHC dealer service)

Brake Service brake Parking brake

Check operation Check operation

Wheel Tyres Wheel nuts

Check pressure Check tightness (torque wrench)

Steering axle Wheel-hub gears - Floating-axle pin - Stub axle joint - Tie rods - Steering knuckle pin

Check oil level according to oil inspection plan Check oil level according to oil inspection plan Lubricate according to lubricate chart grease Lubricate according to lubricate chart grease Lubricate according to lubricate chart grease Lubricate according to lubricate chart grease

Rigid axle Wheel-hub gears Travel gearbox

Check oil level according to oil inspection plan Check oil level according to oil inspection plan Check oil level according to oil inspection plan

Floating-axle blocking cylinder - Piston-rod bearing faces

Grease

Slewing gear Expansion reservoir Superstructure holding brake

Check oil level according to oil inspection plan Check operation

Working equipment

Lubricate according to lubricate chart grease

Cardan shaft

Lubricate according to lubricate chart grease

Slewing ring - gearing - bearing

Check grease filling Lubricate according to lubricate chart grease

1)

Quantity / Number

2 2

1

not required for maintenance-free batteries

140

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OPERATOR’S MANUAL EW 160 Plan V - Once before first commissioning Component designation

Superstructure Locking bolt Tappet of pedal valve (travelling/braking) Tappet of pedal valve (boom-adjusting cylinder) Tappet of control lever

Servicing activity

Quantity / Number

Grease Clean / grease Clean / grease

1 2x1 1x2

Clean / grease

2x4

Undercarriage - stabilizers

Lubricate according to lubricate chart grease

Lines, fittings and connections

Visual inspection for leaks

All articulated joints and hinges

Grease/Lubricate according to lubricate chart grease

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Page 2 of 2

141

OPERATOR’S MANUAL EW 160 Plan N - After first commissioning Component designation

Page 1 of 1 Servicing activity

Quantity / Number

After 30 to 50 OH (once) Cooling system

Cooling liquid, check level

Fuel system Filter Pre-filter

Replace Check / drain off water

2 1

Air-intake system Vacuum-meter Dust collector Suction and clean-air line

Check indicator, if it is red, check filter element Check / empty Check for leaks and tightness

1 1

Replace Check pressure (NEW HOLLAND CONSTRUCTION dealer-Service)

1

Hydraulic system Return-flow filter Operating pressure Wheel Wheel nuts

Check for tightness (torque wrench)

Steering axle

Change oil according to oil inspection plan

1

Wheel-hub gears

Change oil according to oil inspection plan

2

Rigid axle Fastening screws

Change oil according to oil inspection plan Check for tightness (torque wrench)

1

Wheel-hub gears

Change oil according to oil inspection plan

2

Travel gearbox

Change oil according to oil inspection plan

1

Slewing gear Fastening screws

Change oil according to oil inspection plan Check for tightness (torque wrench)

Slewing ring Fastening screws

Check for tightness (torque wrench)

Superstructure Ballast fastening screws

Check for tightness (torque wrench)

Undercarriage Axle fastening screws

Check for tightness (torque wrench)

Lines, fittings and connections

Visual inspection for leaks

142

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OPERATOR’S MANUAL EW 160 Plan T - Every 10 OH or per working shift (whichever occurs first) Plan W - Every 50 OH or weekly (whichever occurs first) Component designation

Servicing activity

Machine

Page 1 of 2 Plan T

Plan W

Check the machine and its assemblies visually for defects, leaks and losses of consumables

•

•

Engine

Daily / weekly maintenance procedures as described in the "Engine operation and maintenance manual"

•

•

Cooling system Combinated cooler

Cooling liquid, check level Check / clean

Fuel system Prefilter

Drain off water

1 1

Dust collector Suction and clean-air line

Check indication, if it is "RED" check filter element Check / empty Check for leaks and tightness

Electrical system Battery Lighting

Check acid level Check operation

1)

2

Air-intake system Vacuum-meter

Monitoring, warning and control Check operation elements Hydraulic system Oil reservoir Oil cooler

Visual inspection for leaks Check oil level according to oil inspection plan Check / clean

Brake Service brake Parking brake

Check operation Check operation

Wheel Tyres

Visual inspection for condition Check pressure

Steering axle - Floating-axle pin - Tie rod

Lubricate Lubricate

1)

Quantity / Number

• •

1

• • •

• • •

• •

• • • • • •

• • • •

• • • • • •

not required for maintenance-free batteries

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143

OPERATOR’S MANUAL EW 160 Plan T - Every 10 OH or per working shift (whichever occurs first) Plan W - Every 50 OH or weekly (whichever occurs first) Component designation

Slewing gear Expansion reservoir Superstructure holding brake

Servicing activity

Check oil level according to oil inspection plan Check operation

Working equipment

Lubricate according to lubricate chart grease

Slewing ring - bearing

Lubricate according to lubricate chart grease

Undercarriage

Clean

Lines, fittings and connections

Visual inspection for leaks

Machine

Overall cleaning

144

Page 2 of 2 Quantity / Number

Plan T

Plan W

• •

• • •

1

• • •

• • •

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OPERATOR’S MANUAL EW 160 Plan A - After every 250 OH

Plan C - After every 1000 OH

(at 250, 750, 1250 ... OH)

(at 1000, 2000, 4000 ... OH)

Plan B - After every 500 OH

Plan D - After every 3000 OH

(at 500, 1500, 2500 ... OH)

(at 3000, 6000, 9000 ... OH)

Component designation

Servicing activity

Page 1 of 3

Quantity / Plan Plan Plan Plan Number A B C D

Maintenance in acc. with W or T

•

•

•

•

Engine

Carry out all maintenance procedures listed and described in the "Engine operation and maintenance manual".

Engine maintenance intervals are: 250 hours or 6 month 1500 hours 6000 hours or 2 years

•

•

•

•

Cooling system Radiator contamination Cooling liquid Cooling liquid

Visual inspection for leaks Check / clean Check additive concentration Replace 2)

• •

• • •

• • •

• • • •

Air intake system Main filter element Safety filter element

Change 3) Change 3)

1 1

• •

• •

Fuel system Filter Tank Pre-cleaner

Replace Clean Check/clean,change if damaged

1 1 1

•

• •

• • •

Electrical system Battery and cable connections Battery terminals

Check for tightness Grease with terminal grease

• •

• •

• •

1 1

• •

• • •

2

•

•

• • • • •

Hydraulic system Return-flow filter Oil-reservoir breather valve Operating pressure Oil reservoir Line filter 1) 2) 3) 4)

Replace Replace Check pressure (NHC dealer-Service) Change oil and clean reservoir4) according to oil inspection plan Replace

• •

Change oil after 1 year at the latest, see "Engine operation instructions".

Replace cooling liquid after 2 years at the latest Replace filter element after 1 year at the latest Change hydraulic oil after 3 years at the latest

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145

OPERATOR’S MANUAL EW 160 Plan A - After every 250 OH

Plan C - After every 1000 OH

(at 250, 750, 1250 ... OH)

(at 1000, 2000, 4000 ... OH)

Plan B - After every 500 OH

Plan D - After every 3000 OH

(at 500, 1500, 2500 ... OH)

(at 3000, 6000, 9000 ... OH)

Component designation

Servicing activity

Steering axle

- Brake disks

Check oil level according to oil inspection plan Change oil according to oil inspection plan Check oil level according to oil inspection plan Change oil according to oil inspection plan Lubricate according to lubricate chart grease Lubricate according to lubricate chart grease Lubricate according to lubricate chart grease Check lining thickness

Floating-axle blocking cylinder - Bearing face of piston rod

Clean / grease

Wheel-hub gears

- Stub axle joint - Tie rods - Steering knuckle pin

Rigid axle

-Fastening screws - Brake disks Wheel-hub gears

Travel gearbox

Check oil level according to oil inspection plan Change oil according to oil inspection plan Check for tightness (torque wrench) Check lining thickness Check oil level according to oil inspection plan Change oil according to oil inspection plan Check oil level according to oil inspection plan Change oil according to oil inspection plan

Page 2 of 3

Quantity / Plan Plan Plan Plan Number A B C D 1

•

•

•

•

• • •

• • •

• •

• •

•

•

•

•

1 2 2

1 1

2 2 1 1

• • • • • • • •

• • • • • • • •

• • • • • • • • •

• • • • • • • • •

•

• •

Slewing gear Fastening screws

Change oil according to oil plan Check for tightness (torque wrench)

Cardan shaft

Lubricate according to lubricate chart grease

•

•

•

•

Slewing ring

Check grease filling according to lubricate chart grease Check for tightness (torque wrench) Check for condition

• • •

• • •

• • •

• • •

Fastening screws Pinion gearing

146

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OPERATOR’S MANUAL EW 160 Plan A - After every 250 OH

Plan C - After every 1000 OH

(at 250, 750, 1250 ... OH)

(at 1000, 2000, 4000 ... OH)

Plan B - After every 500 OH

Plan D - After every 3000 OH

(at 500, 1500, 2500 ... OH)

(at 3000, 6000, 9000 ... OH)

Component designation

Superstructure Ballast fastening screws Superstructure locking pin Pedal valve tappet (travelling/braking) Pedal valve tappet (boom adjusting cylinder) Control lever valve tappets Undercarriage - Levelling blade/stabilizers

Servicing activity

Quantity / Plan Plan Plan Plan Number A B C D

Check for tightness (torque wrench) Grease Clean / grease

1 2x1

Clean / grease

1x2

Clean / grease

2x4

Lubricate according to lubricate chart grease

Page 3 of 3

• • • • •

• • • • •

• • • • •

• • • • •

•

•

•

•

Heating Filter mat

Visual inspection for leaks Clean / change

• •

• •

• •

Driver’s cab Fastening screws

Check for tightness

All articulated joints and hinges

Lubricate according to lubricate chart grease

• •

• •

• •

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147

OPERATOR’S MANUAL EW 160 LUBRICATING CHART - GREASE

= Operating hours

2472220

Fig. 1

148

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OPERATOR’S MANUAL EW 160 Lubricating chart - Grease Working equipment (Key to chart Fig. 1) Pos.

Greasing point

Number

1

Stick cylinder bearing Backhoe cylinder bearing Stick bearing

1 1 2x1

2

Grease nipples - Stick cylinder bearing - Boom cylinder bearing - Boom cylinder bearing bolt

1 2x1 2x1

3

Boom bearing (lower section of boom 2))

2x1

4

Boom cylinder bearing

2x1

5

Grease nipples 2) - Boom-adjusting cylinder bearing - Stick cylinder bearing - Boom cylinder bearing - Boom cylinder bearing bolt - Connecting bolt - lower section of boom/upper section of boom

1 1 2x1 2x1 2x1

6

Boom-adjusting cylinder bearing 2)

7

8

Lubricant properties

Greasing every ... OH 10 10 10 10

10

V1)

10 10

1

10

Articulated joints on toggle lever and link Backhoe cylinder bearing Backhoe/stick bearing

6 1 2x1

10 10 10

Clamshell grab (optional equipment) - Joints - Gearing grab rotating devide - Grab / stick bearing

10 1 2x1

10 10 10

1) cf. section "LUBRICANTS" 2) Only for boom-adjusting equipment (optional equipment)

Working equipment from other manufacturers: Carry out inspection and servicing work according to manufacturer’s instructions

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149

OPERATOR’S MANUAL EW 160 LUBRICATING CHART - GREASE

= Operating hours

2801580

Fig. 2

150

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OPERATOR’S MANUAL EW 160 Lubricating chart - Grease Undercarriage (Key to chart Fig. 2) Pos.

Greasing point

Number

Lubricant properties

Greasing every ... operating hours

1

Swing ring - bearing

1

50

2

Swing ring - grease filling of gearing

1

250

3

Stabilizer feet

8

250

4

Universal joints of cardan shafts

2

250

5

Steering knuckle pin

4

6

Stub axle joint

4

250

7

Tie-rods

4

50

8

Levelling blade bearing and levelling blade cylinder

12

250

9

Floating-axle blocking - Bearing faces of piston rods

2

250

10

Floating-axle pin

2

50

V

1)

250

Filling quantities - grease Lubricating point, component

Gearing of swing ring (permanent grease filling)

Lubricant properties Refilling quantity in kg

V

1)

approx. 6,0

1) cf. "LUBRICANTS" section

Joints and hinges

2411970

Grease or oil all joints and hinges, e.g. on covers and flaps, in accordance with the inspection and servicing plan.

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151

OPERATOR’S MANUAL EW 160 OIL INSPECTION PLAN

= Operating hours

1946504

Fig. 3

152

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OPERATOR’S MANUAL EW 160 Oil inspection plan (Key to chart Fig. 3) Pos.

Number

Lubricant properties 1)

Check oil level every ... OH

Change oil every ... OH

1

Hydraulic system

1

II

50

30004)

2

Swing gear

1

III

50

30002)

3

Engine

1

I

10

2502) 3)

4

Rigid axle Wheel-hub gears Travel gearbox

1 2 1

III

250

10005)

Steering axle Wheel-hub gears

1 2

III

250

10005)

5 1) 2) 3) 4) 5)

Component

cf. "LUBRICANTS" section First after 30 - 50 OH Change oil after 1 year at the latest, see "Engine operation instructions".

Change hydraulic oil after 3 years at the latest Change oil after 1 year at the latest

Refilling quantities - oil Component Drive engine (incl. oil filter)

Refilling quantity (liters) 6) approx. 11,5 (3 gal)

Hydraulic system tank capacity

approx. 250 (66.1 gal) approx. 150 (39.7 gal)

Slewing gear

approx. 3,5 (0.9 gal)

Rigid axle housing

approx. 7,5 (2.75 gal)

Rigid axle wheel-hub gears

approx. 2 x 1 (0.26 gal)

Travel gearbox

approx. 3,2 (0.85 gal)

Steered axle housing

approx. 11 (2.9 gal)

Steered axle wheel-hub gears

2 x approx. 1,3 (2 x approx. 0.34 gal)

Refilling quantities - other Component

Refilling quantity (liters) 6)

Engine cooling liquid

approx. 18.5 (4.9 gal)

Fuel tank

approx. 250 (66.2 gal)

Screen-washer reservoir 6)

approx. 1,5 (0.4 gal)

The listed quantities of consumables are approximate data designed as a guide. Each unit has appropriate control devices, e.g. dipstick or control plugs, with which the exact filling level is checked.

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153

OPERATOR’S MANUAL EW 160 LUBRICANTS

I.

API:

Oils for internal combustion engines

2732720

American Petroleum Institute Engine pre-heating necessary. Cold-starting aid may be sufficient in upper range. Warm up engine. When warming up, increase engine speed and loading gradually.

When using single-range or other multi-range motor oils, and at temperatures lower than those stated, the oil recommendations of the engine manufacturer are to be observed. For details, see engine instruction manual.

154

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OPERATOR’S MANUAL EW 160

II.

Oils for hydraulic system, mineral

2732721

Warming-up phase necessary before commencing operation.

Warm up hydraulic system for approx. 10 minutes by running engine at half speed and by actuating all control valves repeatedly.

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155

OPERATOR’S MANUAL EW 160

III.

Oils for axles and gearboxes (selection)

2905902

Oils of inferior quality may cause damage to axles and gearboxes.

Use only high-quality oils with additives in the prescribed amount (see "Specification").

API:

American Petroleum Institute

MIL:

US armed forces fuel specifications for engine and machine manufacturers

LS:

Limited slip

P+S:

Phosphorus and sulphur doping as with Anglamol 99

* e.g.: Titan Gear LS 90 Fina Pontonic LS 90 BP Energear LS 90 Ambra TX Fluid

156

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OPERATOR’S MANUAL EW 160

V.

Greases for bearings and swing rings

2732723

for centralized lubricating systems and tensioning systems, e.g. track chain Minimum requirement Grease base

:

lithium

Solid lubricant content (MoS2 or graphite)

:

max. 3%

NLGI - class

:

see above

Corrosion protection acc. ASTMD 17 43 (CRC)

:

code No. 1

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157

OPERATOR’S MANUAL EW 160 SERVICING Draining hose for oil changes

2411336

Collect escaping oil and evacuate it without polluting the environment.

Carry out oil changes when the engine is at operating temperature; warm oil drains away more easily.

The engine, hydraulic oil reservoir and gearboxes may be equipped with special oil drain valves (1, Fig. 1).

These plugs permit to perform oil changes in a clean and non-polluting way.

