CASE CX16B MINI EXCAVATOR Service Repair Manual by 163215

Mini Excavators CX16B and CX18B SERVICE MANUAL

CNH

Cre 9-88670

CX16B and CX18B

SECTION 1

HOW TO USE

INDEX Sections index ...................................................................................................................1-1 Introduction .......................................................................................................................1-4 Manual handling ............................................................................................................................................ 1-4 Symbols and indications ............................................................................................................................... 1-5

Features of the manual .....................................................................................................1-6

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Manual composition ...................................................................................................................................... 1-6 Brief information for manual consultation ...................................................................................................... 1-8

SECTIONS INDEX

PAGES

SECTION 1 - HOW TO USE Sections index ............................................................................................................................................... 1-1 Introduction ................................................................................................................................................... 1-4 Features of the manual ................................................................................................................................. 1-5 SECTION 2 - SAFETY RULES Safety rules .................................................................................................................................................... S1 Safety signs .................................................................................................................................................. S38 SECTION 3 - PRELIMINARY General precautions for repairs ..................................................................................................................... 3-1 Escaping procedure in case of emergency ................................................................................................... 3-6 International unit conversion system ............................................................................................................. 3-7 SECTION 4 - SPECIFICATION Foreword ....................................................................................................................................................... 4-1 Identification data .......................................................................................................................................... 4-2 Noise levels (2000/14/EC) ............................................................................................................................ 4-3 Summary plate for maintenance operations ................................................................................................. 4-4 Basic components of the mini excavator ....................................................................................................... 4-5 Technical specifications ................................................................................................................................ 4-7 Digging performances (canopy) .................................................................................................................... 4-8 Digging performances (cab) .......................................................................................................................... 4-9 Transport dimensions (canopy) ................................................................................................................... 4-10 Transport dimensions (cab) ........................................................................................................................ 4-11 Lifting capacities (cab) ................................................................................................................................ 4-12 Lifting capacities (canopy) ........................................................................................................................... 4-13 Machine and components weight (dry) ....................................................................................................... 4-14 Buckets application ..................................................................................................................................... 4-15 Filling chart .................................................................................................................................................. 4-16 SECTION 5 - TOOLS Tools of cylinders .......................................................................................................................................... 5-1 Tool of hydraulic pump .................................................................................................................................. 5-4 Tool of pilot valve track ................................................................................................................................. 5-4 Tool of roller track ......................................................................................................................................... 5-4 Tool of idler adjuster ...................................................................................................................................... 5-5 Tools of engine .............................................................................................................................................. 5-5 Tools of travel motor ..................................................................................................................................... 5-8

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SECTION 6 - STANDARD MAINTENANCE TIME TABLE Preface .......................................................................................................................................................... 6-1 Standard working time table for the maintenance ......................................................................................... 6-2 SECTION 7 - MAINTENANCE STANDARDS AND TEST PROCEDURES How to use maintenance standards and precuations ................................................................................... 7-1 Performance inspection standard table ......................................................................................................... 7-2 Measuring engine speed ............................................................................................................................... 7-4 Measuring hydraulic oil pressure .................................................................................................................. 7-5 Measuring travel performances ..................................................................................................................... 7-8 Measuring slew performances .................................................................................................................... 7-10 Measuring attachment operating performances .......................................................................................... 7-12 Measuring slew bearing performances ....................................................................................................... 7-14 Measuring crawler tension .......................................................................................................................... 7-15

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SECTIONS INDEX SECTION 8 - HYDRAULIC SYSTEM Function and features of hydraulic circuit ...................................................................................................... 8-1 Hydraulic circuits and components ............................................................................................................... 8-2 Hydraulic circuit operation ............................................................................................................................. 8-6 SECTION 9 - ELECTRICAL SYSTEM How to read circuit diagram .......................................................................................................................... 9-1 SECTION 10 - ATTACHMENT Attachment assy and name ......................................................................................................................... 10-1 Bucket ......................................................................................................................................................... 10-2 Arm .............................................................................................................................................................. 10-5 Boom ......................................................................................................................................................... 10-10 Swing ........................................................................................................................................................ 10-15 Dozer ......................................................................................................................................................... 10-22 Hydraulic cylinders .................................................................................................................................... 10-26 SECTION 11 - UPPER STRUCTURE Canopy ........................................................................................................................................................ 11-1 Cab .............................................................................................................................................................. 11-4 Guard .......................................................................................................................................................... 11-6 Floor plate ................................................................................................................................................. 11-10 Battery ....................................................................................................................................................... 11-13 Counterweight ........................................................................................................................................... 11-14 Fuel tank ................................................................................................................................................... 11-17 Hydraulic oil tank ....................................................................................................................................... 11-20 Air cleaner ................................................................................................................................................. 11-25 Muffler ....................................................................................................................................................... 11-27 Hydraulic pump ......................................................................................................................................... 11-28 Radiator ..................................................................................................................................................... 11-43 Engine ....................................................................................................................................................... 11-47 Control valve ............................................................................................................................................. 11-49 Solenoid valve ........................................................................................................................................... 11-84 Pilot valve .................................................................................................................................................. 11-86 Pilot valve travel ........................................................................................................................................ 11-96 Slew motor .............................................................................................................................................. 11-105 Joint swivel .............................................................................................................................................. 11-139 Selector valve .......................................................................................................................................... 11-154 Upper frame ............................................................................................................................................ 11-159

SECTION 13 - TROUBLESHOOTING HYDRAULIC SYSTEM General precautions .................................................................................................................................... 13-1 Trouble diagnosis: Hydraulic ....................................................................................................................... 13-2 Troubleshooting .......................................................................................................................................... 13-3 SECTION 14 - TROUBLESHOOTING ELECTRICAL SYSTEM Trouble diagnosis: Electrical ....................................................................................................................... 14-1 Troubleshooting .......................................................................................................................................... 14-2

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SECTION 12 - TRAVEL SYSTEM Low structure ............................................................................................................................................... 12-1 Crawler ........................................................................................................................................................ 12-3 Slide plate ................................................................................................................................................. 12-12 Roller tracks .............................................................................................................................................. 12-14 Idler adjuster ............................................................................................................................................. 12-19 Sprocket .................................................................................................................................................... 12-28 Travel motor .............................................................................................................................................. 12-29 Slew bearing ............................................................................................................................................. 12-71 Lower frame .............................................................................................................................................. 12-76

SECTIONS INDEX SECTION 15 - TROUBLESHOOTING ENGINE Trouble diagnosis: Engine ........................................................................................................................... 15-1 Troubleshooting .......................................................................................................................................... 15-2

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SECTION 16 - ENGINE Specifications and Performance ............................................................................................................... 16-1 Cross Sectional Views .............................................................................................................................. 16-15 Cooling water, lubricating oil and fuel oil .................................................................................................. 16-17 Troubleshooting ........................................................................................................................................ 16-21 Measuring instruments .............................................................................................................................. 16-25 Measurement, inspection and adjustment ................................................................................................ 16-29 Adjustment the valve head clearance ....................................................................................................... 16-31 Checking the v-belt tension ....................................................................................................................... 16-32 Measuring and checking the injection pressure and spray patterns of the fuel injection valve ................. 16-32 Checking and adjustament the fuel injection timing .................................................................................. 16-36 Adjustament the no-load maximum (or minimum) revolutions .................................................................. 16-38 Checking the cooling water system and radiator for water leakage .......................................................... 16-38 Checking the battery ................................................................................................................................. 16-39 Checking the sensors ................................................................................................................................ 16-41 Checking the oil cooler .............................................................................................................................. 16-42 Checking the piston cooling nozzle ........................................................................................................... 16-43 Measuring Procedure, Service Data and Corrective Action ...................................................................... 16-45 Disassembly and reassembly ................................................................................................................... 16-73 Service data .............................................................................................................................................. 16-83 Tightening torque ...................................................................................................................................... 16-89 Fuel injection pump for indirect injection system ....................................................................................... 16-91 Fuel Injection Pump for Direct Injection System ....................................................................................... 16-97 Governor ................................................................................................................................................. 16-111 Turbocharger ........................................................................................................................................... 16-123 Service information for CARB ULG regulation ........................................................................................ 16-129

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INTRODUCTION

INTRODUCTION INTRODUCTION This service manual has been prepared in order to increase repair quality, providing to the technicians the elements for a good knowledge of the product and showing the proper procedures to carry out the maintenance operations. We recommend to thoroughly read the content and follow it when necessary. It is a concise guide. It covers construction features, operation principle, troubleshooting, disassembly and assembly of components and repair action. Using this manual in systematic and rational way it is possible to reduce the repairing errors and delay that could cause machine stop with a detriment of cost management. The information quoted in this service manual are supplied also to be used for training aids. Therefore it is advisable to be used in the training of new personnel that will be employed in the machine maintenance.

All the information, illustrations and specifications contained in this service manual are based on the latest product information available at the time of publication. The dealer reserves the right to makes changes at any time without notice to this service manual for technical or trading reasons.

MANUAL HANDLING

This service manual is carried out in loose-leaf and therefore can be easily kept up-to-date. The personnel in charge is responsible for updating the manual and will insert the changes or supplements that the Dealer will issue to its service organisation.

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CHANGES AND SUPPLEMENTS

INTRODUCTION

SYMBOLS AND INDICATIONS In this service manual, symbols and indications are used to draw the attention on important points for safety and quality.

SAFETY This safety symbol is used for important safety message. When you see this symbol, be alert to the potential for personal injury. Strictly follow the recommended precautions.

INDICATIONS Reading this service manual you can find indications as “IMPORTANT” or “NOTE” that have the following meaning: • IMPORTANT Indicates a situation which, if not avoided, could caused damages to the machine.

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• Note Indicates supplementary technical information or know-how.

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FEATURES OF THE MANUAL

FEATURES OF THE MANUAL MANUAL COMPOSITION This service manual is divided into ten Sections. The Section names and its contents are as below. To fully use this service manual it is essential to understand how it is organised. Therefore, in order to speed up the searching of wished subject, it is advisable to carefully read this chapter.

SECTION 1 - HOW TO USE Begin to read first this Section to know the manual composition. This will help you for subject searching.

SECTION 2 - SAFETY RULES Indication on how to avoid dangerous situation during the use and maintenance are given in this Section. Furthermore safety decals and related indications used on the machine are listed on this Section.

SECTION 3 - PRELIMINARY This Section contains the information related to general precautions for repairs and escaping procedure in can of emergency.

SECTION 4 - SPECIFICATION This Section quotes the specification and data of the machine.

SECTION 5 - TOOLS This Section contains the list of special tools.

SECTION 6 - STANDARD MAINTENANCE TIME TABLE

SECTION 8 - HYDRAULIC SYSTEM This Section describes the operation of the machine from hydraulic point of view.

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SECTION 7 - MAINTENANCE STANDARDS AND TEST PROCEDURES

FEATURES OF THE MANUAL SECTION 9 - ELECTRICAL SYSTEM This Section describes the electric system of the machine and the connection with the electrical users.

SECTION 10 - ATTACHMENT This Section describes the attachments and its components and maintenance rules with related disassembly/ assembly.

SECTION 11 - UPPER STRUCTURE This Section contains the information related to the operation principle of the system, of the assemblies and their components located on the machine upper frame. Furthe more the assembly/disassembly procedures of main devices are quotated.

SECTION 12 - TRAVEL SYSTEM This Section contains the information related to the operation principle of the system, of the assemblies and their components located on the machine travel system. Further more the assembly/disassembly procedures of main devices are quotated.

SECTION 13 - TROUBLESHOOTING HYDRAULIC SYSTEM In this section information is provided for troubleshooting the hydraulic system.

SECTION 14 - TROUBLESHOOTING ELECTRICAL SYSTEM In this section information is provided for troubleshooting the electric system.

SECTION 15 - TROUBLESHOOTING ENGINE In this section information is provided for troubleshooting the engine.

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SECTION 16 - ENGINE This section descibes specifications, performance, measurament, inspection, disassembly/assembly and service data of engine.

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FEATURES OF THE MANUAL

BRIEF INFORMATION FOR MANUAL CONSULTATION The manual is divided into sections, each of them quotes a specific portion of the machine or a specific related subject. Some sections (those related to main mechanical assembly) are divided into: • Operation Principle • Disassembly/Assembly In the Operation Principle, the assemblies and their components are described with technical data. In the Disassembly and Assembly section the procedures are described to perform, repair or overhaul, with special tools required and technical data. Page numbers have the following meaning:

• example:

Section number.

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Consecutive page number.

▼

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CX16B and CX18B

SECTION 2

SAFETY PRECAUTIONS

INDEX

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Safety rules ....................................................................................................................... S1 Safety signs ..................................................................................................................... S38

SAFETY PRECAUTIONS SAFETY PRECAUTIONS

Keep head, body, limbs, hands and feet inside the operator’s compartment at all times to reduce exposure to external hazards. Be careful of possible slippery conditions of the steps and hand rails as well as of the ground around the machine. Wear protective boots or shoes with the soles made of highly no-slip rubber. Do not leave the machine until it has come to a complete stop. Always check height, width and weight limitations which may be encountered in the working site and ensure the machine does not exceed them. Assess exact paths of gas ducts, water mains, telephone lines, sewers, overhead and underground electric lines and all other possible obstacles. Such paths should be opportunely defined by competent Authorities. If necessary, require that the service is interrupted or said installations are moved prior to starting the work. You must know the working capacity of the machine. Define the rear upperstructure swing area and provide for opportune barriers to prevent access into it. Never exceed machine lifting capacity. Remain within the limits shown in the loading capacity chart located on the machine.

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GENERALITIES Read the Operation and Maintenance Instruction Manual carefully before starting, operating, maintaining, fuelling or servicing the machine. Carefully read the explanation to each and all safety signs in the special section of this Manual before starting, operating, maintaining, fuelling or servicing the machine. Machine-mounted safety plates are colour coded yellow with black borders when they refer to points where special WARNING must be paid and failure to observe them may cause a serious DANGER to the integrity of machine operators. They are white with red borders and black lettering when they refer to a FORBIDDEN practice. It is fundamental that all machine operators know very well the meaning of each safety plate as this considerably decreases operating hazards and accidents. Do not allow unauthorised personnel to operate or service this machine. Do not wear rings, wrist watches, jewellery, loose or hanging garments, such as ties, torn clothing, scarves, unbuttoned or unzipped jackets that can get caught in moving parts. Wear certified safety clothes such as: hard hat, noslip footwear, heavy gloves, ear protection, safety glasses , reflector vests, respirators every time the job requires it. Ask your employer about safety regulations in force and protective equipment. Always keep the operator’s compartment, step plates, grab-rails and handles clean and clear of foreign objects, oil, grease, mud or snow to minimise the danger of slipping or stumbling. Remove mud or grease from your shoes before operating the machine. Do not jump on or off the machine. Always keep both hands and one foot, or both feet and one hand in contact with steps and/or grab rails. Do not use controls or hoses as hand holds. Hoses and controls are movable parts and do not provide solid support. Besides, controls may be inadvertently moved and cause unexpected movement of the machine or its attachments. Never operate the machine or its attachments from any position other than sitting in the driver’s seat.

STARTING Never start or operate a failed machine. Walk all around the machine before mounting. Before operating the machine, make sure that any possible dangerous condition has been properly removed. Before starting machine, check that steering and attachment controls are in the neutral position and the safety lever is in the LOCK position. Immediately report any malfunction of parts or systems to the maintenance managers for proper action. Prior to starting the engine, check, adjust and lock the driver’s seat for maximum riding comfort and control accessibility. Prior to operating the machine and/or its attachments, check that bystanders are outside the machine operating range. Sound the horn. Obey all hand signals, safety indications and signs.

Due to the presence of flammable fluids, never check fuel level, refuel, charge the batteries or use the starting fluid in the presence of smoking materials, open flames or sparks. Ensure that nobody is within the excavator operating area before starting the machine, swinging the upper structure or moving in any direction. Adjust all rear-view mirrors for maximum visibility of the area behind the machine. Ensure that engine speed is appropriate to the job to be carried out. If any hydraulic control or system exhibits erratic performance or responds abnormally, have the machine checked for air in the system. Air in these circuits may cause incorrect movements with consequent accident hazard. Refer to the Operation and Maintenance Instruction Manual about corrective action to be taken.

slack carefully. Avoid kinking or twisting chains or cables. Carefully inspect cables or chains for flaws or problems before proceeding. Do not pull through a kinked chain or cable as the high anomalous stresses existing in this condition may induce failures in the kinked portion. Always wear heavy gloves when handling chains or cables. Chains and cables should be securely anchored using suitable hooks. Anchor points should be strong enough to withstand the expected load. Keep anyone clear of anchor points and cables or chains. Do not pull or tow unless the operatorâ&#x20AC;&#x2122;s compartments of the machines involved are properly protected against possible backlash in case of cable or chain failure or detachment. Be alert of soft ground conditions close to newly constructed walls. The fill material and machine weight may cause the wall to collapse under the machine. In darkness, check area of operation carefully before moving in with the machine. Use all lights provided. Do not move into low visibility areas. If the engine tends to slow down and stall for whatever reason under load or at idle, immediately report this problem to the maintenance managers for proper action. Do not operate the machine until this condition is corrected. Regularly check all exhaust system components, as exhaust fumes are toxic for the operator. Operators must know the performance of the machine they are driving. When working on slopes or near sudden level drops in the terrain, pay attention not to lose adherence and avoid loose soft ground since overturn or loss of machine control could result. If noise level is high and exceeds 90 dB(A) over 8 hours at the operatorâ&#x20AC;&#x2122;s ear, wear approved ear protection in compliance with local regulations. Do not operate the machine if you are extremely tired or feel ill. Be especially careful towards the end of the working shift. Where removable counterweights are provided, do not operate the machine if they have been removed. When operating the machine, keep in mind height limits of overhead doors, arches, overhead cables

OPERATING Do not run the engine of this machine in closed buildings without proper ventilation capable to remove harmful exhaust gases which concentrate in the air. Keep the operatorâ&#x20AC;&#x2122;s compartment free of foreign objects, especially if not firmly secured. Never use the machine to transport objects, unless proper securing points are provided. Do not carry riders on the machine. Study and familiarise with escape routes alternative to normal exit routes. For your personal safety, do not climb on or off the machine while it is in motion. Make sure that bystanders are clear of the machine operating range before starting the engine and operating the attachment. Sound the horn. Obey all hand signals, safety indications and signs. When backing, always look to where the machine is to be moved. Be alert of the position of bystanders. Should someone enter the work area, stop the machine. Maintain a safe distance from other machines or obstacles to ensure required visibility conditions. Always give way to loaded machines. Maintain a clear vision of the surroundings of the travel or work area at all times. Keep cab windows clean and repaired. When pulling loads or towing through a cable or chain, do not start suddenly at full throttle. Take-up

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SAFETY PRECAUTIONS

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SAFETY PRECAUTIONS and lines as well as width limits of corridors, roads and narrow passages. Also, get to know load limits of the ground and paving type of the ramps you are to work on. Beware of fog, smoke or dust that obscure visibility. Always inspect the working area to identify potential risks such as: inclines, overhangs, trees, demolition bble, fires, ravines, steep slopes, rough terrain, ditches, crowns, ridge trenches, diggings in traffic areas, crowded parking lots, crowded service areas, fenced zones. In such conditions, proceed with extreme care. Whenever possible, avoid crossing over obstacles such as very rough terrain, rocks, logs, steps, ditches, railroad tracks. When obstructions must be crossed, do so with extreme care and at a square angle, if possible. Slow down. Ease up to the break-over point, pass the balance point slowly and ease down the other side also using the attachment, if necessary. To overcome deep trenches or sinking ground, place the machine perpendicular to the obstacle, drastically reduce ground speed and start crossing using also the attachment if necessary, only after assessing that ground conditions allow the traverse safely and without risks. The gradient you may attempt to overcome is limited by factors such as ground conditions, load being handled, machine type and speed, and visibility. There is no substitute for good judgement and experience when working on slopes. Avoid operating the attachment too close to an overhang or high wall, either above or below the machine. Beware of caving edges, falling objects and landslides. Remember that such hazards are likely to be concealed by bushes, undergrowth and such. Avoid faggots, bushes, logs and rocks. Never drive over them, nor over any other surface irregularities that discontinue adherence or traction with the ground, especially near slopes or drop-offs. Be alert to avoid changes in adherence conditions that could cause loss of control. Work with extreme care on ice or frozen ground and on stepped slopes or near drop-offs. The word â&#x20AC;&#x153;bulldozingâ&#x20AC;? generally refers to work in virgin rough terrain, characterised by the presence of all the perils and risks listed above.

We emphasise the danger represented in these conditions by large tree limbs (possibly falling on the machine) and large roots (which may act as a leverage under the machine when up-rooted and cause the unit to overturn). Position the machine dependent upon the loading and unloading areas in order to swing leftwards to load to obtain best visibility. Never use the bucket or attachment as a man lift or carry riders. Never use the machine as a work platform or scaffolding. The machine must not be improperly used for works not consistent with its features (such as pushing railway cars, trucks or other machines). Always pay attention to people within the machine operating range. Never move or stop the bucket, other loads or the attachment above ground personnel or truck cabs. Ensure the truck driver is in a safe place before loading the truck. Load trucks from side or rear. Use only the type of bucket recommended considering machine type, materials to be handled, material piling up and loading characteristics, ground type and other typical conditions of the work to be performed. When travelling with a loaded bucket, keep it as rolled-back as possible. Keep boom and arm as low as possible. Ground speed should be adequate to the load and ground conditions. The load must always be properly arranged in the bucket; move with extreme care when transporting oversize loads. Do not lift and move the bucket overhead where persons are standing or working, nor downhill when working on a slope as this would decrease machine stability. Load the bucket from the uphill side. Loads to be raised using the machine should be exclusively hooked to the hitch specially provided. The excavator is no lifting and transportation means, therefore it should not be used to position loads accurately. Should it be exceptionally used to lift and lay building components, special caution must be taken as follows: â&#x20AC;˘ The machine should necessarily be equipped with the special option supplied by Dealer. Follow also safety rules for the excavator used as lifting means.

• Secure the loads to be raised using cables or chains fastened with appropriate hooking mechanisms. • Nobody should be allowed to remain under the raised load or within the excavator operating range for any reason whatever. Never exceed specified loading capacity. Incorrect fastening of slings or chains may cause boom/ arm failure or failure of the lifting means with consequent bodily injuries and even death. Always ensure that slings and chains used for lifting are adequate to the load and in good condition. All loading capacities are referred to the machine on a level surface and should be disregarded when working on a slope. Avoid travelling across slopes. Proceed from uphill downhill and vice-versa. If machine starts slipping sideways when on a slope, lower the bucket and thrust bucket teeth into the ground. Working on slopes is dangerous. Grade the working area if possible. Reduce work cycle time if it is not possible to grade the working area. Do not move full bucket or a load from uphill downhill as this would reduce machine stability. Do not work with the bucket turned to the uphill side. Do not work with the bucket turned uphill as counterweights protruding downhill would reduce machine stability on the slope and increase risk of overturning. We recommend to work on slopes with the bucket downhill, after checking machine stability with the bucket empty and attachment retracted, by slowly swinging the upper structure by 360°. Position the carriage at a right angle relative to slopes, hanging walls, etc. to exit the working area easily. Be aware when the upperstructure is turned by 180°, steering and travel controls are reversed. Properly judge ground conditions with particular attention to consistency of the area you are going to work on. Keep the machine sufficiently far from the ditch edge. Never dig under the machine. Should it be necessary to dig under the machine, always ensure that digging walls are opportunely propped up against landslide to prevent the machine from falling into the trench.

Do not swing the upperstructure, raise the load or brake abruptly if not required. This may cause accidents. Prior to beginning the work near gas distribution mains or other public utilities: • Contact the company owner of the gas mains or its nearest branch before starting the work. Look up the number in the telephone directory. • Define together which precautions should be taken to guarantee work safety. • Decrease work speed. Reaction time could be too slow and distance evaluation wrong. • When working near gas mains or other public utilities installations, appoint a person in charge of signalling duties. This person will have the responsibility of observing the machine, any part of it and/or the load approaching the gas mains from a standpoint more favourable than the Operator’s. This signal man (flag-man) must be in direct communication with the Operator and the Operator must pay undivided attention to the signals supplied. • The gas distributing Company, if previously advised and involved in the work, as well as machine Operator, Owner and/or any natural person or legal entity having rent or leased the machine or being responsible at the time by contract or by law, are liable for the adoption of the necessary precautions. Working near electric lines can be very dangerous, therefore some special precautions must be observed. Within this Manual, “work near electric lines” means when the attachment or load raised by the excavator (in any position) may reach the minimum safety distance established by local or international Safety Regulations. To work without risks, keep maximum possible distance from electric lines and never trespass minimum safety distance. Ensure that local or national safety regulations concerning work near electric lines are observed. Prior to beginning the work near electric lines: • Contact the Company owner of the electric lines or its nearest branch before starting the work. Look up the in the telephone directory. • Define together with the Company representative which precautions should be taken to guarantee work safety. • All electric lines should be considered as operative live lines even though it might be well known that the line in question is out of work and

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SAFETY PRECAUTIONS

SAFETY PRECAUTIONS visibly connected to the ground. • The Electric Power Company, if previously advised and involved in the work, as well as machine Operator, Owner and/or any natural person or legal entity having rent or leased the machine or being responsible at the time by contract or by law, are liable for the adoption of the necessary precautions. • Decrease work speed. Reaction time could be too slow and distance evaluation wrong. • Warn all ground personnel to keep clear of the machine and/or load at all times. If the load has to be guided down for laying, consult the Electric Power Company to know which precautions should be taken. • Appoint a person in charge of signalling duties. This person will have the responsibility of observing the machine, any part of it and/or the load approaching the electric lines from a standpoint more favourable than the Operator’s. This signal man (flag-man) must be in direct communication with the Operator and the Operator must pay undivided attention to the signals supplied. When working in or near pits, in ditches or very high walls, check that the walls are sufficiently propped up to avoid cave-in hazards. Pay the utmost attention when working near overhang walls or where landslides may take place. Make sure that the support surface is strong enough to prevent landslides. When digging, there is the risk of cave-ins and landslides. Always check ground conditions and conditions of the material to be removed. Support everywhere it is required to prevent possible cave-ins or landslides when: • digging near previous trenches filled with material, • digging in bad ground conditions, • digging trenches subject to vibration from railroads, working machines or highway traffic.

sure that all people are clear of the machine, slowly lower the attachment until resting it safely to the ground. Retract possible auxiliary tools to the closed safety position. Check that all controls are in the neutral position. Move engine controls to the shut-down position. Switch off the key-start switch. Consult the Operation and Maintenance Instruction Manual. Park the machine in a non-operating and no-traffic area. Park on firm level ground. If this is not possible, position the machine at a right angle to the slope, making sure there is no danger of uncontrolled sliding. If parking in traffic lanes cannot be avoided, provide appropriate flags, barriers, flares and other signals as required to adequately warn the oncoming drivers. Always switch off the key-start switch before cleaning, repairing or servicing, or parking the machine to prevent accidental unauthorised start-up. Never lower the attachment or auxiliary tools other than from sitting in the operator’s seat. Sound the horn. Make sure that nobody is within the machine operating range. Lower the attachment slowly. Securely block and lock the machine every time you leave it unattended. Return keys to the safe place previously agreed upon. Perform all necessary operations for stopping as detailed in the Operation and Maintenance Instruction Manual. Drive the machine far from pits, trenches, rocky hanging walls, areas with overhead electric lines, and slopes before stopping it at the end of the working day. Align the upperstructure to the tracks in order to allow to easily get on and off the driver’s compartment. Move all controls to the position specified for machine stopping. Refer the Operation and Maintenance Instruction Manual. Never park on an incline without accurately blocking the machine to prevent unexpected movement. Follow stopping instructions contained in the Operation and Maintenance Instruction Manual.

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STOPPING When the machine is to be stopped for whatever reason, always check that all controls are in the neutral position and that the safety lever is on the lock position to guarantee risk-free start-up. Never leave the machine unattended with the engine running. Prior to leaving the driver’s seat, and after making

MAINTENANCE

attachment from any other position than sitting in the operator’s seat. Before starting the machine or moving its attachment, sound the horn and require that nobody remains near the machine. Raise the attachment slowly. Always lock all moving components or parts of the machine that must be lifted for maintenance purposes using adequate external means as required by local and national regulations. Do not allow anyone to pass or stay near or below a raised attachment. If you are not absolutely sure about your safety, do not stay or walk under a raised attachment. Do not place head, body, limbs, hands, feet or fingers near articulated cutting edges deprived of the necessary guards, unless they are suitably and safely locked. Never lubricate, repair or adjust the machine with the engine running, except when this is specifically required by the Operation and Maintenance Instruction Manual. Do not wear loose clothing, jewellery near rotating parts. When service or maintenance require access to areas that cannot be reached from the ground, use a ladder or step platform conforming to local or national regulations to reach the working area. If such means are not available, use machine grab rails and steps. Always perform all service or maintenance work with the greatest care and attention. Shop and/or field service platforms or ladders should be manufactured and maintained in accordance with local or national safety regulations in force. Disconnect batteries and label all controls to warn that service work is in progress, according to local and national safety regulation requirements. Block the machine and all attachments to be raised according to local and national safety regulation requirements. Do not check or fill fuel tanks or install batteries near burning or smoking materials and open flames due to the presence of flammable vapours. The fuel filler pipe nozzle must be constantly kept in contact with the filler neck and this even before fuel starts flowing in. Keep this contact from the beginning to the end of the fuelling operation to avoid possible generation of sparks due to static electricity. Use a truck or trailer to haul a failed machine.