Fig. 1

Carry out oil changes as follows: - Place a recipient for waste oil under the drain opening (for the capacity see under "Filling quantities").

- Choose the proper drain hose from the tool kit.

- Unscrew protective cap from oil drain valve.

- Screw on drain hose (2); the valve opens and the oil drains away.

- After the oil has drained away unscrew drain hose; the valve closes automatically.

- Screw protective cap back in place.

158

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OPERATOR’S MANUAL EW 160 ENGINE

2411971

Engine, safety instructions for inspection and servicing

Checking the engine oil level / topping 2732733 up with oil • Park machine on a horizontal surface and secure against inadvertent movements.

Risk of injury from rotating fan blades and running V-belts.

Switch off the engine before opening the engine compartment.

• Wait at least 5 minutes after shutting off the engine to check the lubricating oil. This allows time for the lubricating oil to drain to the oil pan.

Risk of burning due to hot parts on engine, exhaust and radiator.

Never begin servicing and repair work until engine, exhaust and radiator have cooled down.

Wear working gloves.

Secure the machine as described in the section "Securing the machine".

Read and observe: "Inspection and Servicing, Safety Instructions" and the operating instructions for the engine.

Fig. 1

2732717

• Withdraw dipstick (Fig. 1) and wipe clean with a clean, lint-free cloth and re-insert.

For more detailled informations about engine maintenance see also: "Engine operation and maintenance manual".

• Draw out oil dipstick once again, check the oil level and top up oil through the filler tube (Fig. 2) up to the "max" mark (Fig. 1) (oil quality cf. "LUBRICANTS").

Fig. 2

If the oil level is just above the "min" mark (Fig. 1), the oil level must be topped up.

The oil level must not drop below the "min" mark and must not raise above the "max" mark.

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159

OPERATOR’S MANUAL EW 160 Checking the drive belts

2732895

Risk of injury from rotating fan blades and running V-belts.

Switch off the engine before opening the engine compartment.

Risk of burning due to hot parts on engine, exhaust and radiator.

Never begin servicing and repair work until engine, exhaust and radiator have cooled down.

• Open engine compartment.

Checking the coolant level

2801748

Risk of scalding from hot coolant.

Unscrew the cap of the cooling system only when the engine is cold and stationary.

An insufficient coolant reserve is indicated by warning lamp (37) on the control panel.

In spite of this warning facility, the coolant level must be checked at least once every week to detect losses of coolant and to prevent any consequential damage.

• Open the cover of the engine compartment.

Fig. 3

• Visually inspect the belts.

• Check the belts for intersecting cracks.

Transverse cracks (1, Fig. 3) are acceptable.

Cracks in direction of belt length that intersect with traverse cracks are not acceptable (2).

• Replace belt if it is frayed or has pieces of material missing.

For more information about adjustment and replacement see: "Engine operation and maintenance manual".

Fig. 4

• Unscrew cap (1, Fig. 4) on filler tube cautiously by one half turn to allow overpressure to escape from the system.

Unscrew completely only after the system is fully depressurized.

• The coolant must reach up to the lower edge of the filler tube. Top up system with coolant, if necessary.

(Type and mixing ratio see engine operating instructions).

• Screw cap back in place.

• Close cover of engine compartment and open cover above the air filter and battery compartment.

• Check coolant level inside the expansion reservoir (2, Fig. 4) using a wooden rod.

The reservoir should be filled between a quarter and half.

• Screw cap back in place.

160

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OPERATOR’S MANUAL EW 160 AIR-INTAKE SYSTEM

2472228

Risk of injury caused by hot or rotating parts of the engine.

Emptying the dust collector

2716647

The dust collector collects all dirt particles that may have penctreted into the air filter housing.

Shut off engine before working on the air-intake system.

Read and observe the section "Engine Safety instructions".

Never start engine when parts of the airintake system have been detached.

Engine damage may occur if the engine is allowed to draw in unfiltered air.

Fig. 1

• Open cover above the air filter compartment.

• To remove dirt, squeeze the mouthpiece together several times.

Loose dirt falls down to the ground.

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161

OPERATOR’S MANUAL EW 160 Removing, checking, and cleaning the main filter element • Open cover above the air filter and battery compartment.

2796964

• The main filter element must replaced once it has been cleaned three times, and at the latest after one year operating time.

There is a red section at the vacuum meter at the air filter housing (Fig. 2). It indicates that the main filter element must be serviced.

Fig. 4

• Carry out a visual inspection: Fig. 2

If this is the case, the main filter element is so badly contaminated that it no longer allows an adequate volume of air through.

- Put a lamp into the filter element. Emission of light indicates damaged locations (Fig. 5).

- The filter element must not be deformed.

- The rubber seals of the filter element must not be damaged.

Fig. 3

• Unsnap clamps (3, Fig. 3) and remove cover (4).

• Draw filter element (2) carefully out of the air filter housing.

• The safety filter element (1) remains installed.

• Clean the filter element using compressed air at max. 6 bar (87 psi). Insert the ompressed air nozzle (Fig. 4) and hold it approx. 3 cm (1.18") from the paper.

Never clean filter element by beating against hard objects to avoid damage.

162

Fig. 5

If damage is present the filter element must not be reinstalled.

• Clean interior of air filter housing and cover.

• Install checked and cleaned filter element or new filter element.

• Install cover.

• Press reset button of vacuum meter. The indicator changes from red to green.

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OPERATOR’S MANUAL EW 160 Checking / replacing the safety filter element

Checking air intake lines 2800865

Never start engine when the safety filter element has been removed.

The engine may be damaged if it is allowed to draw in unfiltered air.

2472232

The engine must not be allowed to take in unfiltered air. Therefore: • Check all hoses and pipes for leaks.

• Check that all clamps are in position and secure.

Replace damaged parts immediately (or have them replaced).

• The main filter element must be removed before the safety filter element (1, Fig. 6) is accessible.

Fig. 6

• Check if safety filter element is clean.

Do not clean the safety element, but always replace when it is contaminated.

Change safety filter element after 3 cleanings of the main filer element or after 1 year of operation at the latest.

• Clean air-filter housing and lid thoroughly inside, using a vacuum cleaner.

• Install new safety filter element if necessary.

• Re-install main filer element.

• Re-install cover of filter housing.

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163

OPERATOR’S MANUAL EW 160 FUEL SYSTEM

2413740

Fuel system - Safety instructions

When working on the fuel system: - switch off engine and additional heating system, - secure machine, - no exposed flames, - no smoking.

The risk of contamination of the fuel system increases if the machine is often or regularly refuelled with fuel from canisters or barrels.

Collect any escaping fuel and dispose of it in an environmentally friendly manner.

The fuel filter must be changed at shorter intervals.

In this case the primary fuel filter must be drained and cleaned more often than indicated in the servicing plan.

Diesel fuel can cause damage to skin.

Therefore, wear protective gloves or use a protective cream.

Dispose of filter in an environmentally responsible manner and separate from other waste.

164

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OPERATOR’S MANUAL EW 160 Cleaning the fuel tank

2796948

• Unscrew cap of filler opening (Fig. 2).

• Remove gauze inset.

Explosion hazard Never use white spirit, paraffin oil or other solvents to clean the tank.

Readily flammable, explosive gases are formed.

• Clean tank with cleaning equipment and flush out.

• Screw drain plug back in place.

• Install covering plate.

So use only diesel fuel or special cleaning oil to clean the tank.

• Fit gauze inset into filler opening.

Observe the instructions for use issued by the manufacturer of the cleaning oil.

• Fill in fuel through gauze inset in filler opening (Fig. 2).

Fuel and cleaning oil must be prevented from penetrating into the soil.

Store for re-use or discard without polluting the environment.

• Use up as much fuel as possible.

• Check how much fuel is left in the tank and place a sufficiently large collecting vessel under the drain plug of the tank.

Fig. 2

• Remove covering plate below fuel tank.

• Unscrew drain plug on underside of fuel tank (Fig. 1) and drain off fuel.

• Place a collecting vessel under the drain plug to catch the cleaning fluid.

Fig. 1

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165

OPERATOR’S MANUAL EW 160 ELECTRICAL SYSTEM

2716610

Electrical system - Safety instructions

Risk of injury from battery acid and gases.

Wear goggles, protective gloves and sturdy working clothing.

Alternator - instructions

2732237

Never disconnect electrical connections on the alternator, regulator and battery when the engine is running.

This would damage the alternator and regulator.

Prior to working on the electrical system Prior to working on the electrical system, where tools, spare parts etc. may come into contact with electric cables or contacts, disconnect the battery.

Disconnect first the negative, then the positive pole.

After work: Connect first the positive, then the negative pole.

Read and observe "Inspection and Servicing - Safety instructions".

Use only measuring instrument for voltage and continuity testing, never use a test lamp.

Never "tap against ground".

This causes a short circuit with consequent damage to the generator or to the electronics of the PCS.

166

When connecting the batteries, never interchange the cables (pay attention to polarity).

Always use measuring instrument for voltage and continuity testing.

Never use a "test lamp".

Never "tap against ground".

This causes a short circuit with consequent damage to the alternator and regulator.

When the engine is started, the alternator is pre-excited by an electronic circuit.

This circuit ensures that the alternator can supply power.

The circuit is part of the Central Electronic System in the control panel.

An LED in the control panel (charge control) indicates the correct functioning of the alternator. This LED must light up when the keyswitch is turned to the "ON" position. It goes out when the engine is running. If this is not the case, either the alternator circuit or the control panel are defective.

To prevent further damage, the cause of the fault must be located and rectified as fast as possible.

Contact your nearest NEW HOLLAND CONSTRUCTION dealer.

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OPERATOR’S MANUAL EW 160 Battery main switch

2796460

The battery main switch is installed in the battery compartment beside the batteries (Fig. 1).

Battery, checking

2732234

Battery - checking the fluid level (Not applicable to maintenance-free batteries) • Unscrew the caps.

• If checking inserts are installed, the battery fluid must reach the bottom of the inserts.

• If no checking inserts are installed, insert a clean piece of wood into the battery down to the top of the plate. The wood must be wet over at least 10 mm (0.39").

• If the fluid level is too low, top up with distilled water only.

Battery - checking the charge Fig. 1

The acid temperature should be 20˚C (68˚F).

If the switch lever is set to OFF, the main switch disconnects the negative pole of the battery from the vehicle chassis so that the electrical system of the machine is without tension.

• Unscrew the battery caps (Fig. 2).

In the OFF position, the lever of the battery main switch can be withdrawn.

• Measure the acid density of the battery with a standard test instrument (Fig. 2).

The acid density is in direct correlation with the battery charge.

Setting the battery main switch to OFF when the diesel engine is running may cause voltage spikes which can cause irreparable damage to electrical and electronic components.

For this reason: shut off the diesel engine before setting the battery main switch to OFF.

Fig. 2

Acid density in kg / dm3

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Charge

Normal

Tropics

1.28

1.23

charged

1.20

1.12

half-charged, recharge

1.12

1.08

discharged, recharge at once

167

OPERATOR’S MANUAL EW 160 Removing and installing the battery

2904402

• Open cover above the air filter and battery compartment.

Switch off the engine before removing the batteries, to prevent damage to the alternator and regulator or to electronic components.

• Switch off the main battery switch and withdraw the switch lever.

Set key-operated switch for electrical system to 0 and remove key.

• Detach the pole terminal at the negative pole of the battery.

Detach and mount the pole terminals in the specified sequence.

• Disconnect cable bridge between batteries.

The incorrect sequence may result in short circuiting.

• Detach the pole terminal at the positive pole of the battery.

• Unscrew the battery holder (Fig. 3).

• Insulate the pole terminals.

• Lift the battery out of the battery box.

Prior to installing the new battery, make the contact surfaces of the battery poles and the pole terminals bright.

• Install the new battery.

• Connect the pole terminal to the positive pole of the battery.

• Connect cable bridge between batteries.

Fig. 3

Tighten the clamping screws of the pole terminals. Never use force when tightening the clamping screws, however, as this might result in damage.

• Connect the pole terminal to the negative pole of the battery.

• Then coat battery poles and pole terminals with pole grease or non-acidic Vaseline.

Loose or corroded pole terminals overload the alternator and the regulator.

168

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OPERATOR’S MANUAL EW 160 HYDRAULIC SYSTEM

2472236

Hydraulic system - safety instructions

Depressurizing the hydraulic system 2796546

Read and observe: "Inspection and servicing - Safety instructions".

Before working on the hydraulic system, make sure the system has been depressurized and that any residual pressure has also been released.

Before beginning work, the hydraulic system must be depressurized: - Set working equipment on the ground - Shut off engine - Switch pilot control on

Switch off engine.

- Turn the keyswitch of the electrical system into position I (ignition ON).

Secure the machine as described in the section "Securing the machine".

- Move the righthand or lefthand control lever to and fro (abt. six times).

Avoid skin contact with hydraulic oils.

Skin contact with hydraulic oils can damage health.

- Set the keyswitch of the electrical system to 0 (ignition OFF).

Wear gloves and protective clothing.

- Switch off the pilot control. The left control console swings up.

- Reduce precharging pressure in hydraulic oil reservoir by unscrewing the venting plug (Fig. 1) carefully until the venting hole is free (audible hissing sound).

Tighten venting plug again.

Fig. 1

The residual pressures in the working equipment and the hydraulic pilot control are now relieved.

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169

OPERATOR’S MANUAL EW 160 Checking the hydraulic oil level

2732834

• Bring hydraulic oil to operating temperature (abt. 50˚C / 122˚F).

• Park machine on a horizontal surface.

Topping up with hydraulic oil

2800279

The hydraulic oil reservoir is at a charging pressure of approximately 0.3 bars (4.36 psi). This pressure must be relieved before the reservoir is opened.

• Bring all hydraulic cylinders to their center position.

• Shut off engine.

• Open cover of the pump compartment at the right side of the superstructure.

Fig. 3

• Relieve charging pressure of reservoir as described in the "Depressurizing the hydraulic system" section.

Fig. 2

• Remove four nuts (1, Fig. 3 and 4). Cover (2) is spring-loaded.

The oil level must lie between the "min" and "max" marks of the inspection glass (Fig. 2).

If the oil level has dropped to the "min" mark, hydraulic oil must be added.

Fig. 4

• Remove cover (2).

Do not lose spring (6, Fig. 4) and sealing ring (7).

• The return-flow filter is now visible in the filter chamber.

• Fill in hydraulic oil through this filter until the oil level is between the "min" and "max" marks of the inspection glass (oil grade cf. "LUBRICANTS").

• Before fitting cover (2), check sealing ring (7) and replace, if damaged.

• Fit cover with sealing ring and spring.

170

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OPERATOR’S MANUAL EW 160 Changing the hydraulic oil returnflow filter

Replacing the breather valve 2800280

The return-flow filter must be replaced: - at the servicing intervals in acc. with the servicing plan - when the "Hydraulic oil filter" warning lamp lights up with the hydraulic oil at operating temperature. In this case, the filter is heavily contaminated

2732698

The breather valve (Fig. 6) ensures aeration and deaeration of the hydraulic reservoir in case of hydraulic oil level fluctuations.

The valve maintains a charging reservoir pressure of approximately 0.3 bars (4.36 psi).

- after repairs on the hydraulic system.

Fig. 6

The breather valve contains a filter element. This element cannot be replaced or cleaned.

Fig. 5

The breather valve must therefore be replaced completely in acc. with the servicing plan.

• Reduce reservoir charging pressure as described in the "Depressurizing the hydraulic system" section.

• Remove cover (2, Fig. 5) as described in the "Topping up with hydraulic oil" section.

• Withdraw return-flow filter (5) from the filter compartment. The filter must be disposed of separately and without polluting the environment.

• Insert new filter.

• Fit cover (2) with new sealing ring (7) and spring (6).

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171

OPERATOR’S MANUAL EW 160 Changing line filters

2472340

The machine is equipped with one line filter for the feed pump of the swing pump and one for the pilot control (servo) circuit.

Change filters according to servicing plan.

The line filter for the feed pump of the swing pump is installed in the engine compartment (Fig. 7).

The line filter for the pilot control (servo) circuit is installed in the frame behind the drivers cab (Fig. 8).

Fig. 9

• Remove housing (5, Fig. 9). Do not spill hydraulic oil.

Fig. 7

• Release residual pressure from hydraulic system, see section "Depressurizing hydraulic system".

• Remove cover plate under the engine compartment.

• Remove cover plate of the frame behind the drivers cab.

• Remove filter element (4) from connection piece (1) by turning and pulling at the same time.

• Clean filter housing and sealing surfaces on the filter head.

• Install new O-rings (2 and 3). Oil lightly before installing.

• Press the new filter element onto the neck (1) with a turn.

• Screw filter housing into filter head.

• After putting the hydraulic system into operation, check that the filter housing does not leak.

• Dispose of used filters in an environmentally responsible manner and separate from other waste.

Fig. 8

172

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OPERATOR’S MANUAL EW 160 Changing the hydraulic oil

2472243

Draining hydraulic oil

2801528

• Operate hydraulic oil to operating temperature (approx. 50˚C / 122˚F).

Danger of scalding due to hot hydraulic oil!

Avoid skin contact with hydraulic oil.

Wear working gloves.

Collect draining oil and dispose of it in an environmentally friendly manner.

Secure the machine against unauthorized operation as described in the section "Securing the machine".

• Park the machine on a horizontal surface.

• Retract hydraulic cylinders as far as possible and set working equipment down on the ground.

• Switch off engine.

• Release tank charging pressure as described in section "Topping up hydraulic oil".

Read and observe: "Inspection and servicing - Safety instructions".

Do not start the drive engine when the hydraulic oil reservoir is empty!

Dry operation can damage the hydraulic pumps.

Fig. 10

• Place a collecting vessel under the oil drain neck of the hydraulic oil reservoir (Fig. 10).

For required capacity see "Filling quantities for oil change".

• Drain the hydraulic oil using the oil drain hose.

Use of the oil drain hose is described in the section "Draining hose for oil change".

• Clean the hydraulic reservoir.

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173

OPERATOR’S MANUAL EW 160 Cleaning the hydraulic oil reservoir

2904403

Renew sealing cord Attach cover with new sealing cord as follows:

Danger of explosion Therefore do not use petroleum ether, paraffine oil or other solvents to clean the reservoir.

They form easily flammable explosive gases.

Therefore use only hydraulic oil or a special cleaning oil to clean and flush the reservoir.

Observe the instructions for application from the cleaning oil manufacturer.

- Clean sealing surfaces and place new sealing cord inside the ring of bolts (round each bolt) (Fig. 12).

- Cross the ends of the sealing cord and place close to one of the bolts.

- Position cover and tighten nuts alternately with a torque of MA = 49 Nm (36.1 lbft).

The sealing cord is made of PTFE material (e.g.

Teflon) with the designation PAM-O-PACK 4RD RD TYP 1. It is supplied by the NEW HOLLAND CONSTRUCTION Spare-Parts Service.

Do not allow hydraulic oil or cleaning oil to escape into the ground.

Store for reuse or dispose of in an environmentally responsible manner.

• Drain hydraulic oil as described in section "Draining hydraulic oil".

• Release all nuts (1, Fig. 11) and remove cover (2).

Fig. 12

Filling with hydraulic oil

2472343

• Remove cover of return-flow filter, as described in section "Topping up hydraulic oil".

• Fill hydraulic oil to "max" mark in inspection glass.

(Filling quantities and oil grade see: "Filling quantities for oil change" and "LUBRICANTS").

Fig. 11

• Place collecting vessel for flushing oil under the hydraulic oil reservoir.

• Bleed the hydraulic system.

• Check oil level in hydraulic oil reservoir. Top up with oil if necessary.

• Clean inside of reservoir with hydraulic oil or flushing oil. Remove completely all deposits and residual cleaning agent.

• Renew sealing cord under cover (2) and attach cover.

• Attach covering plate below the hydraulic tank.

• Fill in hydraulic oil.

174

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OPERATOR’S MANUAL EW 160 Venting the hydraulic system

2801532

Catch escaping oil and discard without polluting the environment.

Hydraulic pumps, motors and cylinders must be carefully vented after oil changes.

Their intake and operating characteristics are otherwise seriously affected.

• Unscrew venting plug on hydraulic pump (Fig. 13).

Hydraulic oil flows out of the tank into the pump, forcing out the air.

Fig. 13

Screw venting plug back in place when bubblefree hydraulic oil emerges from the hole.

• Start up engine and run at moderate speed for about two minutes.

• Extend and retract all hydraulic cylinders repeatedly until the movements are executed smoothly.

• Swing superstructure repeatedly in both directions.

• Turn steering wheel repeatedly to left and right limit stops with the engine running.

When the steering motion is smooth and noisefree, the steering system is vented.

Venting procedures after repair work on other components of the hydraulic system (e.g. on other pumps or on valve assemblies) are more complex and require know-how which cannot be imparted in full within the scope of these Operating Instructions.

In cases of doubt or if questions arise, consult your NEW HOLLAND CONSTRUCTION dealerservice.

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175

OPERATOR’S MANUAL EW 160 Bleeding the supporting cylinder of the full-floating axle

2801173

Collect escaping oil and discard without polluting the environment.

• Stand the working equipment on the ground.

• Shut off the engine.

• Block the wheels with chocks.

• Screw out the plugs (2, Fig. 1) on both supporting cylinders.

Fig. 1

The non-return valve may protrude into the oil filler opening that has now been created by removing the plug. This valve must not damaged when the piston rod is being driven downwards.

• Drive the piston rods down the cylinders until they are in contact with the pressure pad of the axle.

• Fill hydraulic oil into both cylinders and screw the plugs back in place.

• Screw out both bleeding screws (1) and fill hydraulic oil into the bores.

Fig. 2

• Screw bleeding screws back in but do not tighten.

• Start up the engine and release the bakes.

• Unblock the full-floating axle by pushing rocker switch (52, Fig. 2) forwards (the switch face without symbol is depressed).

• Tighten the bleeding screws (1, Fig. 1) as soon as the oil emerges bubble-free from the bore.

176

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OPERATOR’S MANUAL EW 160 Cleaning the hydraulic oil cooler

2800281

Danger of injury due to rotating fan blades and circulating V-belts!

The speed of the fan motor is controlled by a thermostat. The motor reaches its maximum speed at a hydraulic oil temperature of abt.

60oC (140oF).

Switch the engine off before opening the engine compartment.

• Detach cover grid above the hydraulic oil cooler (Fig. 1).

Danger of burns due to hot parts at engine, exhaust, and coolers.

Do not start cleaning work until engine, exhaust, and coolers have cooled. Wear working gloves.

Wear safety goggles when working with compressed air.

• Blow compressed air from above through the cooling fins.

• Wipe off all dirt from cooling gills.

Remove retaining dirt with compressed air or water, blowing from the fan side.

Clean cooler from top to bottom.

• Remove released dirt from cooler area.

If the machine is operated at locations with heavily contaminated ambient air the hydraulic oil cooler must be cleaned more often than indicated in the servicing plan.

Do not use abrasive or hard pointed tools for cleaning work such as wire brushes, scrapers or screwdrivers.

They could damage the cooling gills.

Fig. 1

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177

OPERATOR’S MANUAL EW 160 Cleaning the engine cooler

Danger of injury due to rotating fan blades and circulating V-belts!

Switch the engine off before opening the engine compartment.

Danger of burns due to hot parts at engine, exhaust, and coolers.

2800282

• Open covers of the engine compartment and above the air filter and battery compartment (Fig. 2).

• Wipe off all dirt from the cooling gills. Remove retaining dirt with compressed air or water, blowing from the fan side.

Clean cooler from top to bottom.

• Remove released dirt from the cooler area.

Do not start cleaning work until engine, exhaust, and coolers have cooled. Wear working gloves.

Wear safety goggles when working with compressed air.

If the machine is operated at locations with heavily contaminated ambient air the hydraulic oil cooler must be cleaned more often than indicated in the servicing plan.

Do not use abrasive or hard pointed tools for cleaning work such as wire brushes, scrapers or screwdrivers.

Fig. 2

They could damage the cooling gills.

178

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OPERATOR’S MANUAL EW 160 SWING GEAR

2800284

Swing gear - checking oil level

Swing gear - changing oil 2732712

Read and observe: "Inspection and servicing - Safety instructions".

Danger of scalding due to hot gear oil!

Wear working gloves.

• Switch machine off as described in section "Securing the machine".

Collect draining oil and dispose of it in an environmentally friendly manner.

• Detach cover grid above the hydrailic oil cooler.

• Unscrew cap (red) of expansion reservoir (Fig. 1).

• Provide a collecting vessel for the waste oil.

For required capacity see: "Filling quantities for oil change".

• Unscrew cap of expansion reservoir (Fig. 1).

• Remove cover plate of the frame behind the driver’s cab.

• Twist off cap of drain neck (Fig. 2).

• Drain gear oil using an oil drain hose (1) of approx. 1 m (39") length.

Use of the oil drain hose is described in the section "Draining hose for oil change".

• Raise oil drain hose at swing gear.

Fig. 1

• There must be 1 - 2 cm (0.39" - 0.79") of oil in the reservoir. Top up oil if necessary.

(Oil grade see: "LUBRICANTS").

• Fill new oil through oil drain hose until oil level in expansion reservoir is 1 - 2 cm (0.39" 0.79").

(Filling quantity and oil grade see: "Filling quantities for oil change and LUBRICANTS").

• Remove oil drain hose.

• Screw on cap of expansion reservoir.

• Install cover plate.

Fig. 2

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179

OPERATOR’S MANUAL EW 160 Superstructure holding brake - Function checking

2732236

• Start engine.

Read and observe: "Inspection and servicing - Safety instructions".

The superstructure holding brake is switched into the AUTOMATIC mode by the central electronic unit.

LED A above the key (28, Fig. 4) lights up.

The supertructure is braked when the swing control lever (78, Fig. 3) is not operated and the swing movement is completed.

• Activate pilot control using lever (77).

• If the swing motion control lever (78) is deflected, the superstructure holding brake is released and the superstructure is free to turn.

• Depress key (28, Fig. 4) until all LEDs are extinguished.

Fig. 3

The superstructure holding brake is released.

The superstructure swings freely even if the swing control lever (78, Fig. 3) is not operated.

• Depress key (28, Fig. 4) once. LED I lit up.

The superstructure holding brake is actuated.

The superstructure is braked. It must not be possible to swing it.

• Depress key (28) once again. LED A lit up.

The superstructure holding brake is switched to AUTOMATIC mode.

Inform your NEW HOLLAND CONSTRUCTION dealer-service if malfunctions occur in this system.

Fig. 4

180

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OPERATOR’S MANUAL EW 160 Axles and travel gearbox

2905187

Rigid axle and travel gearbox - checking the oil level Before starting work: • Park machine on an even, horizontal surface.

Risk of scalding through hot oil.

The axle and the gearbox housing may also be hot after a long drive.

Give axle and gearbox housing time to cool off and wear working gloves.

The axle and gearbox may be under slight excess pressure. So unscrew control plug carefully until the pressure has been reduced (audible hissing sound).

Catch escaping oil and discard without polluting the environment.

Read and observe: "Inspection and servicing - Safety instructions".

• Block wheels of steering axle with chocks.

Wheel-hub gears, check oil level Lift machine with levelling blade and working equipment until the wheels of the rigid axle lift from the ground and can be turned freely.

Shut off engine.

• The screw plugs on the wheel hub gearbox (1 and 2, Fig. 1) must be in the position indicated.

• Clean area around screw plug (1).

• Unscrew screw plug (1) gradually until there is no more excess pressure. Only then may the screw plug be removed.

The oil level must reach up to the opening. If necessary, top up through opening.

(For oil grade, see: "LUBRICANTS").

• Screw in screw plug.

• Repeat check at the other wheel-hub gear.

• Lower machine to the ground.

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181

OPERATOR’S MANUAL EW 160 Axle gearbox and travel grearbox, check oil level • Clean area around screw plug on axle (Fig. 2) and travel gearbox (Fig. 3).

• Unscrew screw plugs gradually until there is no more excess pressure. Only then may the screw plugs be removed.

The oil level must reach up to the opening. If necessary, top up through opening.

(For oil grade, see: "LUBRICANTS").

• Screw in screw plugs.

Fig. 1

Fig. 2

Fig. 3

182

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OPERATOR’S MANUAL EW 160 Rigid axle and travel gearbox - changing the oil

Risk of scalding through hot oil.

The axle and the gearbox housing may also be hot after a long drive.

Give axle and gearbox housing time to cool off, and wear working gloves.

The axle and gearbox may be under slight excess pressure. So unscrew control plug carefully until the pressure has been reduced (audible hissing sound).

Catch escaping oil and discard without polluting the environment.

Read and observe: "Inspection and servicing - Safety instructions".

2905188

Data on the quantity and grade of oil to be used are given in the sections: "Refilling quantities" and "LUBRICANTS".

Draining off oil • Park machine on an even, horizontal surface (cf.: "Securing the machine").

• Clean area around screw plugs (Figs. 4 to 5).

• Place a vessel to catch used oil under the travel gearbox (Fig. 5) and wheel-hub gears (Fig. 4).

• Unscrew the drain plugs on the travel gearbox and rigid axle (1 and 2, Fig. 5) and on the wheel-hub gears (2, Fig. 4); the oil drains off.

• Screw in screw plugs (Figs. 4 and 5).

Fig. 4

Fig. 5

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183

OPERATOR’S MANUAL EW 160 Filling in oil Note: The filling quantities listed in the table "Refilling quantities - oil" are approximate data.

Gears and axles are exactly filled when the oil level reaches the lower edge of the screw plug bores named in the text.

First fill in oil into the wheel-hub gears.

To do so: • Block wheels of steering axle with chocks.

Fig. 6

• Lift machine with levelling blade and working equipment until the wheels of the rigid axle lift from the ground and can be turned freely. Shut off engine.

• Position the screw plugs (1 and 2, Fig. 6) as shown.

• Clean area around screw plug (1).

• Unscrew screw plug (1) gradually until there is no more excess pressure. Only then may the screw plug be removed.

• Top up the prescribed amount of oil through the bore of screw plug (1).

Fig. 7

• Screw in screw plug.

• Top up oil at the opposite wheel-hub gear.

• Lower machine to the ground.

Now fill in oil into axle gear and travel gearbox, to do so: • Screw out screw plug at the axle gear (Fig. 7) and at the travel gearbox (8).

• Top up the prescribed amount of oil through the bore of the screw plug.

• Screw in screw plugs.

Fig. 8

184

• Start up the machne. After a while check the oil levels, check that the screw plugs does not leak.

73183099

OPERATOR’S MANUAL EW 160 Steering axle gearbox - checking the oil level

2796516

• Park machine as described under "Securing the machine".

Risk of scalding through hot oil.

The axle and the gearbox housing may also be hot after a long drive.

Give axle and gearbox housing time to cool off, and wear working gloves.

The axle and gearbox may be under slight excess pressure. So unscrew control plug carefully until the pressure has been reduced (audible hissing sound).

Catch escaping oil and discard without polluting the environment.

Read and observe: "Inspection and servicing - Safety instructions".

• Clean area around screw plug (Fig. 9).

• Unscrew screw plug. The oil level must reach up to the opening.

Fig. 9

• If necessary, top up through opening.

(For oil grade, see: "LUBRICANTS").

• Screw in screw plug.

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185

OPERATOR’S MANUAL EW 160 Steering axles wheel hub gears - checking the oil level

2796517

• Park machine on an even, horizontal surface (cf.: "Securing the machine").

Risk of scalding through hot oil.

The axle and the gearbox housing may also be hot after a long drive.

Give axle and gearbox housing time to cool off, and wear working gloves.

The axle and gearbox may be under slight excess pressure. So unscrew control plug carefully until the pressure has been reduced (audible hissing sound).

Catch escaping oil and discard without polluting the environment.

Read and observe: "Inspection and servicing - Safety instructions".

• The screw plugs on the wheel hub gearbox (1 and 2, Fig. 10) must be in the position indicated.

• Clean area around screw plug (1).

• Unscrew screw plug (1) gradually until there is no more excess pressure. Only then may the screw plug be removed.

The oil level must reach up to the opening. If necessary, top up through opening.

(For oil grade, see: "LUBRICANTS").

• Screw in screw plug.

Fig. 10

• Repeat check at the other planetary gearbox.

186

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OPERATOR’S MANUAL EW 160 Steering axle gearbox - changing the oil

2904168

Note: Risk of scalding through hot oil.

The axle and the gearbox housing may also be hot after a long drive.

Give axle and gearbox housing time to cool off, and wear working gloves.

The axle and gearbox may be under slight excess pressure. So unscrew control plug carefully until the pressure has been reduced (audible hissing sound).

Catch escaping oil and discard without polluting the environment.