GENERALITIES Carefully read the Operation and Maintenance Instruction Manual before starting, operating, maintaining, fuelling or servicing the machine in any manner. Read all safety plates mounted on the machine and observe instructions they contain before starting, operating, repairing, fuelling or servicing the machine. Do not allow unauthorised personnel to repair or service the machine. Follow all recommended maintenance and service procedures. Do not wear rings, wrist watches, jewellery, loose or hanging garments, such as ties, torn clothing, scarves, unbuttoned or unzipped jackets that can get caught in moving parts. Wear certified safety clothes such as: hard hat, noslip footwear, heavy gloves, ear protection, safety glasses, reflector vests, respirators when required. Ask your employer about safety regulations in force and protective equipment. Do not use controls or hoses as hand holds. Hoses and controls are movable parts and do not provide solid support. Besides, controls may be inadvertently moved and cause unexpected movement of the machine or its attachments. Do not jump on or off the machine. Always keep both hands and one foot, or both feet and one hand in contact with steps and/or grab rails. Never service the machine with someone sitting in the driver’s seat, unless this person is an authorised operator assisting in the maintenance being carried out. Keep the operator’s compartment, step plates, grab rails and handles clear of foreign objects, oil, grease, mud or snow to minimise the danger of slipping or stumbling. Clean mud or grease from your shoes before climbing on the machine or driving it. Never attempt to operate the machine or its attachments from any position other than sitting in the operator’s seat. Keep the driver’s seat free from foreign objects, especially if these are not secured. Should it be necessary to move the attachment for maintenance purposes, do not raise or lower the

00104 9-88670 GB

SAFETY PRECAUTIONS

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SAFETY PRECAUTIONS Should it be necessary to tow it, provide for suitable danger signals as required by the local norms and regulations and observe recommendations given in the Operation and Maintenance Instruction Manual. Load/unload the machine on firm level ground providing safe support to the wheels of the truck or trailer. Use strong access ramps, with adequate height and angle. Keep the trailer flatbed free of mud, oil or slippery materials. Tie the machine securely to the trailer and block carriages and upperstructure. Never align holes or slots using your fingers; always use appropriate aligning tools. Remove all sharp edges and burrs from re-worked parts. Use only approved and effectively grounded auxiliary power sources for heaters, battery chargers, pumps and similar equipment to reduce electrical shock hazard. Lift and handle heavy components using hoisting devices of appropriate capacity. Ensure the parts are supported by appropriate straps and hooks. Use lifting eyes provided to this aim. Pay attention to bystanders near the lifting area. Never pour gasoline or diesel fuel into open containers. Never use gasoline, solvents or other flammable fluids to clean parts. Use proprietary certified non-flammable, non-toxic solvents only. When using compressed air to clean parts, wear safety glasses with side shields. Limit pressure to max. 2 bars, in accordance with local and national safety regulations in force. Do not run the engine of this machine in closed buildings without proper forced ventilation capable to remove toxic exhaust gases concentrating in the air. Do not smoke, nor allow open flames or sparks nearby while refuelling the unit or handling highly flammable materials. Do not use open flames as light sources to look for leaks or inspect anywhere on the machine. Make sure that all mechanical tools provided are in good condition at all times. Never use tools with mushroomed or damaged heads. Always wear eye protections with side shields. Move with extreme care when working under, on

or near the machine or its attachments. In case of attachment tests during which the engine should be kept running, a qualified operator must sit in the driverâ&#x20AC;&#x2122;s seat at all times while the mechanic is at work. Keep hands and clothes far OFF moving parts. Stop the engine and move the safey lever to the lock position before starting adjusting or repairing an assembly. Do not carry out any work on the attachment without prior authorisation. Observe recommended maintenance and repair procedures. In case of field service, move the machine to level ground and block it. If work on an incline cannot be avoided, securely block the machine and its attachments. Move the machine to level ground as soon as possible. Do not twist chains and cables. Never use a twisted chain or cable for lifting or pulling. Always wear safety gloves to handle chains or cables. Be sure chains and cables are firmly fastened and that the anchor point is strong enough to withstand the expected load. Keep all bystanders clear of the anchor point, cables or chains. Do not pull or tow unless the operatorâ&#x20AC;&#x2122;s compartments of the machines involved are fitted with proper guards against cable or chain backlash. Keep the maintenance area clean and dry at all times. Clean immediately all water and oil spillage. Do not pile up oily or greasy rags as they represent a major fire hazard. Always store them in closed metal containers. Before starting the machine or its attachment, check, adjust and lock the operatorâ&#x20AC;&#x2122;s seat. Also ensure that nobody is within the machine or attachment operating range before starting or operating the machine and/or its attachments. Sound the horn. Rust inhibitors are volatile and flammable. Prepare parts in well ventilated areas. Keep open flames away. Do not smoke. Store containers in a cool well ventilated place where they could not be reached by unauthorised people. Do not carry loose objects in your pockets that might fall unnoticed into open compartments. Wear appropriate safety clothing such as hard hat,

SAFETY PRECAUTIONS

Before moving or transporting the machine, block upperstructure swing to prevent accidental movement. Pay particular attention during transfer on inclines, both uphill and downhill. Keep the bucket in a position to provide a possible anchor point into the ground in case of slipping. During transfers on inclines, both uphill and downhill, keep the upperstructure aligned with the carriages. Do not travel across the slope. Never transfer the machine in the working site, in a crowded area, or near people without having at least one person charged with hand-signals who could guide the Operator. Sound the horn to inform that you are about to move off. It is necessary to know load limits of bridges and dimensional limits of tunnels. Such limits must never be exceeded. You should also know machine height, width, and weight. Have a signal-man help you when clearances are limited. Check distance between boom/arm and dimensional limits during transfer or transportation. Rough terrain may cause the machine to sway and roll to such an extent that boom/arm could get to contact electric lines or other obstacles. Cross obstacles at a right angle at low speed. Pay attention to machine shaking when the centre of gravity overcomes the obstacle. Keep the bucket down at all times during transfers. Drive with the lights on and use appropriate signals and flags. Get to know and respect local and national regulations. Consider boom/arm and upperstructure dimensions while turning. Use a ramp to load the machine on a trailer. If a ramp is not available, fabricate one using blocks. The ramp should be sufficiently strong to support machine weight. Always load and unload on level surface. Tow the machine following the instructions contained in the Operation and Maintenance Instruction Manual.

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TRANSFERS AND TRANSPORTATION

safety shoes and gloves, safety glasses when splinters or other particles may be ejected. Wear the appropriate welderâ&#x20AC;&#x2122;s equipment such as dark safety glasses or mask, hard hat, protective clothing, safety gloves and footwear always while welding or arc-cutting. Wear dark safety glasses when you are near a welding in progress. Do not look the welding arc without proper eye protection. Become acquainted with all your jacking equipment and their capacity. Ensure that the jacking point on the machine is appropriate for the load applied. Also, be sure the supports under the jack and between the jack and the machine are appropriate and stable. Any equipment supported by a jack represents a possible hazard. Always support the load onto appropriate blocking means as a safety measure before proceeding with service or maintenance work, in compliance with local or national safety regulations. Metal cables produce steel splinters. Always wear certified protection clothes such as safety gloves and glasses while handling them. Handle all parts carefully. Keep hands and fingers away from gaps, gears, and similar. Always use and wear certified safety clothes such as safety glasses, gloves and footwear. The attachment is kept constantly in position by an oil column trapped into the high pressure circuit. Lower the attachment to the ground and relieve pressure from all circuits prior to carrying out any type of maintenance or repair work. Do not service or repair the machine if it is parked downhill. Consult the Operation and Maintenance Instruction Manual for correct maintenance procedure. Areas near articulated cutting edges where mechanical parts are in motion are where personal injuries are most likely to occur. Pay attention to prevent possible part movements by means of blocks or by keeping clear of such zones when motion may take place during maintenance or repair. Move the hydraulic system lock safety lever to the lock position when stopping the machine for whatever reason. Always install the safety stays for the hood and other hinged covers before performing any maintenance or repair work in the engine compartment.

SAFETY PRECAUTIONS ENGINE

posts. Keep sparks or open flames away from batteries. Do not smoke near the battery to prevent explosion hazard. Before any maintenance or repair, make sure that there are no fuel or electrolyte leaks from the batteries. If any, correct prior to proceeding with further work. Do not recharge batteries in confined spaces. Ensure proper ventilation is provided to avoid accidental explosions due to build-up of explosive gas released during charging. Disconnect batteries before working on the electrical system or carrying out any other type of work.

Do not run the engine in closed buildings without proper ventilation capable to remove harmful exhaust fumes. Do not place head, body, limbs, feet, hands or fingers near rotating fans or belts. Be especially careful near blower fans. Loosen the radiator cap very slowly to relieve system pressure before removing it. Always top-up coolant level with the engine off or idling if hot. See the Operation and Maintenance Instruction Manual. Keep the exhaust manifold and tube free from combustible matters. Fit the machine with shields and guards when working in the presence of combustible matter free in the air. Do not refuel with the engine running, especially if hot, as this increases fire hazard in case of fuel spillage. Never attempt to check or adjust fan belt tensions when the engine is running. Do not adjust the fuel injection pump when the machine is operating. Do not lubricate the machine with the engine running. Do not run the engine with the air intakes open and not protected. If this cannot be avoided for service reasons, place protection meshes on all intakes before servicing the engine.

HYDRAULIC SYSTEM Pressure fluid escaping from a very small hole can be almost invisible and still have sufficient force to penetrate the skin. Always check any suspected pressure leaks using a piece of cardboard or wood. Do not use hands. If injured by escaping fluid, obtain medical attention immediately or serious infection or reaction may develop. Stop the engine and ensure pressure is relieved from all systems before removing side panels, housings, guards and covers. See the Operation and Maintenance Instruction Manual. Always use gauges of adequate capacity for pressure testing. Refer to the Operation and Maintenance Instruction Manual or Repair Manual.

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ELECTRICAL SYSTEM Pay attention to connect connecting cables to correct poles (+ to +) and (- to -) at both ends. Do not short-circuit terminals. Thoroughly follow instructions given in Operation and Maintenance Instruction Manual. Always move the key-start switch in the lock position before servicing or repairing the machine. Batteries contain SULPHURIC ACID. Protect the eyes when working near the batteries against possible sprays of the acid solution. Should acid contact skin, eyes, or clothes, RINSE IMMEDIATELY IN WATER FOR AT LEAST 15 MINUTES. Immediately seek medical attention. Battery released gas is highly flammable. Leave the battery compartment cover open during recharging to improve ventilation. Never check battery charge by placing metal objects across the

TOOLS Always keep head, body, limbs, feet, hands, and fingers away from the bucket and attachments, when in the raised position. Prior to any maintenance or repair work, install all supports necessary to this aim according to local and national safety regulations. In case the attachment is to be operated for maintenance or repair purposes, do so exclusively while sitting in the driverâ&#x20AC;&#x2122;s seat. Sound the horn before starting the machine or moving the attachment. Require that nobody remain near the machine. Raise the attachment slowly. Do not use the machine to transport loose objects, unless proper securing devices are provided.

SAFETY PRECAUTIONS

00104 9-88670 GB

Never use gases other than nitrogen to charge the accumulators. Refer to the Operation and Maintenance Instruction Manual.

S10

SAFETY PRECAUTIONS RECOGNISE SAFETY INFORMATION This is your SAFETY ALERT SYMBOL. When you see this symbol on your machine or in this Manual, be alert of the potential for personal injury. Follow recommended precautions and safe operating practices.

F3264

UNDERSTAND SIGNAL WORDS In this Manual you will find the following words: DANGER, WARNING, CAUTION, referring to different hazard risks.

DANGER WARNING CAUTION IMPORTANT NOTE

These words are always accompanied by the safety alert symbol. DANGER: indicates an imminent hazardous situation which, if not avoided, will result in death or serious injury. WARNING: indicated a potential hazardous situation which, if not avoided, could result in death or serious injury. CAUTION: indicates a potential hazardous situation which, if not avoided, may result in minor or moderate injury. IMPORTANT: indicates a situation which, if not avoided, may cause damage to the machine. NOTE: indicates an additional explanation for information purposes.

ENVIRONMENTAL PROTECTION This Manual also contains this symbol accompanying instructions for correct behaviour as regards environmental protection. 00104 9-88670 GB

F5041

S11

SAFETY PRECAUTIONS FOLLOW SAFETY INSTRUCTION Carefully read and follow all safety signs on the machine and all safety messages in this manual. Safety signs should be installed maintained and replaced when necessary. If a safety sign or this manual is damaged or missing, order a replacement from your dealer in the same way you order other replacement parts (be sure to state machine model and serial number when ordering). Learn how to operate the machine and its controls correctly and safely.

F1437

Allow only trained, qualified, authorized personnel to operate the machine. Keep your machine in proper working condition. Unauthorized modifications to the machine may impair the function and/or safety and affect machine life. The safety messages in this SAFETY PRECAUTIONS chapter are intended to illustrate basic safety procedures of hydraulic excavators. However it is impossible for these safety messages to cover every hazardous situation you may encounter. If you have any questions, you should first consult your supervisor before operating and servicing the machine.

PREPARE FOR EMERGENCIES Be prepared if a fire starts or an accident occurs.

F1440

S12

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Keep the first-aid kit and fire extinguisher on hand. Thoroughly read and understand the label attached to the fire extinguisher to use it properly. Establish emergency priority procedures to cope with fires and accidents. Keep emergency numbers for doctors, ambulance service, hospitals and fire department posted near the telephone.

SAFETY PRECAUTIONS WEAR PROTECTIVE CLOTHING Avoid wearing loose clothing, jewelry, or other items that can catch on control levers or other parts of the machine. Operating equipment safely requires the full attention of one operator. Do not wear radio or music headphones while operating machine.Wear close fitting clothing and safety equipment appropriate for the job. Standard safety equipment includes: • A hard hat • Safety shoes • Safety glasses, goggles, or face shield • Heavy gloves • Hearing protection • Reflective clothing • Wet weather clothing • Respirator or filter mask. Do not take chances. Wear whatever is needed for the job at hand.