Read and observe: "Inspection and servicing - Safety instructions".

The filling quantities listed in the table "Refilling quantities - oil" are approximate data.

Gears and axles are exactly filled when the oil level reaches the lower edge of the screw plug bores named in the text.

• Park machine as described under "Securing the machine".

• Clean area around screw plugs (1 and 2, Fig. 11).

• Place a vessel to catch used oil under the screw plug (2).

For the necessary capacity, see: "Refilling quantities".

Fig. 11

• Unscrew drain plugs (1 and 2); the oil drains off.

• Screw in screw plug (2).

• Fill in fresh oil through the screw plug hole (1).

The oil level must reach up to the opening.

(Data on the quantity and grade of oil to be used are given in the sections: "Refilling quantities" and "LUBRICANTS".).

• Screw in screw plug (1).

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187

OPERATOR’S MANUAL EW 160 Steering axles wheel hub gears - changing the oil

2904169

Note: Risk of scalding through hot oil.

The axle and the gearbox housing may also be hot after a long drive.

Give axle and gearbox housing time to cool off, and wear working gloves.

The axle and gearbox may be under slight excess pressure. So unscrew control plug carefully until the pressure has been reduced (audible hissing sound).

Catch escaping oil and discard without polluting the environment.

Read and observe: "Inspection and servicing - Safety instructions".

The filling quantities listed in the table "Refilling quantities - oil" are approximate data.

Gears and axles are exactly filled when the oil level reaches the lower edge of the screw plug bores named in the text.

• Park machine as described under "Securing the machine".

• Clean area around screw plugs (1 and 2, Fig. 12).

• The screw plugs (1) and (2) on the wheel-hub gears must be in the position indicated.

Fig. 12

• Place a vessel to catch used oil under the screw plug (2). For the necessary capacity, see: "Refilling quantities".

• Unscrew drain plugs (1 and 2); the oil drains off.

• Screw in screw plug (2).

• Fill in fresh oil through the screw plug hole (1).

The oil level must reach up to the opening.

(Data on the quantity and grade of oil to be used are given in the sections: "Refilling quantities" and "LUBRICANTS".).

• Screw in screw plug (1).

• Change oil in the other wheel-hub gear.

188

73183099

OPERATOR’S MANUAL EW 160 BRAKING

2796924

Working on brakes - Safety instructions

Personnel Never carry out repair work on brakes unless you are qualified to work on brake systems.

If in doubt, have the work done by the NEW HOLLAND CONSTRUCTION aftersales service.

Read and observe : "Repair work - Safety instructions"

Service brake

2904181

Checking the lining thickness of multiple-disk brakes Check the lining thickness of multiple-disk brakes in accordance with servicing plan C. The thickness gauge required to carry out such work can be obtained from the NEW HOLLAND CONSTRUCTION spare-parts service (P/N 73179297).

The lining thickness check must be repeated for each wheel. For this purpose: • Position the machine in such a way that the screw plugs on the wheel hub are in the position indicated (Fig. 1).

Securing the machine Never carry out repair work on brakes unless the machine is secured as described under "Securing the machine".

Fig. 1

• Secure the machine (see: "Securing the machine").

• Unscrew screw plug (1, Fig. 1).

• Block service brake (see: "Operating the service brake").

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189

OPERATOR’S MANUAL EW 160 • Screw thickness gauge (2, Fig. 2) into opening of the screw plug, using a size 22 open-ended wrench.

• Slacken counter-nut (4) of thickness gauge.

• Screw spindle (5) with handle fully into the opening.

• Adjust scale drum (3) to "0" mark on scale, then block with counter-nut (4).

• Release blocking of service brake.

• Screw spindle (5) with handle completely down.

When screwing the spindle into the opening, note the number of full turns (referred to "0" mark on scale) and the numerical value of the partial turn.

A full turn corresponds to a spindle travel of 1 mm (0.039"). A turn by one scale mark corresponds to 0.1 mm (0.0039").

• The limit reference value is:

Fig. 2

3.9 mm (0.15").

• Compare the measured value with the limit reference value.

• If the measured value is greater than or equal to the limit reference value, the brake disks must be replaced. Consult your NEW HOLLAND CONSTRUCTION dealer-service.

• Unscrew thickness gauge (2) and screw plug (1, Fig. 1) back in place.

190

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OPERATOR’S MANUAL EW 160 Bleeding the multiple-disk brakes

2801337

Do not carry out work on braking systems unless you are specially trained for this kind of work.

Read also: "Work on braking systems Safety instructions".

If you are not trained to carry out such work have the work performed for you by your NEW HOLLAND CONSTRUCTION dealer.

The braking system of this machine has two braking circuits. One of the circuits controls the wheels of the steered axle and the other the wheels of the rigid axle.

After performing works on the braking system during which air may have penetrated into the system (e.g. replacing a line), the braking circuit concerned must be bled after these works.

Fig. 1

• Protect the machine against inadvertent movements.

• Connect a hose to the minimess port of a multiple-disk brake. The minimess ports are located directly beside the screwed connections of the brake pressure lines on top of the axle housing (Fig. 1).

• Stick the other end of the hose into a recipient filled with the hydraulic oil or fluid of the machine.

• Start the engine.

• Depress the brake pedal (63) until the hydraulic fluid flowing out of the minimess hose is free from bubbles.

• Repeat this procedure on the second multipledisk brake of this axle.

This terminates the operations of bleeding one of the circuits.

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191

OPERATOR’S MANUAL EW 160 Swing axle cylinder - lubricating the contact surfaces

2796547

Read and observe: Inspection and servicing - Safety instructions".

The contact surfaces of the swing axle cylinder on the steering axle must be greased.

If the surfaces are dry, noises are heard during swinging motions of the axle.

The rounded ends of the piston rods cannot slide, resulting in friction and a jerky movement.

The contact surfaces "seize up".

Fig. 1

• Clean end of piston rod and surface of sliding block.

• Spray lubricant between piston rod and sliding block (Fig. 1).

For lubricant selection, see "Corrosion protection for pins and bearings".

• Repeat procedure at other swing axle cylinder.

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OPERATOR’S MANUAL EW 160 WHEELS AND TYRES

2461470

Tyre inflation pressure - Safety instructions

Bursting tyres and parts splintering away from the rims or from the tyre itself may cause severe injury.

Therefore, the following instructions must be observed: - Before inflating the tyre, check the tyres, rims and rim parts for damage, penetrated foreign objects and proper fitting.

- Have all damage detected repaired by a qualified workshop.

- Check the tyre inflation pressure only when the tyres are cold. After warming up, the pressures indicated are higher than usual.

- Use filling equipment with long filling hose, self-fixing nozzle and pressure gauge.

- Inflate the tyres only with compressed ambient air. Never use inflammable gases: risk of explosion.

- During tyre inflation, do not stand near the tyre and always in the plane of the tyre tread.

- Watch the tyre and the pressure gauge of the filling equipment permanently during the inflation and never exceed the prescribed tyre pressures.

- If available, place a safety cage around the wheel.

- Make sure that nobody is standing near the tyre when it is being inflated.

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In case of twin-tyres: - Pay particular attention to the inner tyre flanks in case of twin-tyres. This is the place where damage may occur due to undetected foreign objects if the tyres had been fitted without intermediate rings.

- If the inner tyre of a twin-wheel was used with insufficient inflation pressure, there is the risk that parts of a multi-rim (e.g. the closing ring) are no longer in their correct positions.

In this case, check the condition of wheel and tyre particularly thoroughly before inflating the tyre. If in doubt, contact an expert.

193

OPERATOR’S MANUAL EW 160 Checking the tyre inflation pressure 2461472 Refilling the tyre

Table of tyre inflation pressures 2905189

Tyre size Read and observe the: "Tyre inflation pressure - Safety instructions".

• Park the machine on level and firm ground.

• Stand the working equipment on the ground.

• Apply the parking brake and the superstructure holding brake.

• Shut off the engine.

• Attach the self-locking nozzle of the filling equipment to the tyre filling valve (Fig. 1).

• Inflate all tyres with the prescribed pressure (cf.

"Table of tyre inflation pressures").

Air pressure bars

Tightening torque

10.00 - 20PR16

6,5

450

18 - 19.5PR16

6,5

450

Alliance 600/40 - 22.5PR16

6,0

450

Nm

The tyre pressures are applicable for the tyre sizes stated under the following conditions: - working equipment attached, - digging bucket emptied, - tyres at ambient temperature (abt. 20oC), - fuel tank filled.

Should you have any questions, please contact your nearest NEW HOLLAND CONSTRUCTION dealer.

Fig. 1

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OPERATOR’S MANUAL EW 160 Tyres and wheels, safety instructions

2905190

Risk of injury

Driving on public roads

from bursting tyres and severed parts of tyres or rims.

When driving on public roads, be sure that the tyres have at least the minimum tread depth prescribed and the correct pressure.

Never do any work for which you are not qualified on tyres and rims.

Have tyres with tread chunking or severe abrasion or with damaged sidewalls replaced without delay.

Have damaged rims or rim components replaced immediately.

Never do mechanical work on rims or rim components of filled tyres. Never do any welding or flame-cutting on rims or rim components.

If the safety of tyres, rims or rim components is in any doubt, take the complete wheel to a specialist workshop.

Purpose-designed tools and special methods are essential for changing tyres, rims or rim components. Have such work done at an appropriately equipped specialist workshop.

Correct tyre pressure Always inflate tyres to the prescribed pressure: - Excessively high pressure results in poor off-the-road handling properties and risks from bursting tyres.

- Excessively low pressure results in increased tread wear and poor machine stability.

Check that both axles are equipped with tyres of the same size and in the same state of wear.

Non-uniform tyre diameters may result in damage to the differential gear.

How to prevent excessive tyre abrasion: - inflate to the correct pressure, - avoid abrupt starting or braking, - avoid fast cornering.

Intermediate rings If your machine is equipped with radialply twin tyres , you must never install intermediate rings. Radial-ply tyres are not designed for use with intermediate rings and would very soon be irreparably damaged.

Radial ply tyres are identified with an "R" in the tyre marking, e.g. "18-R19.5".

Your NEW HOLLAND CONSTRUCTION dealer will be pleased to advise you.

Wheel nuts Always tighten wheel nuts with a torque wrench. Use the torque wrench to check after some operating hours that the nuts are still tightly fitted.

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195

OPERATOR’S MANUAL EW 160 Changing a wheel

2801531

• Tighten the wheel nuts with the prescribed torque.

Read and observe the section on "Tyres and wheel - Safety instructions".

• Park the machine on firm and level ground.

• Apply parking brake.

• Inflate tyres with their correct pressure.

• Check wheel nuts after several operating hours with a torque wrench for tightness.

Tread pattern arrangement

• Loosen wheel nuts by about one turn.

• Jack up the axle with the damaged wheel until the wheels are clear of the ground. To do so, jack up the machine with the working equipment or the stabilizers of the corresponding side.

Observe the tread pattern arrangement of the tyres when fitting the wheels (Figs. 1 and 2).

• Place wooden supports under the lifted axle to prevent it from dropping.

• Secure the machine as described in the "Securing the machine" section.

• Deflate the tyre.

• Unscrew wheel nuts and remove defective wheel together with intermediate ring (optional equipment).

Mark inner ant outer wheel.

Do not lose centering ring, lockwashers and wheel nuts, as they will be re-used for fitting.

Fig. 1

• Fit new wheels: - Inflate both tyres with a pressure of abt.

1 bar (14.5 psi).

Observe the following fitting sequence: - Inner wheel (rim with high-offset dish) - Intermediate ring (optional equipment) - Outer wheel (rim with low-offset dish). It is absolutely necessary to observe the fitting sequence, as an incorrect mounting of the wheels results in the admissible total width of the machine being exceeded.

- Observe the chapter on "Tread pattern arrangement of wheels".

- Avoid damaging the threads of wheels studs.

- Center the intermediate ring.

- Take care that there are no foreign bodies between tyre and intermediate ring.

• Tighten the wheel nuts by hand.

• Remove the support from under the lifted axle and lower the axle.

196

Fig. 2

Fig. 1 shows the recommended tread pattern for four-wheel driven machines requiring the same amount of traction in both travel directions.

Fig. 2 shows the tread pattern of the tyres if the four-wheel driven machine requires an especially high amount of traction in one direction, e.g. for work with the levelling blade.

In some special cases, another tread pattern arrangement may be of advantage. In these cases, please contact the NEW HOLLAND CONSTRUCTION dealer-service.

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OPERATOR’S MANUAL EW 160 SWING RING

2411955

Swing ring - checking grease filling

Swing ring - Instructions

Gearing and bearings of the swing ring must be inspected and re-greased at shorter intervals than specified in the servicing plan in the event of: - great heat, - high moisture levels, - exposure to dust and dirt, - marked temperature fluctuations, - continuous swinging.

2796548

Danger of injury Only swing superstructure when no one is in the swinging area.

The gearing of the swing ring and the slewing drive pinion are enclosed in a grease-filled housing (1, Fig. 1).

The grease packing of the gearing must be replaced when repairs have been carried out to the: - swing ring, - sealing system or - housing of the swing ring.

Remove the used grease completely before replacing.

If major grease losses are noted, find the cause immediately to prevent damage to the swing ring.

Grease the swing ring additionally before and after extended down-times.

Fig. 1

• Unscrew cover (2).

Dispose of grease and greasy cloths separately from other waste in the interests of environmental protection.

Fig. 2

• Check gearing and pinion for damage.

• Check grease filling: All tooth faces must be covered with a thin grease film (Fig. 2).

If the grease film is not o.k., several cartridges of grease must be added (cf. "Swing ring filling with grease").

Check the cause of grease loss and rectify.

• Screw cover (2, Fig. 1) back in place.

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197

OPERATOR’S MANUAL EW 160 Swing ring - filling grease

Swing ring - greasing the bearing 2796549

2796923

Danger of injury

Danger of injury

Only swing superstructure when no-one is in the swinging area.

Only swing superstructure when no one is in the swinging area.

The gearing of the swing ring is filled with grease via the lubricating nipple (Fig. 3).

Grease the bearing at the A-frame through greasing nipple (Fig. 4).

Fig. 3

Fig. 4

• Place filling nozzle of grease gun on lubricating nipple (Fig. 3).

• Place filling nozzle of grease gun on lubricating nipple.

- To regrease gearing, apply approx. a quarter of a grease cartridge.

Swing superstructure by 90˚. Now apply another quarter of the cartridge. Continue as described until the cartridge is empty.

• Inject grease a number of times in each greasing nipple.

• Swing superstructure round slowly, a number of times. The grease is distributed evenly.

- If the gearing requires a new grease filling, please see the "Filling quantities - grease" table for required grease quantity.

• Now swing the superstructure round slowly, a number of times. This ensures even distribution of the grease.

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OPERATOR’S MANUAL EW 160 Swing ring - checking tightness of screws

Lubricating the greasing nipples

2411349

2472263

Danger of injury

Read and observe section "Inspection and Servicing, Safety Instructions".

Only swing superstructure when no-one is in the swinging area.

Before starting lubrication: - Set extended working equipment down onto ground.

- Secure machine as described in section "Securing the machine".

The swing ring fastening screws at the superstructure (Fig. 5) and the undercarriage (Fig. 6) are tightened with a particular torque (see: "Tightening torques - Table").

Never discard greasy cleaning cloths but arrange for separate disposal.

Grease nipples on working equipment and chassis with a grease gun.

• Remove cap from greasing nipple.

• Clean greasing nipple.

• Press grease-gun filler onto greasing nipple.

• Now force in grease until the fresh grease forces the used grease out of the joints of the bearing.

Fig. 5

• Wipe off used grease with cleaning cloths.

Slacken loosened screws tightening them with a torque wrench at the prescribed torque (cf: "Tightening torques - Table").

• After greasing, fit the cap on the greasing nipple again.

Fig. 6

Only part of the fastening screws are shown in the figure. All screws of the swing ring must however be checked.

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199

OPERATOR’S MANUAL EW 160 Greasing the pedal valve tappets

Greasing the control valve tappets 2413884

2472275

Before working on the valves: - protect the machine against inadvertent movements - shut off the engine - depressurize the hydraulic system - switch off the pilot control.

Before working on the valves: - protect the machine against inadvertent movement - shut off engine - depressurize the hydraulic system - switch off the pilot control.

The working equipment or the machine are then protected against inadvertent movements when control levers or pedals are actuated.

The working equipment or the machine are then protected against inadvertent movements when control levers or pedals are actuated.

Fig. 1

Fig. 2

• Clean the valve tappets of the pedal valves (Fig. 1).

• Lift cup leder between control lever and console (Fig. 2).

• Apply a thin layer of grease on the tappet surface.

• Clean four valve tappets and the underside of the control plate.

• Apply a thin layer of grease to the tappet surface.

• Slide protective cover back over the control valve.

• Repeat the same procedure on the other control valve.

200

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OPERATOR’S MANUAL EW 160 WINDSCREEN WASHER

2904039

Topping up the wash fluid

HEATING

2904842

Cleaning the filter mat

The reservoir must be filled with clean and clear water only to prevent clogging up of the screen washer nozzles.

For better cleaning of the windscreen, a commercial detergent can be added to the water.

During the cold season, a special antifreeze compound should also be mixed into the water. The mixing proportion should be chosen in compliance with the manufacturer’s recommendations.

• Depress lock button (1, Fig. 1) to swing the reservoir out of the seat pedestal.

• Remove cap (2) and top up with wash fluid.

The reservoir contains ca. 1,5 l (0.34 gal) of fluid.

• Snap on cap and check that it fits tightly.

• Swing reservoir back into compartment and engage.

Fig. 1

At the rear wall of the driver’s cab the heater fan draws in fresh air.

The filter mat can be reached by removing the cover of the intake opening. The filter mat is inserted into the heating box (arrow, Fig. 1).

• Remove the cover of the intake opening (Fig. 1).

• Remove the filter mat and clean it by beating or washing.

Replace heavily soiled filter mats.

• Insert cleaned or new filter mat into the guide and screw cover in place again.

Fig. 1

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201

OPERATOR’S MANUAL EW 160 AIR CONDITIONER (Option) Safety instructions for inspection and servicing work

2904630

The present section describes inspection and servicing work that can be performed by the machine operator.

Work on the refrigerant circuit (qualified personnel):

Any other work on the air conditioner requires special knowledge and special tools and may therefore be performed by qualified and specially trained personnel only. Entrust the work in these cases to a specialized workshop for air conditioners.

The refrigerating agent (R 134a) used in this system is known as a safety refrigerant. This means that it is non-combustible, non-explosive, non-toxic, non-irritating, odourless and tasteless.

Nevertheless, the following points must be observed:

Observe the following instructions for your personal safety: Never stick your hand or other objects into the air conditioner.

Shut off the engine and let it cool down before performing any servicing work.

Disconnect the fan from the power supply to avoid injury when the fan starts up inadvertently.

Some air conditioner components (e.g. heat exchanger and the resistor on the fan) can still be very hot after shut-off and may cause severe burns. Wait until these components have cooled down before working on them when the machine is open.

Avoid any contact with liquid coolant.

Parts of the skin that have been in contact with refrigerant must be treated like chilblains.

Wear safety goggles to protect your eyes.

In the event of refrigerant coming into contact with your eyes seek medical advice immediately.

When carrying out repairs on the air conditioner, the system must be emptied.

Never allow refrigerant to escape into the environment. For sucking off refrigerant use only approved suction units.

It is strictly forbidden to carry out welding work on parts of the closed system or in the immediate vicinity thereof. Heat leads to strong over-pressure and may cause damage or even an explosion of the system independent of whether the system is filled with refrigerant or empty.

When filled, refrigerant bottles must not be handled roughly and not exposed for prolonged periods to direct sunlight or to other sources of heat. The temperature to which a filled refrigerant bottle is exposed must not exceed 45˚C (113˚F).

It is essential to keep the refrigerant system free from chlorine and chloric substances as well as from oils or greases.

Evacuation and filling units for R134a should not be used for other substances.

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OPERATOR’S MANUAL EW 160 Air conditioner - Inspection and servicing work

2904633

Work to be carried out every month (Machine operator) Read and observe: "Inspection and servicing work - Safety instructions".

Location of components in the machine The heating / air-conditioning (Fig. 1) unit is installed in the driver’s cab under the driver’s seat.

The following components are installed under the seat:

The visual checks should be carried even in those cases where the air conditioner is not used.

The air conditioner should moreover be activated once every month for 10 - 15 minutes to prevent drying out and embrittlement of the shaft seal in the compressor with the risk of refrigerant leaking out of the unit. This measure also ensures regular lubrication of the compressor components.

- blower (1), - heat exchanger (2), - evaporator (3), - filter mat (4), - heating valve (12) and others They are accessible after removal of the top cover. Except for cleaning, the heat exchanger, the evaporator and the blower do not require any servicing.

In machines with the engine installed at right angles to the direction of driving, the - compressor, - condenser and the - refrigerant container with drier are installed in the engine compartment (Fig. 4, 6 and 8).

In machines with the engine installed parallel to the direction of driving, the compressor is installed in the engine compartment and the - condenser and the - refrigerant container with drier in the space above the batteries and the air filter (Fig. 5, 7 and 9).

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203

OPERATOR’S MANUAL EW 160 In the cab: • Evaporator (3, Fig. 1) contaminated or ribs deformed?

Blow out dirt and suck off, straighten the ribs.

• Antifreeze protection sensor on evaporator kinked or leaking? Have sensor repaired.

• Can condensed water (5) run off freely?

Remove obstructions in hose or replace.

• Filter mat (4) contaminated?

Depending on the conditions of use, the filter mat must also be checked more often and cleaned by blowing out or beating. The mat is accessible when the cover over the suction opening for fresh air (back wall of cab) is removed (Fig. 2).

Fig. 1

• Heater valve completely closed when the heater control knob is in the "min" position?

This can be checked when the cover at the back wall of the cab is removed (Fig. 2). The heater valve is attached to the left side of the heating/air conditioning unit. The adjusting lever of the heater valve must be in the "closed" position at the bottom (see also: "Heater valve - Adjusting the Bowden cable").

• Temperature control knob (73, Fig. 3) easyrunning?

If sluggish, check Bowden cable for kinking or corrosion and replace if necessary.

Fig. 2

Fig. 3

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OPERATOR’S MANUAL EW 160 In the engine compartment: • V-belt of compressor (Fig. 4 or Fig. 5) in good condition?

Replace defective V-belt.

• V-belt properly tensioned?

Readjust, if necessary.

• Compressor safely fastened?

Tighten loosened screw.

• Chafing marks on hoses and lines?

Have damaged hoses and lines replaced. Lay / fasten new ones in a safer place.

(This work must be carried out by a specialized workshop).

• Condenser (Fig. 6 or 1, Fig. 7) contaminated?

Contaminated condensers have a bad condensing performance. Clean by blowing out or by flushing with water (do not use high-pressure cleaners). Deformed ribs can be restraightened.

Fig. 4 Fig. 6

Fig. 5 Fig. 7

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205

OPERATOR’S MANUAL EW 160 • Amount of refrigerant (Fig. 8 or 2, Fig. 9) in the system sufficient?

With the engine running and the unit switched on, the refrigerant visible in the inspection glass on top of the refrigerant container (arrow, Fig. 8) must be free from bubbles. Bubbles in the inspection glass are a sign of insufficient amounts of refrigerant in the system. The system must be checked for leaks and refilled by a specialized workshop for air conditioning systems.

Work to be performed every 6 months (Approved special workshop) Check refrigerant circuit and refrigerant level. (Replace contaminated refrigerant).

Check hoses and screwed connections for fastening, tightness and proper laying.

Check compressor and magnetic clutch for proper operation (noise-free running, oil level, safe fastening of compressor).

Check electrical lines and connectors for perfect condition and tight fit.

Check the complete system.

The refrigerant container should be replaced whenever work has been carried out on the refrigerant circuit.

Work to be performed every 2 years (Approved special workshop) All works described in "Work to be performed every 6 months" must be performed.

Fig. 8

Check of the complete system.

Replacement of refrigerant container with drier.

Fig. 9

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OPERATOR’S MANUAL EW 160 Air conditioner - Checking / retensioning the compressor V-belt

2904818

These instructions are valid for machines with engines installed parallel to the direction of driving.

Risk of injury by rotating or hot parts of the engine.

Shut off the engine before opening the engine compartment.

After operation, the compressor may be hot, too. Wait until the compressor has cooled down before working on it.

Read and observe: "Inspection and servicing work - Safety instructions".

Fig. 1

Compressors installed at the bottom of the engine have a tensioning device (Fig. 2).

Tension of the V-belt is checked as described.

For retensioning, proceed as follows: • Loosen the clamping screws (2).

Improper tensioning of the the V-belt reduces the performance of the compressor. The V-belt itself and / or the compressor may also be damaged.

The compressor is flange-mounted on the engine block. Depending on the type of engine, the compressor can be installed at the top (Fig. 1) or at the bottom (Fig. 2). The tension of the V-belt can be checked and adjusted from above through the engine compartment.

- Turn nut (1) clockwise until the belt is properly tensioned.

- Retighten the clamping screws.

• Check that the retaining screws between compressor and bracket and between bracket and engine block are tight. Retighten, if needed.

• Close the cover over the engine compartment.

• Open the engine compartment cover.

• Check the V-belt and replace if damaged.

• Depress the V-belt in the middle between the pulleys with the thumb. The belt must give in by about 10 mm. If the tension does not correspond to this value, the V-belt must be retensioned or slackened. To do so: - Slacken the clamping screws (Fig. 1).

- Use an appropriate lever to increase the space between compressor and engine block until the V-belt is properly tensioned.

Fig. 2

- Retighten the clamping screws.

• Check that the retaining screws between compressor and bracket and between bracket and engine block are tight and retighten, if needed.

• Close the cover over the engine compartment.

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207

OPERATOR’S MANUAL EW 160 Air conditioner - Troubleshooting

2904634

Malfunctions of Blower:

Page 1 of 4

Malfunction

Cause

Remedial action

Blower not working

Fuse defective or loose

Check fuse contact, if necessary, plug in correctly.

Replace defective fuse. Reappearance of the defect after a short time indicates a short-circuit.

Check blower for blocking or other defects and rectify.

Connector loose

Check that connector at the bottom of the unit is firmly in place. Plug in properly, if necessary.

Check connections at blower switch.

Open the unit and check electrical connections inside.

Connecting cable damaged or ripped off

Replace cable, observing correct cable run and connection.

Wrong electrical connections

Check connecting cables and, if necessary, reconnect properly.

Blower switch defective

Replace by OEM part.

Blower assembly blocked

Eliminate cause of blockage, e.g. by removing foreign object from rotor. If necessary, install new blower.

Blower motor defective

Replace blower.

Blower cannot be stopped

Blower switch internally short-circuited

Replace blower switch.

Blower performance reduced

Wrong nominal supply voltage

Nominal voltage of conditioner and of vehicle system must be identical. Replace blower.

Contacts dirty

Clean connector contacts. Work carefully to avoid short-circuits.

Insufficient cross-section of electrical cables

Lay cables with the recommended cross-sections.

Heat exchanger very dirty

Clean carefully to avoid any damage to the exchanger resulting in consequential leaks.

Blower ducts obstructed

Check air ducts and outlets for obstructions and remove any foreign objects.

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OPERATOR’S MANUAL EW 160 Insufficient cooling performance

Page 2 of 4

Malfunction

Cause

Remedial action

Compressor not working

Open circuit in compressor solenoid

Check power supply to the clutch.

Thermostat defective

Replace thermostat.

V-belt loose or broken

Adjust belt tension, replace belt.

Belt pulley not turning although magnetic clutch is engaged

Check compressor and replace, if necessary.

Compressor clutch slipping

Repair clutch or replace compressor.

Evaporator flooded

Expansion valve jammed or stuck in open position

Replace expansion valve.

Evaporator frozen up

Thermostat sensor in wrong position

Install sensor in another place.

Evaporator clogged up

Cooling fins dirty

Clean evaporator.

Loss of refrigerant

Refrigerant line defective

Check all lines for defects caused by external influences or chafing.

Leaks in the system

Evacuate the system, refill, check for leaks and repair.

Air filter

Air filter clogged up

Clean air filter or replace.

Heating is on

Bowden cable wrongly centered or defective

Adjust Bowden cable (see: "Heating valve, adjustment of Bowden cable") or replace.

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209

OPERATOR’S MANUAL EW 160 Insufficient heating performance

Page 3 of 4

Malfunction

Cause

Remedial action

Heating not working

Cooling agent still cold

Wait until the engine has reached its operating temperature.

Water valve closed

Open the valve (see "Heating" section in Operator’s Manual)

Water lines kinked or crushed

Eliminate the causes.

Pressure of water pump insufficient

No coolant flowing through heat exchanger. Install an auxiliary or more powerful main pump.

Heat exchanger or filter strongly contaminated

Clean carefully to avoid any damage resulting in consequential leaks.

Amount of water flowing through heat exchanger insufficient

Water lines crushed or kinked. Change position of hoses. Insufficient pressure of water pump (remedial action see above).

Air in heat exchanger

The radiator is self-venting when the pump pressure is high enough. Install an auxiliary or more powerful water pump.

Conditioning unit under-dimensioned

Consider installing an additional heating or a more powerful conditioning unit.

Bowden cable controlling the water valve wrongly adjusted

Readjust the Bowden cable.

Valve not installed correctly in flow and/or reflow line

Check valve mounting position with respect to flow and reflow direction and correct if necessary.

Control element, i.e.

Bowden cable defective

Check control / Bowden cable and replace if necessary.

Adjustment no longer possible due to kinking of Bowden cables

Check Bowden cables.

Flap hinges sluggish

Check flap and lubricate, if necessary.

Flap deformed

Check flap.

Flap blocked by foreign object

Check flap and remove foreign object if necessary.

Heating working with reduced performance

Heating cannot be stopped

Air distribution flaps uncontrollable

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OPERATOR’S MANUAL EW 160 Conditioner very noisy

Page 4 of 4

Malfunction

Cause

Remedial action

Conditioner very noisy

V-belt loose or excessively worn

Retension V-belt or replace.

Clutch noisy

Repair clutch.

Compressor supporting bracket loose or worn-out parts inside the compressor

Repair bracket, replace compressor.

Blower motor excessively worn

Replace blower.

System overfilled

Evacuate refrigerant until the high pressure reading is normal again.

Not enough refrigerant in the system

Check for leaks, refill the system.

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211

OPERATOR’S MANUAL EW 160 Putting the machine out of operation

Recommissioning 2801534

2801535

Carry out the following measures if the machine is to be put out of operation for a longer period of time:

Prior to recommissioning after an extended outage period, observe the following points:

• Park the machine on firm and level ground.

• Set working equipment on the ground and retract the piston rods as far as possible.

• Engine preservation: Carry out all procedures according to the recommendations of the engine manifacturer.

• Check oil level in hydraulic tank.

• Lock superstructure.

• Check acid density and level of battery fluid.

• Set all control elements to the 0 position.

• Install and connect battery/batteries.

• Clean the machine.

• De-grease piston rods of hydraulic cylinders.

• Carry out a visual check for leaks and damage and have these repaired, if any.

• For machines with main battery switch: Switch on main battery switch.

• Protect all bright metal parts (e.g. piston rods) against rust and dirt by applying a thin layer of grease.

• Start up engine.

• Engine preservation: Carry out all procedures according to the recommendations of the engine manifacturer.

• Bring machine to travelling position and apply parking brake.

• Bleed hydraulic system.

• Removing the battery; cf. also the "Storing the battery" section.

• Protect the machine against unauthorized startup: - Withdraw key from key-switch.

- Lock knock-out windows.

- Close cab door.

- Secure all lockable trap doors.

- Cover up openings.

Battery storage

2801533

For extended outage periods (for longer than two weeks), remove battery / batteries and store on dry, well ventilated premises at ca. 20˚C (68˚F).

Observe following maintenance points: • Clean battery/batteries.

• Check acid density and battery fluid level once a fortnight.

• Charge batteries when acid density has fallen to 1.23 kg/dm3 or earlier.

• Keep battery / batteries clean and dry externally.

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OPERATOR’S MANUAL EW 160 PART 4 - REPAIR WORK

Operating manual

2261179

Target group Operating personnel + Inspection and servicing personnel

Part 1 INTRODUCTION + FUNDAMENTAL SAFETY INSTRUCTIONS Repair personnel

Operating personnel

Part 2 OPERATION

The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Inspection and servicing personnel

Part 3 INSPECTION AND SERVICING

The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

Repair personnel

Part 4 REPAIR WORK

Part 5 ANNEX

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The repair personnel must have know-how and experience relevant to the repair of this or comparable machines.