F1438

PROTECT AGAINST NOISE Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear a suitable hearing protective device such as earmuffs or earplugs to protect against constant or uncomfortably loud noised. F1439

FASTEN SEAT BELT

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Should the machine overturn, the operator may become injured and/or thrown from the cab. Not only, the operator may be crushed by the overturning machine resulting in serious injury or even death. Prior to operating the machine, thoroughly examine belt webbing, buckle, and attaching hardware. If any item is damaged or worn, replace the seat belt or component before operating the machine. Be sure to remain seated with the seat belt securely fastened at all times when the machine is in operation to minimise injury hazard in case of accident. After a significant accident, replace the seat belts even though they do not look damaged.

F3261

S13

SAFETY PRECAUTIONS INSPECT THE MACHINE Inspect the machine carefully every day or work-shift by an attentive visual inspection of machine outside prior to starting it to prevent damages and personal injuries. In the walk-around inspection, be sure to cover all points detailed in the Chapter “MAINTENANCE”, paragraph “EXTERNAL VISUAL INSPECTION”.

F1441

USE HANDHOLDS AND STEPS Falling is one of the major causes of personal injury. When you get on and off the machine, always maintain a three-point contact with the steps and handrails and face the machine. Do not use any controls as hand-holds. Never jump on or off the machine. Never mount or dismount a moving machine. Be careful of slippery conditions on platforms, steps, and handrails when leaving the machine. F1442

ADJUST THE OPERATOR'S SEAT A seat poorly adjusted for operator or work requirements may quickly fatigue the operator leading to improper operations. • The seat should be adjusted whenever machine operator changes. • The operator should be able to fully press the pedals and correctly move the control levers with his back resting against the seat back. F1443 00104 9-88670 GB

• If not, move the seat fore and aft, and check again.

S14

SAFETY PRECAUTIONS OPERATE ONLY FROM THE DRIVER’S SEAT To start the motor with an unsuitable procedure may cause sudden movement of the machine with possibility to cause serious injuries or mortal incidents • start the engine only from the driver’s seat. • NEVER start the engine while standing on a shoe or on the ground. • Do not start the engine by short circuiting between starter motor terminals. • Before starting the engine, ensure that all control levers are in the neutral position.

F13043

DONT CARRY RIDERS ON THE MACHINE Riders on the machine are subject to injuries such as being struck by foreign objects and being thrown off the machine. • Only machine operator is allowed on the machine. Keep riders off. • Riders also obstruct the operator’s visibility, resulting in the machine being operated unsafely.

F22015

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AVOID ELECTRIC LINES Serious injury or death can result if the machine or front attachments are not kept a safe distance from electric lines. • When operating near an electric line, NEVER move any part of the machine or load closer than 3 m plus twice the line insulator length (L). • Check and comply with any local regulations that may apply. • Wet ground will expand the area that could cause any person on it to be affected by electric shock. • Keep all bystanders or co-workers away from the site. F14377

S15

SAFETY PRECAUTIONS AVOID INJURY FROM BACK-OVER AND SWING ACCIDENTS If someone stands near the machine when this is carrying out swinging or reverse-gear movement, the same can hit or run over this person causing heavy injuries or even death. To avoid back-over and swing accidents: ALWAYS LOOK AROUND BEFORE YOU BACK UP AND SWING THE MACHINE. BE SURE THAT EVERYONE IS IN THE CLEAR. F1447

Keep travel alarm in working condition (if equipped). ALWAYS BE ALERT FOR BYSTANDERS MOVING INTO THE WORK AREA. USE HORN OR OTHER SIGNAL TO WARN BYSTANDERS BEFORE MOVING MACHINE. A PERSON COULD STAND BEHIND THE MACHINE, IN A DEAD AREA, NOT VISIBLE FROM REARVIEW MIRRORS. BEFORE BACKING UP, MAKE SURE NOBODY IS STANDING IN THAT AREA. F3625

Use a signal person when backing up if your view is obstructed. Always keep signal person in view. No excavator or backhoe motions shall be made unless signals are clearly understood by both signalman and operator. Learn the meaning of all flags, signs, and markings used on the job and confirm who has the responsibility for signaling.

Keep windows, mirrors, and lights clean and in good condition. Dust, heavy rain, fog, etc., can reduce visibility. As visibility decreases, reduce speed and use proper lighting.

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

S16

SAFETY PRECAUTIONS DIG WITH CAUTION Accidental severing of underground cables or gas lines may cause an explosion and/or fire, possibly resulting in serious injury or death. Before digging, check the location of cables, gas lines, and water lines. Keep the minimum distance required by law from cables, gas lines, and water lines. If a fiber optic cable should be accidentally severed, do not look into the end. Doing so may result in serious eye injury. Contact local authorities and/or the utility companies directly (electric power, gas, telephone, water, sewers, telecommunications, etc.) to obtain information about underground utility lines.

F22024

MOVE AND OPERATE MACHINE SAFELY Bystanders are in danger of being run over. Confirm the location of bystanders before moving, swinging, or operating the machine. Always keep the travel alarm in good working condition. (if equipped). It warns people when the machine starts to move. Use a signal person when moving, swinging, or operating the machine in congested areas. Coordinate hand signals before starting the machine.

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F22025

S17

SAFETY PRECAUTIONS INVESTIGATE JOB SITE BEFORE HAND Clear all persons from area of operation and machine movement. Make sure worksite footing has sufficient strength to firmly support the machine. When working close to an excavation, operate the machine with che chassis frame positioned perpendicular to the cliff face, so that the machine can more easily evacuate if the cliff face collapses. Confirm that your machine is equipped with a F.O.P.S. (Falling Object Protective Structure) cab before working in areas where there is the possibility of falling stones or landslides. When digging deeply, avoid hitting bottom of boom or bucket cylinder hoses against the ground. Use the bucket only for digging. To avoid accidents, do not use it as a jack hammer or wrecking ball.

F22026

WORKS ON SLOPES â&#x20AC;˘ Cross-travelling on a slope can cause the machine skidding or overturning. When travelling up or down a slope, make sure the tyres are oriented in the slope direction. â&#x20AC;˘ Turning on an incline may cause the machine to tip over. If turning on an incline is absolutely unavoidable, do so at a place where the slope is gentle and the surface is firm.

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F13056

S18

SAFETY PRECAUTIONS AVOID TIPPING When operating on a slope, keep bucket low to ground and close to machine. Point chassis frame uphill to avoid tipping. To avoid tipping: • Be extra careful before operating on a grade. • Prepare machine operating area flat by grading. • Keep the bucket low to the ground and close to the machine. • Reduce machine operating speed to avoid tipping or slipping. • Avoid changing direction when travelling on grades. • Never attempt to travel across a grade steeper than 15 degrees. • Reduce swing speed as necessary when swinging loads.

F22235

Be careful when working on frozen ground. • Temperature increases will cause the ground to become soft and make ground travel unstable.

DRIVE MACHINE SAFELY Before starting the machine, read carefully the "use and instructions manual" to get familiar with pedals and levers. Before moving the machine, confirm which way to move travel pedals/levers for the corresponding direction you wish to go.

90°~110°

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

F14372

BEWARE OF EXHAUST FUMES

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Before starting the machine, read carefully the "use and instructions manual" to get familiar with pedals and levers. Before moving the machine, confirm which way to move travel pedals/levers for the corresponding direction you wish to go. When traveling up or down a grade, keep the bucket in the direction of travel, approximately 30 to 40 cm (A) above the ground. If the machine begins to slip or becomes unstable, lower the bucket immediately. F1446

S19

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

F22027

OPERATE WITH CAUTION If the front attachment or any other part of the machine hits against an overhead obstacle, such as a bridge, both the machine and the overhead obstacle will be damaged, and personal injury may results as well. Take care to avoid hitting overhead obstacles with the boom or arm. F22028

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

00104 9-88670 GB

To avoid roll-aways: • Select level ground when possible to park machine. • Do not park the machine on a grade. • Lower the bucket and/or other work tools to the ground. Thrust the bucket teeth into the ground if you must park on a grade. • Turn the auto-idle switch off. • Run the engine at slow idle speed without load for 5 minutes to cool down the engine. • Stop the engine and remove the key from the key switch. • Pull the safety lever (pilot control shut-off lever) to LOCK position. • Block both tracks. • Position the machine to prevent overturning. • Park a reasonable distance from other machines.

F14375

S20

SAFETY PRECAUTIONS PARK MACHINE SAFELY Before working on the machine: • Park machine on a level surface. • Lower bucket to the ground. • Move turret swing lever to lock position. • Run engine at slow idle speed without load for 5 minutes. • Turn key switch to to stop engine. Remove key from switch. • Pull pilot control shut-off lever to LOCK position. • Allow engine to cool. • Close windows, roof window, and cab door. • Lock all access doors and compartments.

F14376

F2440

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

F14439

PROVIDE SIGNALS FOR JOBS INVOLVING A NUMBER OF MACHINES For jobs involving several machines, provide signals commonly known by all personnel involved. Also, appoint a signal person to co-ordinate the job site.

00104 9-88670 GB

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

F3614

S21

SAFETY PRECAUTIONS CONFIRM DIRECTION WHERE THE MACHINE IS TO BE DRIVEN • Instinctive travel pedal operation may result in serious injury and even death. • Before driving the machine, be aware of the undercarriage position relative to the operator’s seat. If swinging/steering axle is located behind towards the counterweight, the machine will move reverse when control pedal is moved forwards.

F14381

KEEP PERSONNEL CLEAR FROM WORKING AREA A person may be hit severely by the swinging front attachment or counterweight and/or may be crushed against an other object, resulting in serious injury or death. Keep all persons clear from the area of operation and machine movement. Before operating the machine, set up barriers to the sides and rear area of the bucket swing radius to prevent anyone from entering the work area. F14446

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

F22041

S22

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

SAFETY PRECAUTIONS AVOID UNDERCUTTING Never undercut or the footing might collapse. Before starting to work, make sure of the excavator control direction. If the footing starts to collapse and if sufficient retreat is not possible, do not panic. Often, the machine can be secured by lowering the front attachment. F22029

SAFETY TRANSPORTING The danger of tipping is present when loading/ unloading the machine onto/from a truck or trailer bed. • Be sure to observe local regulations when transporting the machine on public roads. • Provide an appropriate truck or trailer for transporting the machine. 15°

F14382

Take the following precautions when loading/ unloading the machine: • Select firm level ground. • Be sure to use a loading dock or ramp. • Be sure to have a signal person when loading/ unloading the machine. • Always turn the auto-idle (A/I) switch off when loading or unloading the machine, to avoid unexpected speed increase due to unintentional operation of a control lever.

00104 9-88670 GB

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

WEDGES BLOCKS RAMPS

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

F5827

S23

SAFETY PRECAUTIONS • Avoid steering while driving up or down the ramp as it is extremely dangerous. • If steering is unavoidable, first move back to the ground or flatbed, modify travelling direction, and begin to drive again. • Operate the safety lever but do not operate any other control except travel control when driving up or down the ramp. • The top end of the ramp where it meets the flatbed is a sudden bump. Take care when traveling over it.

F14383

• Prevent possible injury from machine tipping while the upperstructure is rotating. • Keep the arm tucked under and rotate the upperstructure slowly for best stability. • Securely fasten machine frame using chains or cables. Refer to “Transport” chapter in this manual for details.

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F14384

S24

SAFETY PRECAUTIONS PRACTICE SAFE MAINTENANCE Understand service procedures before doing work. Keep work area clean and dry. Never lubricate or service the machine while it is moving. Keep hands, feet and clothing from power-driven parts. Before servicing the machine, park the machine on a level surface. If maintenance procedure must be performed with engine running, do not leave machine unattended.

F1458

If the machine must be raised, keep a 90 to 110Â° between boom and arm. Securely support any machine elements that must be raised for service work. Never work under a machine raised by the boom. Inspect certain parts periodically and repair or replace as necessary. Keep all parts in good condition and properly installed. Fix any damage immediately. Replace worn or broken parts. Remove any building of grease, oil, or debris. Disconnect the ground cable (-) from the batteries before servicing electrical systems or welding on the machine.

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F5832

F14385

S25

SAFETY PRECAUTIONS CLEAN TRASH FROM MACHINE Keep engine compartment, radiator, batteries, hydraulic lines, fuel tank, and operatorâ&#x20AC;&#x2122;s station clean. Temperature in engine compartment may go up immediately after engine is stopped. BE ON GUARD FOR FIRES DURING THIS PERIOD. Open access door (s) to cool the engine faster, and clean engine compartment.

F1460

WARN OTHERS OF SERVICE WORK Unexpected machine movement can cause serious injury. Before performing any work on the machine, apply the "Maintenance in progress" tag (see SAFETY PLATES in this Chapter). This tag can be applied to the left-hand control lever, safety lever or cab door.

F2431

CLEAN THE MACHINE REGULARLY Remove any grease, oil or debris build-up to avoid possible injury or machine damage. Do not spray water or steam inside the cab.

F1462

STORE ATTACHMENTS SAFELY

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Stored attachments such as buckets, hydraulic hammers, and blades can fall and cause serious injury or death. Securely store attachments and implements to prevent them from falling. Keep playing children and bystanders away from storage area. F1463

S26

SAFETY PRECAUTIONS SUPPORT MACHINE PROPERLY Never attempt to work on the machine without securing the machine first. Always lower the attachment or tool to the ground before working on the machine. If you must work on a lifted machine or attachment, securely support the machine or attachment. Do not support the machine on cinder blocks, bollow tires, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack. F3634

PREVENT PARTS FROM FLYING OFF Grease in the track adjuster is under high pressure. Failure to follow the precautions below may result in serious injury, blindness, or death. • NEVER attempt to remove GREASE FITTING or VALVE ASSEMBLY. • As pieces may fly off, be sure to keep body and face away from valve. Travel reduction gears are under pressure. F3635

00104 9-88670 GB

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

S27

SAFETY PRECAUTIONS STARTING THE ENGINE WITH BOOSTER BATTERIES Battery gas may explode causing serious damages and injuries. If the engine is to be started using booster batteries, ensure to comply with all procedures detailed in the chapter “OPERATING INSTRUCTIONS”. The operator should be sitting in the driver’s seat to keep the machine under control when the engine starts. Starting the engine with booster batteries is a two man operation. Do not recharge batteries that have been stored in the cold for a long time as they might explode. Heat them at 15°C.

F1464

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

PROTECT AGAINST FLYING DEBRIS Guard against injury from flying pieces of metal or debris; wear goggles or safety glasses. Keep bystanders away from the working area before striking any object, to avoid personal injury.