Operating personnel + Inspection and servicing personnel + Repair personnel

213

OPERATOR’S MANUAL EW 160

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OPERATOR’S MANUAL EW 160 Repair work - safety instructions

2732233

Operating instructions

Pressurized or spring loaded units

Never carry out repair work without having read and understood the operating instructions.

Never open defective pressurized or spring loaded units but replace them as an entirety.

Pay special attention to:

In exceptional cases, open only when the system and the operating sequence are precisely known and any special tools required are available.

"Fundamental Safety Instructions", "Inspection and servicing - safety instructions" and all warnings and safety instructions attached to the machine.

The descriptions of job sequences provide only experienced personnel with the necessary instructions.

The operating manual contains no information on this point.

The operating manual must be kept with the machine at all times.

Dismantling components

Repair personnel

Oils, greases, brake fluid or coolants may have a high temperature and result in burning or scalding.

Repair personnel must have know-how and experience relevant to repairing this or comparable machines.

Working at greater heights Always wear safety harnesses when working at greater heights.

Wear an approved safety harness; it must be equipped with stabilizers and safety cables.

Never dismantle while the machine is at operating temperature.

Leave time for the machine to cool down.

Before starting work, depressurize piping and hoses, cylinders, radiator, hydraulic tank, air-brake reservoir and other systems or units.

Replace defective components in good time to prevent major damage.

Clean the defective component carefully before dismantling it.

Mark the dismantled parts in the correct sequence to facilitate assembly.

When dismantling the component, close off exposed hose and piping connections, exposed drill holes and housing carefully to prevent any dust from penetrating.

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215

OPERATOR’S MANUAL EW 160 Accumulators, safety instructions 2801536

Never remove lead seals Never change rated pressure of pressure relief valves without the explicit authorization of NEW HOLLAND CONSTRUCTION. Never remove lead seals from pressure relief valves and accumulators.

After the repair work To prevent corrosion, coat all bright metal machine parts with a grease film.

On completing the work, reassemble all protective devices, covers, and soundand vibration-insulation material.

Never start up the driving motor while work is being done on the machine.

Check the repaired components and all machine functions with a trial run.

Never release the machine for recommissioning until it is fully functioning.

216

Accumulators are installed in the hydraulic system. These accumulators contain nitrogen under high initial pressure.

Wear safety goggles.

Even when the hydraulic pressure in the system is reduced, the nitrogen remains in the accumulator.

The accumulators are completely safe in operation. If incorrectly handled, however, there is a risk of explosion!

The accumulators installed in this machine should not be repaired. Defective accumulators have to be changed.

Never handle accumulator mechanically, never weld or solder it.

Prior to change the accumulator, always wear goggles and working gloves, depressurize the hydraulic part of the system.

Use only genuine NEW HOLLAND CONSTRUCTION-spare parts. In case of questions ask your NEW HOLLAND CONSTRUCTION-dealer.

Never remove or paint over warning and information plates, rating plates or type identification markings. Replace illegible or damaged plates immediately.

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OPERATOR’S MANUAL EW 160 ENGINE

2801537

Engine, repair instructions

Read and observe: "Repair, safety instructions" and operating instructions for engine before working on engine.

Risk of injury from rotating or hot engine parts!

Switch off engine and leave to cool down.

Do repair work only if machine is secured as described in section "Securing the machine" of these operating instructions.

Assisted starting (with jump-leads) - Safety instructions 2904638

Explosion hazard Keep any potential ignition sources such as unshielded lights or burning cigarettes away from the batteries. The battery vapours are highly flammable.

Wear safety goggles.

Do not lean over the batteries when starting the machine from another vehicle.

Check and change V-belts only when engine is stationary.

Risk of injury from acid splashes and battery gases.

Repair work on the engine demands extensive know-how and special tools.

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

In case of doubt ask your NEW HOLLAND CONSTRUCTION dealer to carry out such work.

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

Use only tested jump-leads with insulated terminal clips and an adequate lead diameter.

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

Do not assist in starting up other vehicles by supplying over-voltage e.g. from three or four batteries connected in series or from auxiliary units producing voltages higher than 24 V. Never use welding generators or welding transformers as a source of current.

Position the jump-leads in such a way that they cannot be caught by rotating engine components.

Read and observe: "Inspection and servicing, safety instructions", paying particular attention to the section "Handling batteries".

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217

OPERATOR’S MANUAL EW 160 Assisted starting (with jump-leads)

2904639

Prior to assisted starting

Read and observe the section: "Assisted starting, safety instructions".

• Switch off all consumers at the receiving machine (empty batteries) and switch the keyoperated switch to 0.

• Switch off all consumers at the supplying machine (charged batteries) and switch off the engine.

Explosion hazard When the negative terminal is connected to ground, a strong current flows through the jumper cable. The sparks produced in the contact area can ignite the gases emanating from the discharged battery.

The negative terminal must therefore be connected to ground at a place as far away from the discharged batteries as possible.

Connecting the jumper cables Starting up the engines • Start up the engine of the supplying machine and run it at high speed.

• Start up the engine of the receiving machine. If the engine fails to start up after 15 seconds, wait for one minute and then start up again.

• After starting the engine proceed as follows:

Fig. 1

• Connect the red jumper cable to the positive pole of the empty battery (1), then to the positive pole of the charged battery (2).

• Connect the black jumper cable first to the negative terminal of the booster battery (3) and then to a bare-metal part of the machine (4).

- switch on some high-current consumers such as the complete lighting system, the fan in stage 3 and possibly also the air conditioner to prevent voltage spikes which are caused by disconnecting the jump-leads from the battery and which may damage electronic components of the vehicle.

- Observe the following working sequence for disconnecting the jump-leads: - Negative pole at receiving machine (4) - Negative pole at supplying machine (3) - Positive pole at supplying machine (2) - Positive pole at receiving machine (1) - switch the high-current consumers off again.

- Work for about half an hour mit medium engine speeds to charge up the batteries partially.

Have the electrical system of the machine checked to find out why the batteries were discharged.

218

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OPERATOR’S MANUAL EW 160 FUSES Checking / replacing the fuses

Shut off engine and set key-switch to 0 before removing the fuses.

Defective fuses must be replaced only by fuses of the same rating.

The fuses are located on a special board in the lower part of the control panel.

2904162

If an electric function is interrupted, check first the fuse concerned: • Withdraw fuse from holder and check.

A tool is located in the fuse box (Fig. 2).

• In most cases a blown fuse wire can be found out by visual inspection (Fig. 3). In case of doubt check fuse with an ohmmetre or replace right away by a new one.

• If the fuse is defective, insert a new one with the same rating.

• If the fuse is o.k check electrical components connectors and cables (or have them checked).

Fig. 1

• Unscrew cover plate (Fig. 1)

Fig. 3

• Unsnap cover above fuse box. Remove transparent cap of fuse box by opening the two lateral clips.

The fuses are then accessible. (Fig. 2). The circuits protected and the fuse currents are set out in the "Table of fuses".

Fig. 2

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219

OPERATOR’S MANUAL EW 160 Fuse table

1946505

F1

10 A

Interior cab light; PCS diagnostic socket; 24V - 12V voltage transformer (for radio and cool-box)

F2

5A

Coolant level switch; multiple-disk brake swing initiator; fuel level sensor

F3

5A

Load limit regulator

F4

10 A

Screen wiper motor; compressor for luxury seat (option)

F5

15 A

Central electronic system

F6

5A

Braking light

F7

5A

Switch 2.nd gear / crawling speed

F8

5A

Servo pressure cutout control, stick-bullgrader/stabilizers switchover, claws right/left (option) switchover

F9

5A

Servo pressure cutout solenoid

F 10

5A

Auxiliary rotation circuit (option) solenoids

F 11

5A

Inductive sensor - gear change; solenoids crawling speed

F 12

5A

Free for options

F 13

15 A

Refuelling system (optional equipment)

F 15

15 A

Additional floodlamps, rotary beacon (optional equipments)

F 16

5A

Inductive sensor and horn for Travel Alarm; solenoid coupling air conditioning system (optional equipment)

F 17

10 A

Connector box gear shift; pressure sensor 0 - 400 bar

F 20

10 A

Cold starting device

F 33

7.5 A

In feed line to 24V - 12V voltage transformer (for radio and cool-box)

F M2

10 A

Fan

220

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OPERATOR’S MANUAL EW 160 BULBS

2732217

Replacing the headlamp bulb

Replacing the bulbs - Notes

2472268

Replace defective bulbs only by bulbs with the same rating.

Before installing a new bulb: Remove all traces of corrosion from the lamp holder and the electrical contacts.

This helps to avoid contact problems and high contact resistance.

Never touch the new bulb with your bare fingers. Finger marks and dirt will burn in when the bulb is hot and may reduced the service life of the bulb and the reflector.

So hold the bulb in a clean cloth or in a piece of packaging material to insert it into the holder.

Bulbs - Table Headlamps Dipped beam Floodlamp Turn signal lamps Stoplamp Tail lamp Cab interior lamp

Fig. 1

• Remove headlamp body from superstructure frame (Fig. 1).

2796925

55/50W/24V 4W/24V 70W/24V 21W/24V 21W/24V 10W/24V 10W/24V Fig. 2

• Withdraw electrical connectors (Fig. 2).

• Remove protective cap from lamp holder.

• Release spring clip and replace bulb.

• Re-install headlamp.

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221

OPERATOR’S MANUAL EW 160 Replacing the front turn signal lamp 2472269

Replacing the bulb in the cab interior 2472270 lamp

Fig. 3

Fig. 5

• Turn out fastening screws of lamp cover (Fig. 3) and withdraw cover.

• Snap off lamp cover (Fig. 5) and withdraw.

• The bulbs in the lamp are now accessible and can be replaced.

• Snap on cover.

Fig. 4

• The bulb is located in a plug-in lamp holder (Fig. 4): - press down bulb and turn counter-clockwise, - withdraw bulb, - lock new bulb safely in the socket.

• Refit lamp cover with the screws.

222

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OPERATOR’S MANUAL EW 160 Replacing the tail-lamp bulb 2472271

Replacing the bulb of the floodlamp on 2472272 driver’s cab (Option)

Fig. 6

Fig. 8

• Unscrew the fastening screws of the lamp cover and withdraw (Fig. 6).

• Remove floodlamp on driver’s cab roof (Fig. 8).

Fig. 7

Fig. 9

• The bulbs (Fig. 7) are located in plug-in lamp holders.

• Snap back spring clip of bulb (Fig. 9).

- Press down bulb and turn counter-clockwise.

- Withdraw bulb.

Lock new bulb safely in the socket.

- Replace bulb.

• Refit floodlamp.

• Refit lamp cover by tightening the screws.

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223

OPERATOR’S MANUAL EW 160 Replacing the bulb of the boom floodlamp

2472273

• Unscrew fastening screw of lamp cover (Fig. 10).

Remove lamp cover.

• Snap back spring clip of bulb (Fig. 11).

- Replace bulb.

• Refit lamp cover by tightening the screw.

Fig. 10

Fig. 11

224

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OPERATOR’S MANUAL EW 160 Working equipment - replacing a tooth

2413674

Read and observe the section on "Fitting of working equipment - Safety instructions".

Secure the machine (cf. "Securing the machine").

Nobody must stand in the direction of the ejected safety latch and tooth.

The safety latch or the tooth can suddenly be ejected when driven out and hit persons.

Metal splinters may cause injury.

Fig. 2

Wear your personal protective equipment and goggles.

• Clean inside of housing and remove dirt and corrosion.

• Drive out tooth safety latch (1, Fig. 1) using a piece of smooth metal or of hard wood.

• Insert new tooth (3, Fig. 3) into housing (4).

The tooth must be in contact with the housing (arrow, Fig. 4).

Fig. 1

Fig. 3

• Drive tooth (3, Fig. 2) out of housing (4) using a piece of smooth metal or of hard wood.

• Drive in new safety latch (1, Fig. 4).

The latch can be driven into the housing from either side.

Fig. 4

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225

OPERATOR’S MANUAL EW 160 Clamshell, Wear Limits

2732229

To enable the wear status to be checked, new clamshells are marked at the factory (Fig. 5): Wearing parts of the clamshell are made of high-grade alloyed steels.

When repairs are done by welding on new parts, special procedures must be observed.

- with prick-punching on the guide rail (1), - and with a chisel mark on the cylinder guide (2).

Repairs should therefore be carried out only by trained personnel with appropriate equipment.

If the natural wear on clamshell cutters and stops exceeds an admissible limit, the clamshell cylinder may be damaged. The admissible stroke of the clamshell cylinder is then exceeded, and there is an impact between piston and cylinder tube in the limit positions.

Fig. 5

The clamshell must be repaired before the marking on the cylinder guide (2) is at the same level as one of the markings on the guide rail (1).

The lower marking (1) indicates the wear on the clamshell cutters, and the top marking the wear on the clamshell stops.

226

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OPERATOR’S MANUAL EW 160 PART 5 - ANNEX

Operating manual

2261969

Target group Operating personnel + Inspection and servicing personnel

Part 1 INTRODUCTION + FUNDAMENTAL SAFETY INSTRUCTIONS Repair personnel

Operating personnel

Part 2 OPERATION

The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Inspection and servicing personnel

Part 3 INSPECTION AND SERVICING

The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

Repair personnel

Part 4 REPAIR WORK

Part 5 ANNEX

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The repair personnel must have know-how and experience relevant to the repair of this or comparable machines.

Operating personnel + Inspection and servicing personnel + Repair personnel

227

OPERATOR’S MANUAL EW 160

This page intentionally left blank.

228

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OPERATOR’S MANUAL EW 160 TROUBLESHOOTING Instructions on troubleshooting Faults are often due to the machine not being correctly operated or serviced.

For this reason, it is vital to read through the relevant section of the operating manual once again before rectifying any faults.

If you are unable to detect the cause of the fault or rectify it, apply to the NEW HOLLAND CONSTRUCTION dealer after-sales service.

Describe the fault and all accompanying circumstances as precisely as possible. Exact data allow for fast troubleshooting.

Never do any jobs for which you are not qualified.

This fault table lists all faults which have been reported to date and outlines their possible causes and rectifying measures. In exceptional cases, a described fault may also have a different cause.

2801369

Layout of the fault table Fault The fault is described here as the outcome of an observation or a previous activity.

Therefore make careful observations.

Study the problem carefully, First think, then act.

Ask yourself the following questions: - Which warning signals preceded the fault?

- What repair and servicing work was carried out previously?

- Has this defect already occurred?

- Is it one or several simultaneously occurring faults?

Possible causes The possible causes of the observed fault are outlined in this group. They are arranged in order of probability, i.e. the possible cause occurring in most cases heads the list.

Measure This describes the troubleshooting procedure.

Section This specifies where information on troubleshooting is given in the operating manual. If there is no entry, the NEW HOLLAND CONSTRUCTION after-sales service should be consulted.

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229

OPERATOR’S MANUAL EW 160 FAULT TABLES

2801540

Combustion engine fault table Fault Engine fails to start or starts only with difficulty Engine cannot be turned Engine starts, but runs unevenly or intermittently Engine gets too hot, temperature warning is activated

Remedial action Check Adjust Replace Top up Reduce Clean

P E W A S R

Engine power insufficient Engine not working on full cylinder capacity Engine without oil pressure or oil pressure too low

Engine oil consumption too high

NHC = contact the NEW HOLLAND CONSTRUCTION dealer Service

Engine emits blue smoke Engine emits white smoke Engine emits black smoke Engine cannot be shut off, pilot lamps extinguished Engine is choked heavily

• •

•

• • •• •• ••• • • • • • • • • • • • •• • • • • • • • • • • •••• • • • •• • •••• •• • •

230

Cause

Chapter reference

Temperature below limit starting temperature

Starting engine P

Oil level too low

Engine oil level A

Oil level too high

Engine oil level S

Inclination of engine too great

Engine OI

P

Wrong SAE class of engine oil

Lubricants

W

Fuel quality does not correspond to operating manual specification

Engine OI

W

Air filter contaminated/Turbo-charger defective

Air-intake sys.