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

F1467

S28

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

SAFETY PRECAUTIONS SUPPORT MACHINE PROPERLY Always lower the attachment or implement to the ground before you work on the machine. If you must work on a lifted machine or attachment, securely support the machine or attachment. Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under ontinuous load. Do not work under a machine that is supported solely by a jack. Follow the procedures in this manual. F1468

PREVENT BURNS After operation, the engine coolant is hot and is under pressure. Hot water or steam are contained in the engine, radiator and heater lines. Skin contact with escaping hot water or steam can cause severe burns. Be sure to stop the engine, and let engine and radiator cool. Slowly loosen the cap to release pressure after the system has cooled, then remove it. Engine oil, gear oil and hydraulic oil also become hot during operation. The engine, hoses, lines and other parts become hot as well. Wait for the oil and components to cool before starting any maintenance or inspection work. The hydraulic oil tank is pressurized. Again, be sure to release all pressure before removing the cap.

F1477

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F1469

S29

SAFETY PRECAUTIONS REMOVE PAINT BEFORE WELDING OR HEATING Avoid potentially toxic fumes and dust. Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. Do all such work outside or in a well-ventilated area. Dispose of paint and solvent properly. If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.

F1446

AVOID HEATING NEAR PRESSURIZED FLUID LINES Flammable spray can be generated by applying heat near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lined or other flammable materials. Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area. Install temporary fire resistant guards to protect hoses or other materials when engaging in welding, soldering, etc.

F1470

Do not weld or flame cut pipes or tubes that contain flammable fluids. Clean them thoroughly with nonflammable solvent before welding or flame cutting them. F22236

S30

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AVOID APPLYING HEAT TO LINES CONTAINING FLAMMABLE FLUIDS

SAFETY PRECAUTIONS AVOID HIGH PRESSURE FLUIDS Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines. Relieve the pressure by moving the control levers several times. Tighten all connections before applying pressure. Wear a shield or protection glasses to protect your eyes.

F3636

Search for leaks with a piece of cardboard; take care to protect hands and body from high-pressure fluids. If an accident occurs, see a doctor familiar with this type of injury immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result.

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F1471

S31

SAFETY PRECAUTIONS PREVENT FIRES 1. Check for oil leaks: Fuel, hydraulic oil and lubricant leaks can lead to fires that may result in serious injury. Check for missing or loose clamps, kinked hoses, lines or hoses that rub against each other, damaged oil-cooler, and loose oil-cooler flange bolts, for oil leaks. F3638

Search for leaks with a piece of cardboard. Escaping fluid under pressure can penetrate the skin causing serious injury. Do not use your bare hand to check for oil leaks. Tighten, repair or replace any missing, loose or damaged clamps, lines, hoses, oil-cooler and oil cooler flange bolts. Do not bend or strike high-pressure lines. Never install bent or damaged lines, pipes or hoses. 2. Check for short circuits: Short circuits can cause fires that may result in serious injury. Clean and tighten all electrical connections. Check before each shift or after eight (8) hours of operation for loose, kinked, hardened or frayed electrical cables and wires. Check before each shift or after eight (8) hours of operation for missing or damaged terminal caps. DO NOT OPERATE MACHINE if cable or wires are loose, kinked, etc. Tighten, repair or replace any loose or damaged electrical cables, wires, and terminal caps before operating the machine. 3. Clean flammables:

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Spilled fuel and oils, and accumulated coal dust and other flammables may cause fires and serious personal injury. Prevent fires by keeping machine clean every day.

S32

SAFETY PRECAUTIONS 4. Check key-start switch: If a fire breaks out, failure to stop the engine will escalate the fire, hampering fire fighting. Always check key-start switch function before operating the machine every day: - Start the engine and run it at slow idle. position to - Turn the key-start switch to the confirm that the engine stops. If any abnormalities are found, be sure to repair them before operating the machine. 5. Check heat shields: F1464

Damaged or missing heat shields may lead to fires. Damaged or missing heat shields must be repaired or replaced before operating the machine.

HANDLE CHEMICAL PRODUCTS SAFELY Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with your machine include such items as lubricants, coolants, paints, and adhesives. For these products it is necessary to provide specific details about physical dangers for health, safety procedures, and emergency response techniques. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and use recommended equipment.

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F1465

S33

SAFETY PRECAUTIONS DISPOSE OF WASTE PROPERLY Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste on excavators includes such items as oil, fuel, coolant, brake fluid, filters, and batteries. Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them. Do not pour waste onto the ground, down a drain, or into any water source. F1473

Air conditioning refrigerants escaping into the air can damage the Earthâ&#x20AC;&#x2122;s atmosphere. Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants. Obtain information on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your authorized dealer.

PREVENT ACID BURNS Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes. Avoid the hazard by: Filling batteries in a well-ventilated area. Wearing eye protection and rubber gloves. Avoiding breathing fumes when electrolyte is added. Avoiding spilling or dripping electrolyte. Use proper jump start procedure. If you spill acid on yourself: Flush your skin with water. Apply baking soda or lime to help neutralize the acid. Flush your eyes with water for 10-15 minutes. Get medical attention immediately.

F1474

00104 9-88670 GB

If acid is swallowed: Drink large amounts of water of milk. Then drink milk of magnesia, beaten eggs, or vegetable oil. Get medical attention immediately.

S34

SAFETY PRECAUTIONS HANDLE FLUIDS - AVOID FIRES Handle fuel with care; it is highly flammable. Do not refuel the machine while smoking or near open flame or sparks. Always stop engine before refueling machine. Fill fuel tank outdoors. Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers. Make sure machine is clean of trash, grease, and debris.

F1475

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

F22236

SERVICE MACHINE SAFELY Tie long hair behing you head. Do not wear a necktie, scarf, loose clothing, or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result. Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.

F1476

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

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

F1477

S35

SAFETY PRECAUTIONS DISPOSE OF FLUIDS PROPERLY Improperly disposing of fluids can harm the environment and ecology. Before draining any fluids, find out the proper way to dispose of waste from your local environmental agency. Use proper containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them. DO NOT POUR oil into the ground, down a drain, or into a stream, pond, or lake. Observe relevant environmental protection regulations when disposing of oil, fuel, coolant, brake fluid, filters, batteries, and other harmful waste.

F1478

WORK IN A CLEAN AREA Before starting a job, clean the work area. Remove objects that may be a safety hazard to the mechanic or bystanders.

F5835

ILLUMINATE WORK AREA SAFELY Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the machine. Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel or oil.

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F1480

S36

SAFETY PRECAUTIONS USE TOOLS PROPERLY Use tools appropriate to the work. Makeshift tools and procedures can create safety hazards. Use power tools only to loosen threaded tools and fasteners. For loosening and tighening hardware, use the correct size tools. Do not use U.S. measurement tools on metric fasteners. Avoid bodily injury caused by slipping wrenches. F1479

Use only original spare parts.

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

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F3638

S37

SAFETY SIGNS SAFETY DECALS 1. 2.

Decal, equipment safe area of operation. Decal, counterweight safe area of operation.

F22047

Decal for engine hood warning, belts. Decal for engine hood warning, fan and pulleys. Decal for hot surfaces. Decal for pressurized fluids & lubricants. Decal for hooking point.

4 7

F22046

5 6

S38

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3. 4. 5. 6. 7.

SAFETY SIGNS 8. 9. 10. 11. 12. 13.

Track adjuster tag. Battery tag; danger warning. Electrical lines tag; safety controls. Window lock tag. Windscreen wiper connector tag. Plate, maintenance in progress.

10 11 9

F22048

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F14402

S39

SAFETY SIGNS 1 - Decal, equipment safe area of operation Make sure that possible people standing in the operation area, are out of the machineâ&#x20AC;&#x2122;s reach before starting the same er to move its attachments. Sound the horn. Background: yellow Stripe and lettering: black

F22042

2 - Decal, counterweight safe area of operation Make sure that possible people standing in the operation area, are out of the machineâ&#x20AC;&#x2122;s reach before starting the same er to move its attachments. Sound the horn. Background: yellow Stripe and graphics: black

F13235

3 - Decal for engine hood warning, belts It indicates you have to stop the engine before opening the hood.

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Danger of serious injury due to rotating parts such as fans, pulleys and belts. Background: transparent Stripe and graphics: black

F10391

S40

SAFETY SIGNS 4 - Decal for engine hood warning, fan and pulleys It indicates you have to stop the engine before opening the hood. Danger of serious injury due to rotating parts such as fans and pulleys. Background: transparent Stripe and graphics: black F13236

5 - Hot surfaces tag Located on radiator cover. Immediately after the machine is operated, the temperature and pressure of the engine coolant, engine oil, and hydraulic oil are very high. Burns may result if caps are removed, or oil, water, or filters are changed under these conditions. Wait until the temperature goes down, before attempting to check fluids or change filters. Background: yellow Stripe and graphics: black

F13234

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6 - Pressurized fluids & lubricants tag Located on radiator cover. Always release pressure from hydraulic reservoir, engine coolant, fuel system and all systems containing pressure before removing any caps or components. Be cautious of hot fluids and gasses from systems on machines that have just been stopped, allow sufficient time for systems to cool before performing any inspection or maintenance procedures. Background: yellow Stripe and graphics: black

F12690

S41

SAFETY SIGNS 7 - Decal, hooking point Indication of the eight hooking points (two on front axle, two on the back axle,two on counterweight, two on the frame) to be used for towing or lifting the machine. Background: white Edging and graphic: black

F22045

8 - Track adjuster tag It shows that obligation is made to consult the Operation and Maintenance Instruction Manual prior to acting on the track adjust valve. Danger of severe injuries. Background: yellow Stripe and graphics: black

F22043

9 - Battery tag; danger warning

F14400

S42

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Flammable gas (hydrogen gas) is generated in the battery. Do not produce sparks near the battery, and do not put bare flame close to it to avoid the battery from catching fire and explosion. Background: yellow Stripe and graphics: black

SAFETY SIGNS 10 - Electrical lines tag; safety controls It warns about danger in case of work near the electrical lines. It is imperative that should the operator abandon the cab with engine running, even for a very short time, the safety lever must be moved to LOCK position. Controls are disconnected and any accidental equipment movement is impossible. Background: white Stripe and graphics: black

F14404

11 - Decal for window lock It indicates the danger of injury deriving from incorrect block of front windshield in open position. Background: yellow Edging and graphics: black

F14408

12 - Windscreen wiper connector tag It indicates to disconnect windscreen wiper before removing lower cab window. Background: transparent Stripe and graphics: black

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F22044

S43

SAFETY SIGNS 13 - Maintenance in progress plate It is compulsory, for maintenance operators, to apply a card warning about incomplete efficiency of the machine and the presence of personnel performing maintenance in unseen positions. This card must be located on the left pilot control or the cab door. Background: yellow Graphic: black Edging: red

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F2431

S44

CX16B and CX18B

SECTION 3

PRELIMINARY REMARKS

INDEX

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General precautions for repairs .........................................................................................3-1 Escaping procedure in case of emergency .......................................................................3-6 International unit conversion system .................................................................................3-7

PRELIMINARY REMARKS

GENERAL PRECAUTIONS FOR REPAIRS PREPARATION BEFORE DISASSEMBLING Understanding operating procedure Read OPERATION & MAINTENANCE MANUAL carefully to understand the operating procedure. Cleaning machines Remove soil, mud, and dust from the machine before carrying it into the service shop to prevent loss of work efficiency, damage of parts, and difficulty in rust prevention and dust protection while reassembling. Inspecting machines Identify the parts to be disassembled before starting work, determine the disassembling procedure by yourself considering the workshop situations etc., and request procurement of necessary parts in advance. Recording Record the following items for communication and prevention of recurring malfunction. • Inspection date and place. • Model name, applicable machine number, and hour meter read. • Trouble condition, place and cause, if any. • Visible oil leakage, water leakage and damage. • Clogging of filters, oil level, oil quality, oil contamination and loosening of connections. • Result of consideration if any problem exists based on the operation rate per month calculated from hour meter indication after the last inspection date.

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Arrangement and cleaning in service shop • Tools required for repair work. • Prepare space to place the disassembled parts. • Prepare oil containers for spilling oil etc.

3-1

PRELIMINARY REMARKS SAFETY IN DISASSEMBLING AND ASSEMBLING • Wear appropriate clothes with long sleeves, safety shoes, safety helmet and protective glasses. • Suspend warning tag "DO NOT OPERATE" from the doorknob or the operating lever, and have a preliminary meeting before starting work. • Stop the engine before starting inspection and maintenance to prevent the operator being caught in machine. • Identify the location of a first-aid kit and a fire extinguisher, and also where to make contact in a state of emergency. • Choose a hard, level and safe place, and place the attachment on the ground securely. • Use a lifter such as a crane to remove heavy parts (20 kg [45 lbs] or more) from the machine. • Use proper tools, and replace or repair defective tools.

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• Support the machine and attachment with supports or blocks if the work is performed in the lifted condition.

3-2

PRELIMINARY REMARKS HYDRAULIC EQUIPMENT DISASSEMBLY/ REASSEMBLY

• Remove dirt and moisture from and perform degreasing on the surface where liquid gasket to be applied. • Remove rust preventive agent from the new parts before use. • Fit bearings, bushings and oil seals using special jigs. • Assemble the parts utilizing matching marks. • Ensure all the parts are completely assembled after the work.

Hydraulic equipment removal • Before disconnecting pipes, release the hydraulic pressure of the system, or open the return side cover and take out the filter. • Carefully drain oil of the removed pipes into a containers without spilling on the floor. • Apply plugs or caps on the pipe ends to avoid oil spillage and dust intrusion. • Clean off the external surface of the equipment before disassembling, and drain hydraulic and gear oil before placing it on the workbench.

Hydraulic equipment installation • Ensure hydraulic oil and lubricant are properly supplied. • Perform air bleeding when: - Hydraulic oil changed - Parts of suction side piping replaced - Hydraulic pump installed - Slewing motor installed - Travel motor installed - Hydraulic cylinder installed

Hydraulic equipment disassembly • Do not disassemble, reassemble or modify the hydraulic equipment without the permission of the manufacturer, who is not responsible for the performance and function of the product after reassembling. • When disassembling and reassembling for unavoidable reason, refer the work to qualified personnel who have the specific knowledge or completed the parts service training. • Provide matching marks to facilitate reassembling work. • Before starting the work, read the manual of disassembling procedure, if it is provided, and decide whether the work can be performed by yourself. Use the special jig and tools without fail if they are specified. • If it is hard to remove a part according to the procedure, do not try it by force but investigate the cause. • Place the removed parts in order and attach tags to facilitate the reassembling. • Note the location and quantity of parts commonly applied to multiple locations.

WARNING Operation of the hydraulic equipment without filling hydraulic oil or lubricant or without performing air bleeding will result in damage to the equipment.

• Perform air bleeding of the hydraulic pump and slewing motor after loosening the upper drain plug, starting the engine and keep it in low idle condition. Complete the air bleeding when seeping of hydraulic oil is recognized, and tightly plug. • Perform air bleeding of the travel motor and the hydraulic cylinders by running the engine for more than 5 minutes at low speed without load.

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Inspecting parts • Ensure that the disassembled parts are free from seizure, interference and uneven contact. • Measure and record wear condition of parts and clearance. • If the problem is found in a part, repair or replace it with a new one.