P

Fuel filter contaminated

Fuel filter

P/W

Charge-air line leaks

P

Oil cooler/cooling fins dirty

Clean cooler

R

Cooler fan defective, belt broken or loose

Engine OI

P/W

Cooling-air heating/Heat build-up Battery defective or not charged

P Battery

Loose or corroded cable connectors in starter circuit

P

Starter defective or pinion not in engagement

P

Shut-off solenoid jamming Incorrect valve clearance setting

NHC Engine OI

Leaks in injection line Injection valve defective

•

P

E P

Engine OI

P/W

Engine internally blocked

NHC

Combustion engine blocked at power output side

NHC

PCS malfunction

NHC

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OPERATOR’S MANUAL EW 160 Steering system fault table

2801541

Fault Steering not operational Steering wheel hard to turn, grab rotation not operational Steering wheel hard to turn when driving on level ground Steering inexact, permanent correction required Steering easy to turn at limit stop Steering wheel turns fast for a short moment during fast-steering action (steering discontinuous)

Cause

•

•

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Remedial action Check Adjust Replace Top up Reduce Clean

NHC = contact the NEW HOLLAND CONSTRUCTION dealer Service Chapter reference

Double pump without frictional connection

•

Hydraulic oil level too low

• •

Malfunction of primary/secondary pressure limiting valve Tyre pressure too low

• • • • • •

P E W A S R

NHC Top up with P hydraulic oil NHC Tyres and wheels

P/A

Air in hydraulic system

NHC

Internal leaks in steering valve / cylinder

NHC

Oil delivery insufficient

NHC

231

OPERATOR’S MANUAL EW 160 Service brake and parking brake, fault table Fault No braking or insufficient braking action of machine Machine braking action too strong Parking brake blocked Parking brake not operational

2801542

Remedial action Check Adjust Replace Top up Reduce Clean

P E W A S R

NHC = contact the NEW HOLLAND CONSTRUCTION dealer Service

Cause

• • • • • • • • • • •

232

Chapter

Malfunction or defect of brake pedal valve

NHC

Leaks in brake accumulators

NHC

Hydraulic oil leakage / external leaks

P

Brake disks worn out

NHC

Air in hydraulic brake system

NHC

Malfunction in hydr. service brake system

NHC

Malfunction in solenoid parking brake

NHC

Not enough pressure to unlock parking brake

NHC

Rocker switch defective

NHC

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OPERATOR’S MANUAL EW 160 Working hydraulics (incl. boom-adjusting and grab cylinder) fault table Fault Working and swing movements not operational Boom not operational Backhoe not operational Stick not operational

2801543

Remedial action Check Adjust Replace Top up Reduce Clean

P E W A S R

Boom-adjusting cylinder not operational Working movements too slow Power losses in working hydraulics Uncontrolled working movements

NHC = contact the NEW HOLLAND CONSTRUCTION dealer Service

Grab opens inadvertently Backhoe cylinder extends inadvertently during grab operation Grab opens and closes too slowly

• • ••••• • • • • •••• • • • • • • •

• • • • •

• • • • •

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• •

Cause

Chapter reference

Pilot control lever not in working position / defective

Working operation

P

Hydraulic oil level too low

Hydraulic oil

P/A

Malfunction in pressure limiting valve

NHC

Pilot control pump defective

NHC

Main pump drive coupling defective

NHC

Malfunction in primary/secondary pressure limiting valve

NHC

Engine speed too low

P

Working operation PCS power switch in position LIFT Working operation Fuel filter contaminated Fuel filter Engine lacks power Engine malfunction Hydraulic oil temperature too high (warning lamp lit, PCS fault Clean code), oil cooler contaminated hydraulic oil cooler Engine cooling-agent temperature too high, warning lamp lit and PCS fault code Malfunction of pilot control valve Malfunction of control spool Express coupling not completely open Switch-over valve backhoe/grab operation not completely Grab closed, internal leaks operation

P P/W NHC P/R

NHC NHC NHC P P

233

OPERATOR’S MANUAL EW 160 Transmission fault table

2801544

Fault No forward travel, no reversing Nor forward travel or no reversing Max. travelling speed not reached Insufficient traction power

Remedial action Check Adjust Replace Top up Reduce Clean

P E W A S R

NHC = contact the NEW HOLLAND CONSTRUCTION dealer Service

• • • • • •

• •

Chapter reference

Hydraulic oil level too low Pilot control pump defective

Hydraulic oil P/A NHC

Main-pump drive coupling defective Fuse F7 defective Parking brake blocking, required storage pressure too low

•

• •

234

Cause

NHC Fuses

P NHC

Travel direction solenoid valve defective

NHC

• • • • • • • •

Malfunction in travelling valve (pedal)

NHC

Engine nominal speed too low

NHC

Malfunction of control spool

NHC

• • • • • •

Cooling-agent temperature too high, warning lamp lit and PCS fault code

PCS power switch in position LIFT

Driving

P

Insufficient engine power

Engine malfunction

NHC

Hydraulic oil temperature too high (warning lamp lit, PCS fault code), oil cooler contaminated

Clean hydraulic oil cooler

P/R

Wheel-brake setting incorrect Malfunction of travel motor regulator Tyre inflation too low or not the same Travel selector switch defective

NHC Service brake

P/E NHC

Wheels and P/A tyres P

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OPERATOR’S MANUAL EW 160 Swing system fault table

2801373

Fault Swinging not operational Swinging left or right not operational Swinging power insufficient Inadvertent swinging movements Superstructure holding brake not operational

Cause

• • • • •

• • • • • • • • • •

• • • • • •

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• •

P E W A S R

NHC = contact NEW HOLLAND CONSTRUCTION dealer Service Section Work. operation

P

Hydraulic oil level too low

Hydraulic oil

P/A

Pilot control pressure limit valve(linkage) set too low/defective

NHC

Pilot control pump defective

NHC

Malfunction of swing pump feeding circuit

NHC

Malfunction of swing system high pressure circuit

NHC

Malfunction of moment control valve

NHC

Malfunction of swing pump displacement variation

NHC

Secondary valve opening too early

NHC

Excessive leakage in swing motor

NHC

Pressure cutoff set too low

NHC Superstructure holding brake

Brake linings worn Fuse F2 defective

•

Check Adjust Replace Top up Reduce Clean

Pilot control lever not in working position/ defective

Superstructure holding brake blocked

•

Measure

P P/W

Fuses

P/W

Solenoid valve defective

NHC

Speed sensor defective

NHC

Swing mode pressure switch in cascade open / defective

NHC

Superstructure holding brake emergency operated

P

235

OPERATOR’S MANUAL EW 160 Floating-axle blocking fault table Fault Floating-axle support not blocking Floating-axle support not releasing Floating-axle support instable in blocked condition Noises during floating of axle

2801539

Remedial actions Check Adjust Replace Top up Reduce Clean

P E W A S R

NHC = Contact the NEW HOLLAND CONSTRUCTION dealer Service Cause

• • • • • • • • • • • • •

236

Malfunction of Floating-axle blocking valve Malfunction of control valve

NHC NHC

Cylinder overloaded Air in system Hydraulic pressure too low Control spool of blocking valve in cylinder sluggish Rocker switch 52 in blocked position

P P NHC NHC P

Float.-axle blocking valve not vented

•

Chapter reference

Check valve in cylinder defective Piston rod seal defective Contact faces of blocking cylinder not lubricated

Block float.-axle Vent float.-axle supporting cylinder

Floatingaxle cylinder, grease contact faces

P

NHC NHC P

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OPERATOR’S MANUAL EW 160 Stabilizer system (PLA - A 2) fault table Fault Levelling blade not operational Stabilizer legs not operational Individual control of stabilizer leg cylinders not switchable Inadvertent extension of a stabilizer leg cylinder

2801545

Remedial action Check Adjust Replace Top up Reduce Clean

P E W A S R

Inadvertent retraction of a stabilizer leg cylinder Inadvertent extension or retraction of the levelling blade cylinders Levelling blade support working only on one side

NHC = contact the NEW HOLLAND CONSTRUCTION dealer Service

Stabilizer leg support working only on one side

• • • • • • • •

• • • • • • • • • • • • • • • • • • • • • • •

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Cause

Chapter reference

Pilot control lever not in working position / defective

Working operation

P

Hydraulic oil level too low

Hydraulic oil

P/A

Malfunction of pilot control pressure limiting valve

NHC

Main pump drive coupling defective

NHC

Malfunction of primary pressure limiting valve

NHC

Malfunction of pilot control valve

NHC

Internal leaks in rotor

NHC

Malfunction of double check valves in the cylinders

NHC

Braking system storage pressure too low

P

Rocker switch defective

NHC

Switch-over valve in stabilizer leg cylinders defective

NHC

Internal leaks in cylinders

NHC

237

OPERATOR’S MANUAL EW 160 Hammer operation (optional equipment) fault table Fault Hammer equipment not operational Hammer performance insufficient

2801374

Remedial action Check Adjust Replace Top up Reduce Clean

P E W A S R

NHC = contact the NEW HOLLAND CONSTRUCTION dealer Service Cause

•

•

238

Chapter reference

• •

Malfunction of hammer equipment pressure limiting valve

•

Hydraulic oil temperature too high (warning lamp lit, PCS fault code), oil Hydraulic oil P/R cooler contaminated cooler

•

Engine cooling-agent temperature too high, warning lamp lit and PCS fault code

•

Pilot control lever not in working position / defective

Working operation

• • • •

Hydraulic oil level too low

Hydraulic oil P/A

Engine speed too low

NHC Hydraulic hammer

P

NHC

P

Malfunction of pilot control pressure limiting valve

NHC

Malfunction of primary control spool pressure limiting valve

NHC

Pump delivery rate insufficient or PCS not programmed for attached type of hammer

NHC

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OPERATOR’S MANUAL EW 160 Grab rotation circuit (optional equipment) fault table Fault Grab rotation circuit not operational Grab rotates too slowly Grab does not rotate at cylinder limit stops

NHCult

• • • • • • • • • • • • • • • •

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2801375

Remedial action Check P Adjust E Replace W Top up A Reduce S Clean R NHC = contact the NEW HOLLAND CONSTRUCTION dealer Service Chapter reference

Grab rotating pump defective Hydraulic oil level too low

NHC Hydraulic oil P

Malfunction of grab-rotation pressure limiting valve Fuse F 10 defective

NHC Fuses

P

Pushbutton in control lever defective

NHC

Loose or corroded cable connections

P

Grab-rotation solenoid valve defective

NHC

Express couplings not completely open

P

Express couplings not opened

P

Grab rotating motor defective

NHC

Grab blades or limit stops show excessive wear

P

Pinion or swing ring defective

P

239

OPERATOR’S MANUAL EW 160 Table of fault codes The part of the electrical system used for controlling and monitoring the engine and the hydraulic system is permanently monitored by the central electronic control unit.

If a fault occurs, the working hours display (5, Fig. 1) shows a fault code and the word ERROR. The fault code is displayed alternately with the total number of hours run.

In individual cases, several faults may occur at the same time.

The corresponding fault codes are then displayed alternately with the total number of hours run (e.g: 2345 OPR. HOUR 02 ERROR 2345 OPR. HOUR 2345 100 ERROR 2345 OPR. HOUR 2345 ...).

2801376

The following fault codes can be indicated: 02

100

8000

04

200

10000

08

400

20000

10

800

40000

20

1000

80000

40

2000

80

4000

You cannot rectify these faults yourself, as they require special testing equipment and expert knowledge.

Therefore, note the fault code and inform your nearest NEW HOLLAND CONSTRUCTION dealer.

Besides the fault code, the following information must be given to the NEW HOLLAND CONSTRUCTION specialist: - in which working situation did the fault occur?

- did the machine show a different behaviour?

- which indicator and warning lamps have lit up?

- was there any other information shown on the display?

- which were the external influences acting on the machine (such as great heat/cold, dust, permanent load over a longer period)?

Fig. 1

240

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OPERATOR’S MANUAL EW 160 Tightening torques - Table

2801546

The screws and nuts used in this machine have an ISO metric thread.

If new screws or nuts are needed, they must have the same dimensions and be of the same grade as those replaced.

For tightening of screws and nuts please use tools with metric size indication of the width over flats only. The width-over-flats dimensions of the screws to be checked in compliance with the servicing schedules are set out in the following table.

The grade is indicated on the screw head or on the nut (e.g. 8.8, 10.9 or 12.9).

A table with all other width-over-flats dimensions can be found in the Technical Handbook.

Screw

Screw size Thread size Material grade Wrench size (mm)

MA Nm

Torque lbft

Wheel nuts

M 22x1,51)

8.8

SW 30

450

332

Swing ring

M 161)

10.9

SW 24

250

184

Swing gear

M 161)

10.9

SW 24

250

184

Ballast

M 301)

12.9

SW 46

2250

1660

Rigid axle

M 201)

8.8

SW 30

410

302

1)

= lightly oiled

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OPERATOR’S MANUAL EW 160

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242

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OPERATOR’S MANUAL EW 160 ABBREVIATIONS A A A2 A4 abt. acc.

Ad. 1 Ah

Ampere (SI base unit of electric current) Four-wheel drive 2-point bracing (claws) 4-point bracing (claws) about according to with reference to 1 Ampere hours (SI base unit of quantity of electricity) API American Petroleum Institute approx. approximately bar Bh

unit of pressure measurement (1 bar = 14.5 psi) = OH = Operating hour

Communaute Européenne = European Community CECE Committee for European Construction Equipment (Defines a measure for bucket, grab, or scoop filling) CEN European Standardization Committee cf. refer to cm centimeter (= 1/100 m) 3 cm /rev Cubic centimeters per revolution cw clockwise ccw counterclockwise

2732218

i i.e.

IFN incl.

ISO kg kg/dm3 km/h kNm kW l lbft

CE

dB(A) dia.

DIN

Decibel (Sound intensity according to measuring method A) Diameter German Standardisation Organization

EDCV EDS eff. e.g. etc.

Electronic drive control (grader only) Electronic diagnostic system effective for example etcetera

fig.

FOPS

Figure, serial number of illustration Falling objects protective structures

gal GLR

gallon (1 gal = 3.78 litres) Full-load controller (electronic module for POWER-system)

HD HDS hp Hydr.

Heavy duty Heavy duty small Horsepower (1 hp = 0.7457 kW) Hydraulic, Hydraulics

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Lb/in2 LC LDA LED l/min LpA LS LwA

m MA mA max. min. min-1 mm

Transmission ratio id est = that is ISO service rating, blocked including, inclusive of International Standardisation Organisation Kilogram (unit of weight) Kilograms per cubic decimeter ( = unit of specific density) Kilometers per hour KiloNewtons per meter (1 kNm = 1000 Nm) = unit of torque Kilowatt (1 kW = 1.36 hp) Liter pound foot (1 lbft = 1.356 Nm) (unit of torque) Pounds per square inch (= psi) Long carriage Charge pressure-dependent full-load limiter Light-emitting diode Liters per minute Sound pressure at workplace Limited slip Sound power level of the machine in stationary operation Meters Tightening torque Milliampere (= 1/1000 A) maximal, maximum minimal, minimum Revolutions per minute Millimeter (= 1/1000 m)

N NHC N, kN NLGI

Normal, standard version NEW HOLLAND CONSTRUCTION Newton, kiloNewton (unit of force) National Lubricating Grease Institute (USA) NLGI- Consistency - lubricant classification Klasse acc. to DIN 51 818 Nm Newtonmeter (unit of torque) No./Nos. number/numbers OH Operating hour OI Operating Instructions (op.inst.) Operating Instructions

243

OPERATOR’S MANUAL EW 160 ABBREVIATIONS PCS

PLA P/No. PS

Power Control System (Electronic unit for engine and hydraulic pumps management) Levelling blade Part number Metric horsepower (1 PS = 0.74 kW)

Qty.

Quantity

R, r resp.

ROPS rpm SAE sec.

SW t tm typ.

U/min

Radius Respectively Roll-over protective structures Revolutions per minute (= min-1) Society of Automotive Engineers (USA) Second Width across flats (hex head screws) Metric ton (= 1000 kg) Tons by meters (obsolescent unit of swing torque) Typical Revolutions per minute (= rpm)

V

Volt (unit of electric voltage)

W

Watt (unit of electric power)

o

o

Degrees Celsius (temperature) Degrees Fahrenheit (temperature) Degrees crank angle

> <

greater than less than

C F o kW

244

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OPERATOR’S MANUAL EW 160 INDEX

2486289

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OPERATOR’S MANUAL EW 160

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Applying the parking brake ................................ 6677

A

Applying the service brake ................................ 66

ABBREVIATIONS .................................... 243, 244

Applying the superstructure retaining brake...... 88

Accumulators, safety instructions .................... 216

Assembling working equipment - safety instructions .......................................................... 100

Activate the horn ................................................93 Activate the Power Assist function...................... 93

Assisted starting (with jump-leads) .................. 218 Activate the Power Boost function...................... 93

Assisted starting (with jump-leads) - Safety instructions ...................................................... 217

Activating the overload warning system .......... 116

Attaching and detaching the grab equipment .. 104

Activating the servo control ................................ 85

Attaching and detaching the grab equipment Safety instructions ............................................ 104

Adjusting the armrests ...................................... 125 Adjusting the backrest ...................................... 125 Adjusting the control console position................ 33 Adjusting the heating performance .................... 62 Adjusting the lumbar support .................... 124, 126 Adjusting the Mirrors ..........................................34 Adjusting the pneumatic suspension ................ 125 Adjusting the seat cushion ................................ 125 Adjusting the steering column ............................ 69 Adjustment of armrests ......................................32 Adjustment of backrest inclination ...................... 32 Adjustment of driver’s seat ................................ 32 Adjustment of seat position ................................ 32

Attaching the grab ............................................ 104 Axles and travel gearbox .................................. 181

B Battery - checking the charge .......................... 167 Battery - checking the fluid level ...................... 167 Battery main switch .......................................... 167 Battery storage ................................................ 212 Battery, checking .............................................. 167 Before beginning work ........................................ 81 Before Operation ................................................ 12 Bleeding the multiple-disk brakes .................... 191

Adjustment of seat suspension .......................... 32

Bleeding the supporting cylinder of the fullfloating axle ...................................................... 176

Adjustment of steering column .......................... 69

Blocking the swing axle ...................................... 71

After daily operation ............................................ 99

BRAKING ........................................................ 189

After recovery / towing ........................................ 77

Braking and stopping .......................................... 73

After travel operation ..........................................79

Braking system .................................................. 66

AIR CONDITIONER ........................................ 202

Braking the superstructure ................................ 87

Air conditioner - Checking / retensioning the compressor V-belt ............................................ 207

Bringing the machine into its basic position ........ 71

Air conditioner - Inspection and servicing work 203 Air conditioner - Troubleshooting ...................... 208 Air conditioner, switching on / off ...................... 127 AIR-INTAKE SYSTEM ...................................... 161 Alternator - instructions .................................... 166 Application of Voler A.C. .................................. 108

BULBS .............................................................. 221 Bulbs - Table .................................................... 221

C

D

Cab interior lamp - switching on and off ............ 37

Defrosting the front and rear screens ................ 63

California, Proposition 65 Warning ...................... 9

Depressurizing the hydraulic system ................ 169

Changing a wheel ............................................ 196

Description of control panel ................................ 38

Changing line filters .......................................... 172

Description of multi-position boom.................... 109

Changing the hydraulic oil ................................ 173

DESCRIPTION OF THE MACHINE .................. 24

Changing the hydraulic oil return-flow filter ...... 171

DESIGNATED USE .............................................. 4

Checking / replacing the fuses ........................ 219

Detaching / attaching the backhoe bucket ........107

Checking / replacing the safety filter element.. 163

Detaching the grab .......................................... 105

Checking air intake lines .................................. 163

Display (key 18), function ................................129

Checking the coolant level ................................ 160

Display, setting the contrast ............................130

Checking the drive belts ..................................160

Draining hose for oil changes .......................... 158

Checking the engine oil level / topping up with oil ...................................................................... 159

Draining hydraulic oil ........................................ 173

Checking the hydraulic oil level ........................170 Checking the lining thickness of multiple-disk brakes .............................................................. 189

DRIVER’S CAB .................................................. 30 Driver’s seat - adjusting the lumbar support.... 124 Driver’s seat with pneumatic suspension and integrated heating ............................................ 125

Checking the tyre inflation pressure - Refilling the tyre.............................................................. 194

DRIVING ............................................................ 64

Clamshell, Wear Limits .................................... 226

Driving - Safety instructions ................................ 64

Cleaning the engine cooler .............................. 178

Driving in case of PCS failure ............................ 79

Cleaning the filter mat ...................................... 201

Driving on and off the road ................................ 73

Cleaning the fuel tank ...................................... 165

Driving on slopes and gradients ........................ 74

Cleaning the hydraulic oil cooler ......................177

Driving with a load on the hook .......................... 75

Cleaning the hydraulic oil reservoir ..................174

During recovery / towing .................................... 77

Climbing Up and Down ...................................... 30 Closing the Door ................................................ 31 Combustion engine fault table .......................... 230 Component numbers .......................................... 29 Connecting the jumper cables .......................... 218 Control elements (SAE-control) .......................... 52 Control panel ...................................................... 40 Control panel operating instructions .................. 39 Corrosion protection for pins and bearings (bushings and hubs) ........................................ 108

......................................................

Electrical system ................................................ 25 ELECTRICAL SYSTEM.................................... 166 Electrical system - Safety instructions .............. 166 Emergency exit .................................................. 35

E Emptying the dust collector ..............................

161 Electric energy159, 217 ENGINE ....................................................

Engine does not start ..........................................61 Engine number ..................................................29 Engine, repair instructions ................................ 217

Engine, safety instructions for inspection and servicing .......................................................... 159

H

Excavator load capacity .................................... 115

Hammer operation (optional equipment) fault table .................................................................. 238

Extending and retracting the stick...................... 93

Heating .............................................................. 62

Extreme positioning of working equipment Instructions ........................................................ 81

HEATING .......................................................... 201 Hydraulic and pneumatic equipment .................... 9

F

HYDRAULIC HAMMER .................................... 110

Fastening the retaining belt ................................ 65

Hydraulic system ................................................ 25

Fault .................................................................. 229

HYDRAULIC SYSTEM .................................... 169

FAULT TABLES ..............................................230 Filling and emptying the bucket.......................... 93 Filling quantities - grease .................................. 151 Filling with hydraulic oil .................................... 174 Fire-extinguisher ................................................ 70 First-aid kit .......................................................... 70 Floating axle ......................................................25 Floating-axle blocking fault table ...................... 236 Fore and aft adjustment of seat.......................... 32

Hydraulic system - safety instructions.................169

I Immobilizer, deactivate / activate ...................... 132 Immobilizer, entering the code ............................58 INDEX .............................................................. 245 Inspection and servicing - safety instructions .. 135 Inspection and servicing plans - instructions .... 139 Instructions on troubleshooting ........................ 229

Fore-and-aft adjustment .................................. 125

J

Front window - Removing the lower part ............ 35

Joints and hinges.............................................. 151

FUEL SYSTEM ................................................ 164 Fuel system - Safety instructions ...................... 164

K

Function of overload warning system .............. 116

KEYBOARD, FURTHER FUNCTIONS ............ 128

Further servicing work ...................................... 139 Fuse table ........................................................ 220 FUSES.............................................................. 219

L Layout of the fault table .................................... 229 LIFTING-GEAR OPERATION .......................... 114

G

Lifting-gear operation - safety instructions ........ 114

Gas, dust, steam and smoke ................................ 8

Loading hook capacity ...................................... 115

General .............................................................. 10

Loading hooks on backhoe buckets and couplers .................................................................... 115

Grab rotation circuit (optional equipment) fault table .................................................................. 239

Location of components in the machine .......... 203

Greases for bearings and swing rings .............. 157

Locking the superstructure ................................ 86

Greasing the control valve tappets .................. 200

Lowering boom upper section .......................... 109

Greasing the pedal valve tappets .....................200

LUBRICANTS .................................................. 154 LUBRICATING CHART - GREASE .......... 148, 150 Lubricating chart - Grease Undercarriage ........151

Lubricating chart - Grease Working equipment 149

P

Lubricating the greasing nipples ...................... 199

Parking brake .................................................... 25 PART 1 - INTRODUCTION .................................. 1

M Machine in working position .............................. 90 Machine layout ..................................................25 Machine number ................................................ 29 Measure............................................................ 229

PART 2 - OPERATION ...................................... 19 PART 3 - INSPECTION AND SERVICING ...... 133 PART 4 - REPAIR WORK ................................213 PART 5 - ANNEX ............................................227 Part nos. for Voler A.C. ....................................108

MONITORING-, WARNING- AND CONTROL ELEMENTS ........................................................ 38

Pipe-fracture safety system, function ................ 118

Multi-position boom .......................................... 109

Plan A - After every 250 OH............................ 145 Plan B - After every 500 OH............................ 145

N

Plan C - After every 1000 OH.......................... 145

Noise .................................................................... 9

Plan D - After every 3000 OH.......................... 145 Plan N - After first commissioning .................... 142

O OIL INSPECTION PLAN .................................. 152 Oil inspection plan ............................................ 153 Oil, grease and other chemical substances .......... 9 Oils for axles and gearboxes (selection) .......... 156 Oils for hydraulic system, mineral ....................155 Oils for internal combustion engines ................154 Opening / closing side window .......................... 35 Opening / Closing the Driver’s Cab Door ............ 31 Opening and closing the grab............................ 93 Opening and Closing the Windscreen................ 34 Opening the Door from Inside............................ 31

Plan T - Every 10 OH or per working shift ........ 143 Plan V - Once before first commissioning........ 140 Plan W - Every 50 OH or weekly...................... 143 Possible causes ................................................ 229 Power assist, function ........................................94 Power Boost, function ........................................95 PREFACE ............................................................3 Prior to assisted starting .................................. 218 Protective roof against falling objects .............. 101 Putting the machine out of operation ................ 212 Putting the overload warning system out of operation .......................................................... 117

Opening the Door from Outside.......................... 31 Operating methods ............................................ 96 Operation - safety instructions ............................ 21 OPTIONAL EQUIPMENT ................................ 119 Organizational measures ......................................5 Overload warning system ................................ 116

Q QUICK-CHANGE DEVICE .............................. 102 Quick-change device - detaching the excavator bucket .......................................................... 102 Quick-change device - remounting the excavator bucket ...................................................... 103 Quick-change device - safety instructions ........ 102

R

S

Radio ................................................................ 121

Safety instructions governing specific operational phases ............................................................ 6

Raising and lowering the boom.......................... 93 Raising boom upper section ............................ 109 Recommissioning ............................................ 212 Recovering / towing the machine........................ 76 Recovery and towing - Safety instructions.......... 76 Refilling quantities - oil ...................................... 153 Refilling quantities - other ................................ 153

SAFETY PRECAUTIONS FOR OPERATION .... 10 SCRAP SHEARS ............................................ 112 Section.............................................................. 229 Securing the machine ...................................... 101 Selecting the backhoe / grab equipment .......... 106 Selecting the PCS output stage.......................... 84

Refuelling............................................................ 56

Selection and qualification of personnel - basic responsibilities ...................................................... 6

Refuelling system ............................................ 122

Service (key 16), function ................................ 128

Refuelling with the refuelling system ................123

Service brake.............................................. 25, 189

Refuelling with the refuelling system, safety instructions ...................................................... 122

Service brake and parking brake, fault table.... 232

Refuelling, safety instructions ............................ 56 Releasing the parking brake .............................. 67 Releasing the parking brake with the emergency unlocking device ......................................77

SERVICING ...................................................... 158 Setting the time ................................................ 131 Shutting off the engine ........................................61 Shutting off the machine .................................... 99

Releasing the superstructure retaining brake.... 89

SIGNS ................................................................ 26

Removing and installing the battery.................. 168

Slewing superstructure ...................................... 93

Removing, checking, and cleaning the main filter element .................................................... 162

Socket outlet in cab ............................................ 37

Renew sealing cord .......................................... 174 Repair work - safety instructions ......................215 Replacing the breather valve ............................ 171 Replacing the bulb in the cab interior lamp ...... 222 Replacing the bulb of the boom floodlamp ...... 224

Special work in conjunction with utilization of the machine - maintenance and repairs during operation - disposal of parts and consumables .... 7 Speed reset function ..........................................83 Stabilization of the machine ................................91 Stabilizer system (PLA - A 2) fault table .......... 237 Standard operation .............................................. 6

Replacing the bulb of the floodlamp on driver’s cab .................................................................... 223

Starting and stopping the engine........................ 59

Replacing the bulbs - Notes ............................ 221

Starting the engine ............................................ 59

Replacing the front turn signal lamp ................ 222

Starting the engine with cold-starting aid............ 60

Replacing the headlamp bulb .......................... 221

Starting up the engines .................................... 218

Replacing the tail-lamp bulb ............................223

STARTING UP THE MACHINE ..........................56

Rigid axle and travel gearbox - changing the oil ...................................................................... 183

Steering .............................................................. 25 Steering axle gearbox - changing the oil.......... 187

Rigid axle and travel gearbox - checking the oil level .............................................................. 181

Steering axle gearbox - checking the oil level .. 185

Rotary beacon .................................................. 119

Steering axles wheel hub gears - changing the oil ...................................................................... 188

Steering axles wheel hub gears - checking the oil level .............................................................. 186

Switching the windscreen wiper / washer on and off ................................................................ 63

Steering column - Safety instructions................ 69 Steering system fault table ..............................231 Superstructure .................................................... 25 Superstructure holding brake - emergency operation ............................................................ 89 Superstructure holding brake - Function chekking .................................................................. 180 Superstructure retaining brake - function............ 88 Supplementary control panel .............................. 48

T Table of fault codes .......................................... 240 Table of tyre inflation pressures ........................ 194 Testing the overload warning system .............. 117 Tightening torques - Table ................................ 241 To indicate the engine revolutions .................... 129 To indicate the time of day .............................. 129 To switch off the seat heating: .......................... 126

Swing axle cylinder - lubricating the contact surfaces ............................................................ 192

To switch on the seat heating: .......................... 126

SWING GEAR .................................................. 179

Topping up the wash fluid ................................201

Swing gear - changing oil ................................ 179

Topping up with hydraulic oil ............................170

Swing gear - checking oil level ........................ 179

Transmission fault table .................................... 234

SWING RING .................................................. 197

Transport - Safety instructions ............................78

Swing ring - checking grease filling .................. 197

Transporting and towing - recommissioning ........ 9

Swing ring - checking tightness of screws........ 199

Transporting of the machine .............................. 78

Swing ring - filling grease ................................ 198

Transporting the machine with multi-position boom ................................................................ 109

Swing ring - greasing the bearing .................... 198 Swing ring - Instructions ..................................197 Swing system fault table .................................. 235 Swinging - changing the mode of operation ...... 87 Swinging and braking the superstructure .......... 86 Swinging the superstructure .............................. 86 Switching off the hydraulic hammer .................. 111

Travel gear selection ..........................................68 Travelling ............................................................ 72 Tread pattern arrangement .............................. 196 TROUBLESHOOTING .................................... 229 Turning the grab ................................................ 93 Tyre inflation pressure - Safety instructions ......193 Tyres and wheels, safety instructions ..............195

Switching off the pilot control.............................. 85 Switching off the scrap shears .......................... 113 Switching on floodlamps .................................... 82 Switching on the floodlamps at the rear of the cab .................................................................... 120 Switching on the hydraulic hammer .................. 111

....................................................

Unlocking the superstructure .............................. 86 Using the Sunshade .......................................... 36

Switching on the scrap shears .......................... 113 Switching on the seat heating ..........................126 Switching the electrical system on and off .......... 57 Switching the proportional valve over to emergency operation .................................................. 98

..........................................................

Ventilation and heating ...................................... 62 Venting the hydraulic system ............................ 175

U

Undercarriage

W Warning and instruction signs ............................ 27 Warning of special dangers.................................. 8 Warning triangle ................................................70 Warnings and symbols ........................................ 4 WHEELS AND TYRES .................................... 193 WINDSCREEN WASHER ................................ 201 Work to be carried out every month.................. 203 Work to be performed every 2 years................ 206 Work to be performed every 6 months ............ 206 Working equipment ............................................ 25 WORKING EQUIPMENT .................................. 100 Working equipment - replacing a tooth ............ 225 Working hydraulics (incl. boom-adjusting and grab cylinder) fault table ..................................233 Working on brakes - Safety instructions .......... 189 WORKING OPERATION .................................... 80 Working operation - Safety instructions.............. 80 Working operation in case of PCS failure .......... 98 Working with a hydraulic hammer ....................111 Working with backhoe or grab equipment (SAE-control) ...................................................... 92 Working with scrap shears ..............................113 Working with scrap shears, safety instructions 112 Working with the hydraulic hammer, safety instructions ...................................................... 110 Working with the multi-position boom .............. 109

NOTES

CNH America LLC 245 E NORTH AVENUE CAROL STREAM, IL 60188 U.S.A

Part Number North American English Printed in U.S.A.

73183099 September 01 Bur