WARNING Do not allow the hydraulic cylinder to bottom on the stroke end just after the maintenance.

• Perform air bleeding of pilot line by performing a series of digging, slewing and travel. • Check hydraulic oil level after placing the attachment to the oil check position, and replenish oil if necessary.

Hydraulic equipment reassembly • Turn ON the ventilation fan or open windows to maintain good ventilation prior to starting the cleaning of parts. • Perform rough and finish cleaning before assembling. • Remove washing oil by air and apply clean hydraulic or gear oil for assembling. • Always replace the removed O-rings, backup rings and oil seals with new ones by applying grease in advance.

3-3

PRELIMINARY REMARKS ELECTRICAL EQUIPMENT

HYDRAULIC PARTS

• Do not disassemble electrical equipment.

O-ring • Ensure O-rings have elasticity and are not damaged before use. • Use the appropriate O-rings. O-rings are made of various kinds of materials having different hardness to apply to a variety of parts, such as the part for moving or fixed portion, subjected to high pressure, and exposed to corrosive fluid, even if the size is same. • Fit the O-rings without distortion and bend. • Always handle floating seals as a pair.

• Handle it carefully not to drop and give a shock. • Turn the key OFF prior to connecting and disconnecting work. • Disconnect the connector by holding it and pressing the lock. Do not pull the wire to apply force to the caulking portion. • Connect the connector and ensure it is completely locked.

Flexible hose • Use the appropriate parts. Different parts are used depending on the working pressure even the size of fitting and the total length of the hose is same. • Tighten the fitting at the specified torque. Ensure no kink, tension, interference nor oil leakage is recognized.

• Turn the key OFF prior to touching the terminal of starter or generator. • Remove the ground (earth) terminal of battery when handling tools around the battery or its relay. • Do not splash water on the electrical equipment and connectors during machine washing.

WELDING REPAIR • Refer repair welding to qualified personnel according to the appropriate procedure.

• Check for moisture adhesion inside the waterproof connector after pulling it out, since it is hard to remove moisture from the connector. If moisture adhesion is found, dry it completely before the connection.

• Disconnect the ground (earth) cable of the battery before starting the repair. Failure to do so will cause damage to the electrical equipment. • Move away the articles in advance that may cause fire if exposed to sparks.

WARNING Battery electrolyte is hazardous. Battery electrolyte is dilute sulfuric acid. Exposure of skin or eyes to this liquid will cause burning or loss of eyesight. If the exposure occurs, take the following emergency measures and seek the advice of a medical specialist. • When skin exposed: Wash with water and soap sufficiently. • When eyes exposed: Immediately wash away with city water continuously for more than 10 minutes. • When a large amount of the liquid flows out: Neutralize with sodium bicarbonate or wash away with city water. • When swallowed: Drink a large amount of milk or water. • When clothes exposed: Immediately undress and wash.

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• Before starting the repair of the attachment, do not fail to cover the plated surface of the piston rod with flameproof sheet to prevent it from being exposed to sparks.

3-4

PRELIMINARY REMARKS ENVIRONMENTAL MEASURE • Run the engine at the place that is sufficiently ventilated. Industrial waste disposal • Dispose of the following parts according to the relevant regulations: • Waste oil and waste container • Battery Precautions for handling hydraulic oil • Exposure of eyes to hydraulic oil will cause inflammation. Wear protective glasses before handling to avoid an accident. If an eye is exposed to the oil, take the following emergency measures: - When an eye exposed: Immediately wash away with city water sufficiently till stimulative feeling vanishes. - When swallowed: Do not let vomit, and receive medical treatment immediately. - When skin exposed: Wash with water and soap sufficiently.

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Others Use replacement parts and lubricants authorized as the Distributor genuine parts.

3-5

PRELIMINARY REMARKS

ESCAPING PROCEDURE IN CASE OF EMERGENCY WHEN CAB DOOR DOES NOT OPEN (CAB SPEC. ONLY) If the cab door cannot be opened (due to an accident occured while working), recommended escape routes are the following: • by opening the front sliding windscreen. In case the opening of the frontwindscreen is not possible, a hammer is included to break the front or rear glass.

F22735

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

TOWING THE MACHINE • If the machine should become stuck in soft soil areas it may be necessary to tow the machine. Attach a wire rope or chain, with the capacity to pull the machine out, to the lower frame axles. OK

• Attach other end to the vehicle used to pull the machine. Operate the Machine’s Travel Lever in the proper direction while pulling with the other vehicle.

WARNING • While towing, do not enter between the machine and towing vehicle. • Do not apply a shock load onto the towing rope. • Do not use eyes on machine lower frame to tow machine. • Keep the wire rope horizontally, and perpendicularly to the crawler frame. • Tow the machine slowly at low speed mode. • For the towing of the machine body, provide pads to be applied to the corner of crawler frame to prevent the wire rope and crawler frame from any damages.

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F22736

NOTE: Do not pull machine utilizing the brackets welded on the lower plates of the carbody. These brackets are provided for pulling lightweight objects. See figure for better reference.

3-6

PRELIMINARY REMARKS

INTERNATIONAL UNIT CONVERSION SYSTEM Base Units QUANTITY

Given hereinafter is UNIT SYMBOL

Length Mass Time

metre kilogram second

m kg s

Electric current Thermodynamic temperature Amount of substance Luminous intensity

ampere

kelvin

mol candela

mol cd

Supplementary Units QUANTITY Plane angle Solid angle

UNIT radian steradian

SYMBOL rad sr

Derived Units QUANTITY Area Volume

UNIT square metre cubic metre

SYMBOL m2 m3

Velocity Acceleration Density

metre per second metre per second squared kilogram per cubic metre

m/s m/s2 kg/m3

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Derived Units bearing Peculiar Designations QUANTITY Frequency Force Pressure and Stress Energy, Work and Quantity of heat Power Quantity of electricity Electric potential difference, Voltage, and Electromotive force Quantity of static electricity and Electric capacitance Electric resistance Celcius temperature Illuminance

UNIT hertz newton pascal joule

SYMBOL Hz N Pa J

FORMULA 1/s kg • m/s 2 N/m2 N•m

watt coulomb

W C

J/s A•s

volt

W/A

farad

C/V

ohm

‰

V/A

celcius degree or degree lux

°C

(t+273.15)K

l m/m

F23730gb

3-7

PRELIMINARY REMARKS Prefixes of SI PREFIX giga mega kilo hecto deca deci centi milli micro nano pico

SYMBOL

MULTIPLICATION FACTORS

G M k h da d c m µ n p

10 9 10 6 10 3 10 2 10 10-1 10-2 10-3 10-6 10-9 10-12

Unit Conversion QUANTITY Gravitational SI CONVERSION FACTOR Weight kgf Mass kg Force kgf N 1 kgf=9.807 N Torque kgf · m N·m 1 kgf·m=9.807 N·m Pressure kgf/cm2 MPa 1 kgf/cm2=0.09807 MPa Motive power HP kW 1 HP=0.7355 kW Revolution rpm min-1 r/min 1 1 Units that are allowed to use

1 N=0.10197 kgf 10

100

500

1.000

100

5,000 10.000 500

20.000 N

1.000 2.000 kgf

1 kgf=9.807 N

1 N · m=0.102 kgf · m 10

100

5,000

10,000 20,000 N • m

500

1.000 2.000 kgf • m

1 kgf · m=9.807 N · m

1 MPa=10.197 kgf/cm2 1

100

1.000

1 kgf/cm2=0.09807 MPa

3-8

MPa kgf/cm2 F23739gb

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0.1

CX16B and CX18B

SECTION 4

SPECIFICATIONS

INDEX Foreword ...........................................................................................................................4-1 Identification data ..............................................................................................................4-2 Noise levels (2000/14/EC) .................................................................................................4-3 Summary plate for maintenance operations .....................................................................4-4 Basic components of the mini excavator ...........................................................................4-5 Fixed crawler frame version .......................................................................................................................... 4-5 Adjustable crawler frame width version ......................................................................................................... 4-6

Technical specifications .....................................................................................................4-7 Digging performances (canopy) ........................................................................................4-8 Digging performances (cab) ..............................................................................................4-9 Transport dimensions (canopy) .......................................................................................4-10 Transport dimensions (cab) .............................................................................................4-11 Lifting capacities (cab) ....................................................................................................4-12 Lifting capacities (canopy) ...............................................................................................4-13 Machine and components weight (dry) ...........................................................................4-14 Buckets application .........................................................................................................4-15

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Filling chart ......................................................................................................................4-16

SPECIFICATIONS

FOREWORD This manual has been prepared to assist you in the correct safe procedures for driving, operating and servicing the machine. Only continuous compliance with the norms herein detailed guarantees best performance, economic operation, and durability of your machine and prevents the commonest causes for accidents which might occur during operation or maintenance. Particularly, as regards safety, we recommend to carefully read the general safety precautions detailed from the chapter SAFETY PRECAUTIONS. Repair procedures for this machine are contained in specific Service Booklets, which you may obtain from your Dealer.

nufacturing requirements. For exact information, please consult your Dealer or contact the Manufacturerâ&#x20AC;&#x2122;s Branch Offices.

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

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

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

F22049

4-1

SPECIFICATIONS

IDENTIFICATION DATA 7

1 2

0000

F23963

1. 2. 3. 4.

Machine technical type Frame identification number Machine total mass Machine manufacturing year

5. 6. 7.

4-2

Engine power in kW Frame identification number Identification decal: diesel engine type and serial number

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EXCAVATOR MARKING PLATES

SPECIFICATIONS

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

SOUND PRESSURE LEVEL AT THE OPERATOR’S SEAT 3

Lpa = 79 dB (A) Sound pressure level continuous, equivalent and average (A) measured in compliance with ISO 6396:1992 on an identical machine with conditioning fan at the maximum operating speed. VIBRATION TO THE OPERATOR

00104 9-88670 GB

The vibration level to the operator depends mainly on the conditions of the ground where the machine is being operated and on the use conditions of the machine and its equipment. The exposition to vibrations can be remarkably reduced if the recommendations herebelow are followed: • use equipment suitable for the machine and the type of work to be carried out; • adjust and lock the seat in the correct position; regularly check for the seat suspensions and carry out adjustments or maintenance as required; • regularly carry out the maintenance of the operator’s seat; • operate the equipment evenly, avoiding sudden motion or extreme shocks, if possible; • adjust speed and transfer route. Avoid very irregular routes or the impact with possible obstacles, in order to minimize the vibration level. The weighted average quadratic acceleration value to which the operator’s arms are subjected does not exceed 2.5 m/s2. The weighted average quadratic acceleration value to which the operator’s body is subjected does not exceed 0.5 m/s2.

F22051

NOTE: This machine is equipped with an operator’s seat in compliance with standard ISO 7096:2000. This guarantees that the operator’s body exposures to vibrations respect the requirements for protection against vibrations when the machine is used according to its destination as explained in this manual.

4-3

SPECIFICATIONS

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

1 F22052

2000 h 1000 h 500 h 250 h 50 h

W S

50 h 250 h 500 h 1000 h 2000 h

F22053

Replacement of fuel prefilter

Replacement of engine oil filters

Lubrication Replacement of engine coolant Replacement of reduction gear oil, axles and gearbox Replacement of engine oil Replacement of hydraulic system oil Replacement of air filter

IMPORTANT: if the machine has been refilled with biodegradable hydraulic oil (on demand), be informed this oil cannot be mixed with mineral hydraulic oil.

Replacement of fuel filters

Engine valves

4-4

00104 9-88670 GB

Replacement of hydraulic system return oil filter

SPECIFICATIONS

BASIC COMPONENTS OF THE MINI EXCAVATOR FIXED CRAWLER FRAME VERSION

5 4

1 9

00104 9-88670 GB

F22066

1. 2. 3. 4. 5. 6. 7. 8. 9.

Bucket Link rod Linkage Bucket cylinder Arm Arm cylinder (penetration) Boom Fuel tank Boom cylinder

10. 11. 12. 13. 14. 15. 16. 17.

4-5

Counterweight Hydraulic oil tank Crawler Travel motor Canopy Track roller Idler adjuster Dozer

SPECIFICATIONS

ADJUSTABLE CRAWLER FRAME WIDTH VERSION

5 4

1 9

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

11. 12. 13. 14. 15. 16. 17. 18.

Bucket Link Linkage Bucket cylinder Arm Arm cylinder Boom Fuel tank Boom cylinder Counterweight

4-6

Hydraulic oil tank Crawler Travel motor Cab Track roller Idler adjuster Dozer Crawler width cylinder

00104 9-88670 GB

F22067

SPECIFICATIONS

TECHNICAL SPECIFICATIONS DIESEL ENGINE Model Type

YANMAR 3TNE74 vertical, 4-cycles, Swirl chamber, water cooled 11 kW 3 in-line 74 mm x 78 mm 1.006 L

Net power at flywheel at 2000 rpm-1 (ISO9249) Number of cylinders Bore x Stroke Total displacement

ELECTRICAL SYSTEM Voltage of operation Batteries (capacity 20 h) Alternator (current) Starter motor (Power)

12 V 45 Ah 20 A 1 kW

HYDRAULIC COMPONENTS Pump

with axial pistons, with variable displacement + gear pump

Slew motor

orbit at fixed displacement

Travel motor

with axial pistons, variable volume for 2 speeds

Control valve

10-spool multiple

Cylinders boom, arm, bucket, swing, dozer, crawler width

double action

SPEED AND PERFORMANCE ON GRADIENTS Crawlers Slewing speed Travel speed slow fast

rubber / steel 9.0 rpm 2.0 km/h 3.5 km/h

Maximum climbable gradient

58%

SWINGING Type Swinging angle Right side Left side

swinging with cylinder

00104 9-88670 GB

50° 85°

4-7

SPECIFICATIONS

DIGGING PERFORMANCES (CANOPY) With 0.044 m3 bucket

A AI

C H D

B F

F14365

ARM A A' B C D E F G H K L X Y

1020 3780 3683 2178 3530 2490 851 1904 1548 2667 1699 1143 210 270

4-8

1220 3970 3879 2378 3654 2613 654 2099 1579 2667 1970 1065 210 270

00104 9-88670 GB

(Dimensions in mm)

SPECIFICATIONS

DIGGING PERFORMANCES (CAB) With 0.044 m3 bucket

A AI

C H D

B F

F14364

00104 9-88670 GB

(Dimensions in mm) ARM A A' B C D E F G H

1020 3780 3683 2178 3530 2490 851 1904 1548 2667

1220 3970 3879 2378 3654 2613 654 2099 1579 2667

K L X Y

1699 1143 210 270

1970 1065 210 270

4-9

SPECIFICATIONS

TRANSPORT DIMENSIONS (CANOPY) With 0.044 m3 bucket

A B

E F G

N O

N' O'

F14362

(Dimensions in mm)

1020 3620 1050 2350 440 1220 1570 1080 770 2130 250

980

760 1070 990 1300

230

505

560 1050 360

170

1220 3650 1050 2350 440 1220 1570 1080 770 2130 250

980

760 1070 990 1300

230

505

560 1050 360

170

00104 9-88670 GB

* Versions with arm

4-10

SPECIFICATIONS

TRANSPORT DIMENSIONS (CAB) With 0.044 m3 bucket A M

O N' O'

F14363

(Dimensions in mm)

00104 9-88670 GB

1020 3620 1050 2350 440 1220 1570 1080 770 2130 250

980

760 1070 990 1300

230

505

560 1050 360

170

1220 3650 1050 2350 440 1220 1570 1080 770 2130 250

980

760 1070 990 1300

230

505

560 1050 360

170

* Versions with arm

4-11

SPECIFICATIONS

LIFTING CAPACITIES (CAB) With bucket

206 bar 4 3.5

3 2.5 2 1.5 1

0.5

0 0.5 1 1.5 2

2.5 3

3.5

2.5

LD=

L= 1.75 m

1.02 m LD= 1.22 m

Z2 Z1 480 Z3 670 Z2 Z1 Z3

450 890

1.5

2.0

2.5

3.0

220

520 420

290 280

240 -

500 510

320 330

190 200

220

180

1.5

0.5

76 kg

CAPACITY kg F23737

00104 9-88670 GB

1.0

RANGE m

4-12

SPECIFICATIONS

LIFTING CAPACITIES (CANOPY) With canopy

LD 4

76 kg Z2

1 3

(m)

206 bar 3

4.5

3.5

2.5

1.5

0.5

(m)

1.0

RANGE m

LD=

L= 1.75 m

1.02 m LD= 1.22 m

Z2 Z1 480 Z3 670 Z2 Z1 Z3

450 890

1.5

2.0

2.5

3.0

220

460 420

290 280

210 -

440 460

280 290

160 180

200

150

CAPACITY kg

00104 9-88670 GB

F23738

4-13

SPECIFICATIONS

MACHINE AND COMPONENTS WEIGHT (DRY) MODEL COMPLETE MACHINE UPPER FRAME ASSEMBLY (ASSY OF FOLLOWINGS) UPPER FRAME GUARD ENGINE MUFFLER RADIATOR HYDRAULIC PUMP HYDRAULIC TANK FUEL TANK CONTROL VALVE SLEWING MOTOR SWING BRACKET SWING CYLINDER COUNTERWEIGHT BATTERY PILOT VALVE (TRAVEL) PILOT VALVE (OPERATOR MANUAL) CAB CANOPY LOWER FRAME ASSEMBLY (ASSY OF FOLLOWINGS) LOWER FRAME SWIVEL JOINT SLEWING BEARING RUBBER CRAWLER SHOE IRON CRAWLER TRAVEL MOTOR LOWER ROLLER IDLER SPROCKET IDLER ADJUSTER DOZER DOZER CYLINDER CRAWLER WIDTH CYLINDER HOE ATTACHMENT (ASSY OF FOLLOWINGS) BOOM ARM (1020) ARM (1220) BUCKET BOOM CYLINDER ARM CYLINDER BUCKET CYLINDER FLUIDS HYDRAULIC OIL COOLING WATER ENGINE OIL FUEL

Unit; kg

ADJUSTABLE CRAWLER FRAME WIDTH

1730

1805

203 79 100 8 11 10 24 12 23 15 31 19 76 13 3.9 1.6 X 2 180 59

170 11 17 58 X 2 88 X 2 17 X 2 4.5 X 6 16 X 2 5X2 6X2 51 10 ------------------------------

223 11 17 58 X 2 88 X 2 17 X 2 4.5 X 6 16 X 2 5X2 6X2 66.5 10 10.5

52 45 55 -----------------------------12 16.5 9 49 22 liters 3.7 liters 3.5 liters 19.7 liters

52 45 55 -----------------------------12 16.5 9 49 liters 22 liters 3.7 liters 3.5 liters 19.7 liters

00104 9-88670 GB

FIXED CRAWLER FRAME VERSION

F23741gb

4-14

SPECIFICATIONS

BUCKETS APPLICATION

BUCKET

ARM

Type

Width mm

Capacity m3 heaped (ISO 7451)

Mass kg

Length 1020 mm

Length 1220 mm

Buckets for digging

250

0.028

22.52

▲ ●

Buckets for digging

300

0.034

28.21

▲ ●

Buckets for digging

350

0.040

30.37

▲ ●

Buckets for digging

400

0.044

32.38

▲ ●

Buckets for digging

450

0.046

34.01

▲ ●

Buckets for digging

500

0.051

37.01

▲ ●

Buckets for digging

600

0.060

40.09

▲ ●

Buckets for digging

700

0.069

45.11

▲ ●

Ditch cleaning buckets

800

0.056

27.32

■❍◆

Ditch cleaning buckets

1000

0.072

31.75

■❍◆

00104 9-88670 GB

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

●: Width with lateral cutter ❍: Width without lateral cutter ▲: Generic digging for digging and sand loading operations, gravel, clay, earth in general, etc.. The specific weight of the material should not be higher than 1400 kg/m3. ■: Digging for light applications for operations of digging,sand loading/unloading of gravel, clay, earth in friabile and dry state, ditch cleaning, etc.

4-15

SPECIFICATIONS

FILLING CHART QUANTITY

BE FILLED

Litres

RECOMMENDED FLUIDS AND LUBRICANTS

AKCELA

MANUFACTURER'S SPECIFICATIONS

INTERNATIONAL SPECIFICATIONS

NOTES Protective fluid to be mixed with water at 50%. This mix has anticorrosive, antiscaling, and anti-foaming properties; does not freeze down to -35 °C.

Engine cooling system

3.7

PREMIUM ANTI-FREEZE

MS 1710

Fuel tank

19.7

ASTM fuel N. 2-D type TT

Engine

3.5

N°1 ENGINE OIL

MS 1121

API CH-4 ACEA E5

Multigrade oil for aspirated or turbochargerd diesel engine of every types and powers.

Travel reduction gear (each)

0.33

GEAR 135H EP

MS 1316

API GL 5 MIL-L-2105 D

Gear oil with Estreme Pressure (E.P.) performance.

ISO 46 HV

High viscosity lubricant for excavators and earthmoving machine hydraulic controls.

Attachment hydraulic system (**)

Pressure grease fittings Swing joint teeth

Windscreen washer

HYDRAULIC EXCAVATOR FLUID

MULTI-PURPOSE GREASE 251H EP

8.3 (*)

1.5

MS 1230

251H EP

Travel reduction gear

Hydraulic system

NLGI 2

Detergent diluted in water from 10% to 50%. The mix has antifreezing properties until -22 °C.

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

OPERATING RANGE (AMBIENT TEMPERATURE °C)

LUBRICANT TYPE

Engine

Lithium-based grease containing molybdenum disulphide, resists to water, low temperature and high loads; NLGI 2 consistency

TUTELA PROFESSIONAL SC35

Oil quantities shown are necessary for periodical changes following discharging and filling procedures detailed for each assembly. (*) First filling only.

TO BE FILLED

AKCELA

VISCOSITY

N°1 ENGINE OIL

SAE 15W - 40 SAE 10W - 30

GEAR 135H EP

SAE 80W - 90

HYDRAULIC EXCAVATOR FLUID

ISO VG 46

4-16

-30

-20

-10

00104 9-88670 GB

COMPONENT TO

CX16B and CX18B

SECTION 5

SPECIAL TOOLS

INDEX Tools of cylinders ...............................................................................................................5-1 Tool of hydraulic pump ......................................................................................................5-4 Tool of pilot valve track ......................................................................................................5-4 Tool of roller track ..............................................................................................................5-4 Tool of idler adjuster ..........................................................................................................5-5 Tools of engine ..................................................................................................................5-5

00104 9-88670 GB

Tools of travel motor ..........................................................................................................5-8

SPECIAL TOOLS

TOOLS OF CYLINDERS 380001513 Head bushing installer (diam. 30 Boom, Bucket). Part number 380001513

380001514 Head bushing installer (diam. 35, Arm, Dozer, Swing). Part number 380001514

380001515 Pin bushing installer (diam. 30, Boom, Bucket). Part number 380001515

380001516 Pin bushing installer (diam. 35, Arm, Dozer, Swing). Part number 380001516

380001517

00104 9-88670 GB

Seal ring guide (Bucket). Part number 380001517

5-1

SPECIAL TOOLS Seal ring guide (Boom). Part number 380001518

380001518

Seal ring guide (Arm, Dozer). Part number 380001519

380001519

380001520

Seal ring guide (Swing). Part number 380001520

380001521 Seal ring installer (Bucket). Part number 380001521

380001522

00104 9-88670 GB

Seal ring installer (Boom). Part number 380001522

5-2

SPECIAL TOOLS Seal ring installer (Arm, Dozer). Part number 380001523

380001523

Seal ring installer (Arm, Dozer). Part number 380001524

380001524

380001525

Seal ring installer (Bucket). Part number 380001525

380001526 Seal ring installer (Boom). Part number 380001526

380001527

00104 9-88670 GB

Seal ring installer (Arm, Dozer). Part number 380001527

5-3

SPECIAL TOOLS Seal ring installer (Swing). Part number 380001528

380001528

TOOL OF HYDRAULIC PUMP

380001529

Oil seal installer. Part number 380001529

380001530

TOOL OF PILOT VALVE TRAVEL Bushing remover. Part number 380001530

380001531

TOOL OF ROLLER TRACK

00104 9-88670 GB

Oil seal installer. Part number 380001531

5-4

SPECIAL TOOLS

380001532

TOOLS OF IDLER ADJUSTER Idler pin extracting. Part number 380001532

380001533 Idler adjuster assembly/disassembly. Part number 380001533

380000303

TOOLS OF ENGINE Cylinder compression test kit. Part number 380000303

380000179

00104 9-88670 GB

Cylinder compression test adapter. To be used with 380000303. Part number 380000179

5-5

SPECIAL TOOLS Camshaft bushing installer. Part number 380000180

380000180

380000181 Cylinder head valve guide remover. Part number 380000181

380000182 Cylinder head valve guide installer. Part number 380000182

380000183 Cylinder head valve guide reamer. Part number 380000183

380000184

00104 9-88670 GB

Cylinder head valve spring remover/installer. Part number 380000184

5-6

SPECIAL TOOLS Engine overhaul bracket. To be used with 380000301. Part number 380000178

380000178

380000301 Engine overhaul revolving stand. Part number 380000301

380000216 Engine lifting hook. Part number 380000216

380000221 65-110 mm diameter piston ring pliers. Part number 380000221

380000220

00104 9-88670 GB

60-125 mm diameter piston ring clamp. Part number 380000220

5-7

SPECIAL TOOLS

TOOLS OF TRAVEL MOTOR 380001550 Ring for lifetime assembly. Part number 380001550

380001065 Stopper for O-Ring seal assembly on plug 3/4. Part number 380001065

380001066

Stopper for O-Ring seal assembly on plug 1/8. Part number 380001066

380001529

00104 9-88670 GB

Stopper for shaft withbearing assembly. Part number 380001529

5-8

CX16B and CX18B

SECTION 6

STANDARD MAINTENANCE TIME TABLE

INDEX Preface ..............................................................................................................................6-1 Standard working time table for the maintenance .............................................................6-2

00104 9-88670 GB

Attachment .................................................................................................................................................... Floor assy, Canopy (Cab) & Guard ............................................................................................................... Upper slewing structure ................................................................................................................................ Travel system ................................................................................................................................................

6-2 6-3 6-4 6-7

STANDARD MAINTENANCE TIME TABLE

PREFACE Working Conditions

Excluded Time (not included in the standard maintenance time) Repairing time: Time for machining, sheet metal processing, welding, gas cutting, removing broken screw, taking care of parts and painting. Items excluded from maintenance time because of uncertainly in time: Receiving the vehicle into shop,transportation, delivery, final inspection and investigation of causes for trouble, diagnosis and inspection. Indirect time: Time for field work, preparation of required parts, etc., before starting work, going to and from the site, waiting due to user's convenience at the site and paper work for reports, bills, etc. Special time: Working time at early morning, at mid night and on holidays shall be separately calculated. Separate calculation: The cost for service cars, trucks with crane and truck cranes shall be separately calculated.

Technicians: One or more technicians qualified by Manufacturer as a first class service technician (with five years or more of field experience and having completed the training in the operation of vehicle type construction machinery) to be provided. Facilities: General jigs, tools, apparatus, testers to be provided. The maintenance workshop to be equipped with a good enough capacity of building with crane and inspection instruments necessary for specific self inspection activities. Place: The workshop to be located on a flat land at which the work is able to perform and to which a service car or truck crane is accessible.

Applicable Range of Standard Maintenance Time • Standard maintenance time: Direct maintenance time plus spare time. • Direct maintenance time: Net time actually spent for maintenance. • Spare time: Time for transportation of the machine for maintenance, preparation for safety work, meeting for the work and physiological time for the needs of body.

Applicable Machine for Estimation of Standard Maintenance Time

00104 9-88670 GB

• Standard machine. • A well maintained machine combined with standard attachments which has operated in a normal circumstances.

6-1

STANDARD MAINTENANCE TIME TABLE

STANDARD WORKING TIME TABLE FOR THE MAINTENANCE Standard maintenance time table • Units of working time : 6 minutes = 0.1 hour • Calculating method of standard maintenance time: Maintenance time = Working time X Number of workers (Working time = Maintenance time / Number of workers)

• Abbreviations in the table. ASSY: Assembly ATT: Attachment BRG: Bearing C/V: Control valve Cyl: Cylinder E/G: Engine F hose: Flexible hose Inst.: Installation O/H: Overhaul SW: Switch SOL: Solenoid V: Valve

• When more than one work are done, - Add each standard maintenance time - A net time (readily starting) is given except covers easily removed by hand. - Assy works include the following works marked with black dot. • O/H : The removing and installing time are not included.

00 01 02 03 04 05 06 07 10 11 12 13 14 15 16 17 18 20 21 22 23 24 25 26

EQUIPMENT PORTION Bucket portion Bucket ASSY • Bucket removing/ installing position • Bucket installing pin • Bucket drive pin • Bucket sling and transfer Bucket (Single) • Bushing Arm portion Arm ASSY • Bucket cylinder removing/ installing position and piping • Bucket cylinder rod pin • Bucket cylinder head pin • Bucket cylinder assy • Arm cylinder rod pin • Boom top pin • Arm sling and transfer Boom portion Boom ASSY • Boom removing/ installing position • Boom cylinder temporary slinging • Boom cylinder rod pin • Boom cylinder piping • Arm & Bucket piping

WORK TO BE UNIT DONE

REMARK

See section n°10 Removal/Inst. 1 pc. Include adjustment Preparation 1 pc. Removal/Inst. 1 pc. Include stopper pin. - ditto 1 pc. Preparation 1 pc. O/H 1 pc. Not include removing and installing Replace 1 pc. See section n°10 Removal/Inst. 1 pc. Preparation 1 pc. Removal/Inst. - ditto - ditto - ditto - ditto - ditto -

1 pc. Include stopper pin. 1 pc. Include stopper pin. 1 pc. 1 pc. Include stopper pin. 1 pc. 1 pc. See section n°10 Removal/Inst. 1 pc. Preparation 1 pc. - ditto 1 pc. Removal/Inst. 1 pc. Include stopper pin. - ditto 1 pc. - ditto 1 pc.

6-2

UNIT : HOUR 0.4 0.1 0.1 0.1 0.1 0.6 0.5 0.8 0.2 0.1 0.1 0.1 0.1 0.1 0.1 1.0 0.1 0.1 0.1 0.1 0.2

00104 9-88670 GB

Attachment

GROUP No.

STANDARD MAINTENANCE TIME TABLE

Floor assy,Canopy (Cab) & Guard

00104 9-88670 GB

Attachment

GROUP No.

EQUIPMENT PORTION

27 28 29 30 31 32 33 40 41 42 43 50 51 60 61 70 71 80 81 82 83 84 85

• Boom assy temporary slinging • Boom foot pin • Boom assy slinging Arm cylinder removing / installing • Arm cylinder piping • Arm cylinder head pin • Arm cylinder slinging Boom cylinder removing / installing • Boom cylinder piping • Boom cylinder head pin • Boom cylinder slinging Bucket cylinder • Pin bushing Arm cylinder • Pin bushing Boom cylinder • Pin bushing Swing portion Swing bracket assy • Swing cylinder rod pin • Swing bracket slinging • Swing center pin Swing cylinder removing / installing

86 87 88 89 90 91 92 93 94 95 96 00

• Swing cylinder hose • Swing cylinder head pin Swing cylinder • Pin bushing Other necessary works Dozer portion Dozer ASSY • Dozer cylinder hose • Dozer cylinder rod pin • Dozer installing pin Dozer cylinder • Pin bushing Canopy portion

Canopy assy

10 11 12 20 21 22 23 24

Cab portion Cab assy Harness Guard portion Upper side cover Lower side cover Front cover Bonnet assy

WORK TO BE UNIT DONE Removal / Inst. - ditto - ditto - ditto - ditto - ditto - ditto - ditto - ditto - ditto - ditto O/H Replace O/H Replace O/H Replace

1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 set 1 pc. 1 set 1 pc. 1 set

REMARK

Include stopper pin.

Include seal. Include seal. Include seal. See section n°10

Removal / Inst. - ditto - ditto - ditto - ditto -

1 pc. 1 pc. 1 pc. 1 pc. 1 pc. After removing swing bracket. Removal / Inst. 2 pcs. - ditto 1 pc. O/H 1 pc. Replace 1 pc. Include seal. Removal / Inst. 1 set Floor plate, Side cover. See section n°10 Removal / Inst. 1 pc. - ditto 2 pcs. - ditto 1 pc. - ditto 2 pcs. O/H 1 pc. Replace 1 set Include seal. See section n°11 - ditto -

6-3

2 pcs. 2 pcs. 1 pc. 1 pc.

0.1 0.1 0.1 0.3 0.1 0.1 0.1 0.3 0.1 0.1 0.1 2.5 1.0 2.5 1.0 2.5 1.0 0.4 0.1 0.1 0.1 0.3 0.2 0.1 2.5 1.0 0.3 0.6 0.2 0.1 0.2 2.5 1.0

0.2

1 pc. See section n°11

0.4 0.1

See section n°11

0.1 0.1 0.1 0.2

Removal / Inst. 1 pc. Removal / Inst. 1 pc. Removal / Inst. - ditto - ditto - ditto -

UNIT : HOUR

STANDARD MAINTENANCE TIME TABLE

30 31 40 41 42 43 44 00 01 02 03 04

Upper slewing structure

10 11 12 13 14 20 21 22 23

EQUIPMENT PORTION Floor plate portion Floor plate assy Othen necessary works Counterweight portion Counterweight ASSY • Lifting tools • Slinging • Counter weight fixing bolt Other necessary works Control portion E / G control cable Travel yoke Dozer (Crawler width) cable Swing yoke Other necessary works Intake portion Air cleaner ASSY • Hose • Hose • Element Exhaust portion Muffler ASSY • Exhaust tube assy • Band Other necessary works

WORK TO BE UNIT DONE

REMARK

See section n°11 1 set Removal / Inst. Removal / Inst. 1 pc. Canopy removal/inst See section n°11 Removal / Inst. 1 pc. 1set Preparation Removal / Inst. 1 pc. 1 set - ditto 3 pcs - ditto Removal / Inst. - ditto - ditto - ditto - ditto -

1 pc. 2 pcs. 1 pc. 1 pc. 1 set Cover, Hose

UNIT : HOUR 0.5 0.2 0.4 0.1 0.1 0.1 0.3 0.2 0.2 0.1 0.1 1.0

See section n°11 Removal / Inst. - ditto - ditto Replace

1 pc. 1 pc. 1 pc. 1 pc.

0.3 0.1 0.1 0.1

See section n°11 1 pc. Removal / Inst. 1 pc. Include gasket replacing - ditto 2 pcs. - ditto 1 pc. Lower side cover - ditto 1 pc. Counter weight - ditto -

0.3 0.2 0.1 0.1 0.3

See section n°11 1 pc. 1 pc. 2 pcs. 1 pc. Include tension adjusting 1 set Covers 1 pc. Minus terminal of battery 1 pc. 1 pc. 1 pc. 2 pcs. 1 set Cover, Bonnet 1 pc. Minus terminal of battery 1 set Slewing lock assy

0.6 0.1 0.1 0.3 0.2 0.1 0.5 0.1 0.1 0.2 0.2 0.1 0.2

See section n°11 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 4 pcs. 1 pc. Counter weight 1 pc. Guard

0.6 0.2 0.1 0.1 0.1 0.1 0.3 0.3

30 31 32 33 34

E / G Accessory portion Generator • Connector • Generator fixing bolt • V-belt Other necessary works

36 37 38 39

Starter • B-terminal • S-terminal connector • Starter fixing bolt Other necessary works

40 41 42 43 44 45 46

Fuel portion Removal / Inst. Fuel tank ASSY Replace • Fuel • Hose (Supply ; water separator side) Removal / Inst. - ditto • Hose (Return ; filter side) - ditto • Level sensor connector Removal / Inst. • Fuel tank top / bottom fixing bolt - ditto Other necessary works - ditto -

Removal / Inst. - ditto - ditto - ditto - ditto - ditto - ditto - ditto - ditto - ditto - ditto - ditto - ditto -

6-4

00104 9-88670 GB

Floor assy,Canopy (Cab) & Guard

GROUP No.

STANDARD MAINTENANCE TIME TABLE

Upper slewing structure

GROUP No. 50 51 52 53 54 55 56 57 58 59 60 61 62 63

Hydraulic oil tank portion Hydraulic oil tank ASSY • Pressure releasing • Return filter • Hydraulic oil • Suction hose • Suction tube ASSY • Strainer • Pilot return hose • Swivel drain hose • SOL. valve return hose • Slewing, C / V return hose • Tank fixing bolt • Tank slinging Other necessary works

70 71 72 73 74 75 76 77 78 79

Pump portion Pump ASSY • Pressure releasing • Hydraulic oil • Pilot discharge oil hose • Suction hose • Suction tube (pump side) • Main pump discharge hose • Pump fixing bolt Pump ASSY Other necessary works Radiator portion Radiator ASSY • Coolant (LLC) • • Coolant density • Reserve tank hose • Radiator hose • Radiator fixing bolt • Radiator lifing or slinging Other necessary works

80 81 82 83 84 85 86 87

00104 9-88670 GB

EQUIPMENT PORTION

WORK TO BE UNIT DONE Removal / Inst. Preparation Replace - ditto Removal / Inst. - ditto Replace Removal / Inst. - ditto - ditto - ditto - ditto - ditto - ditto - ditto Preparation Removal / Inst. Preparation Replace Removal / Inst. - ditto - ditto - ditto - ditto O/H Removal / Inst. Removal / Inst. Replace Measuring Removal / Inst. - ditto - ditto - ditto - ditto - ditto -

90 91 92

Engine (E / G) Installing portion Engine ASSY • Fuel hose

Removal / Inst. - ditto -

93 94 95

• Harness, connector and cable • Engine fixing double nut • Engine slinging

Removal / Inst. - ditto - ditto -

6-5

REMARK

See section n°11 1 pc. After removing fuel tank ; 1 pc. 1 pc. Include O-ring replacing 1 pc. 1 pc. 1 pc. 1 pc. Include O-ring replacing 1 pc. 1 pc. 1 pc. 1 pc. 5 pcs. Include bracket's 1 pc. 1 pc. Counter weight, Guard 1 pc. Battery 1 pc. Hyd. Oil pressurize See section n°11 1 pc. After removing fuel tank 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 2 pcs. 2 pcs. 1 pc. 1 pc. Hyd. oil tank pressurizing See section n°11 1 pc. 1 pc. 1 pc. 1 pc. 2 pcs. 3 pcs. 1 pc. 1 pc. Counter weight 1 set Guard (Cover, support) See section n°11 1 pc. 4 pcs. For injection pump - 2 For feed pump - 2 1 set 1 pc. 1set

UNIT : HOUR 2.2 0.2 0.2 0.2 0.3 0.1 0.2 0.1 0.2 0.2 0.2 0.1 0.6 0.1 0.2 1.2 0.2 0.1 0.2 0.2 0.2 0.2 3.0 0.2 0.8 0.2 (0.2) 0.2 0.1 0.2 0.3 2.5 1.0 0.2 0.3 0.2 0.2

STANDARD MAINTENANCE TIME TABLE

EQUIPMENT PORTION Other necessary works

100 Control valve portion 101 Control valve ASSY 102 • Piping connector, hose

Upper slewing structure

103 • Control cable, Yoke 104 • Fixing bolt 105 Control valve ASSY Other necessary works 110 Slewing motor portion 111 Slewing motor ASSY 112 • Piping connector, hose 113 • Grease piping hose 114 • Fixing bolt 115 • Greasing 116 Slewing motor ASSY Other necessary works

120 Swivel joint portion 121 Swivel joint ASSY

122

• Piping connector, hose

123 • Stopper 124 • Fixing bolt 125 Swivel joint ASSY Other necessary works 130 Upper frame 131 Upper frame ASSY 132 • Fixing bolt 133 • Upper frame slinging 134 • Cleaning

WORK TO BE UNIT DONE Removal / Inst. - ditto - ditto - ditto - ditto - ditto - ditto - ditto -

1 set 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc.

REMARK Guard Counter weight Air cleaner Muffler Fuel tank Hydraulic oil tank Pump Radiator See section n°11

Removal / Inst. 1 pc. - ditto 1 set Include attaching hose's tag and plug - ditto 1 set - ditto 1 set O/H 1 pc. Removal / Inst. 1 set Floor plate - ditto 1 set Cover, Front / Rear support See section n°11 Removal / Inst. 1 pc. - ditto 3 pcs. Include attaching hose's tag and plug - ditto -. 1 pc. - ditto 1 pc. Greasing 1 pc. O/H 1 pc. Removal / Inst. 1 set Floor plate - ditto 1 set Cover, Front / Lower support Drain / Feed 1 set Oil Drain / Feed Removal / Inst. 1 set For convenience of work, removing / installing / adjusting components. See section n°12 Removal / Inst. 1 pc. After removing slewing motor and crawler width cylinder - ditto 1 set Include attaching hose's tag and plug - ditto 1 pc. - ditto 1 set O/H 1 pc. Preparation 1 pc. Removal / Inst. position. Secure working space. See section n°11 Removal / Inst. - ditto - ditto Cleaning 6-6

1 pc. 1 set Apply sealant 1 pc. 1 pc.

UNIT : HOUR 1.5 0.3 0.3 0.3 0.6 2.2 1.2 0.8 1.6 1.0 0.4 0.1 3.0 0.2 0.4 1.0 0.4 0.1 0.3 0.1 3.0 0.2 0.4 0.2 0.5

1.5

1.0 0.1 0.2 2.0 0.5

1.0 0.4 0.3 0.2

00104 9-88670 GB

GROUP No.

STANDARD MAINTENANCE TIME TABLE

00104 9-88670 GB

Travel System

Upper slewing structure

GROUP No.

EQUIPMENT PORTION Other necessary works

00 01 02 03 04 05 10 11 12 20 21 22 23 24 30 31 40 41 42 43

Travel portion Rubber crawler • Rubber shoe removing / inst. position. • Tension adjusting • Crawler shoe Slide plate Lower roller portion Lower roller ASSY Lower roller Front idler & Idler adjuster portion Idler & Idler adjuster ASSY Idler & Idler adjuster ASSY Idler ASSY Idler adjuster ASSY Sprocket portion Sprocket Travel motor portion Travel motor ASSY • Motor cover • Hydraulic connector, hose

44 45 46 47 50 51 52 53 54 60 61 62 63 64 65 66 67

• Motor fixing bolt • Motor slinging Travel motor Travel reduction unit Slewing bearing Slewing bearing ASSY • Slewing bearing fixing bolt • Slewing bearing • Slewing bearing slinging Adjustable crawler frame width portion Adjustable crawler frame width ASSY • Cylinder cover • Cylinder hydraulic hose • Bracket, pin • Nuts for stopper bolt • Crawler frame ASSY Cylinder Other necessary works

WORK TO BE DONE Removal / Inst. - ditto - ditto Drain / Feed Removal / Inst. - ditto -

UNIT

Removal / Inst. Preparation Adjusting Removal / Inst. - ditto -

One side One side One side One side One side

1 set 1 set 1 pc. 1 pc. 1 set 1 set

REMARK Floor plate Guard (Cover, support) Counter weight Hydraulic oil Swivel joint hose Boom, Swing bracket See section n°12

UNIT : HOUR 0.2 2.0 0.3 0.2 0.5 1.5 0.6 0.1 0.2 0.2 0.1

See section n°12 Removal / Inst. 1 pc. O/H 1 pc.

0.2 1.0

Removal / Inst. Disassembly O/H - ditto -

See section n°12 One side After removing crawler shoe One side One side One side

0.5 0.1 1.0 0.5

Replace

See section n°12 One side After removing crawler shoe

0.5

See section n°12 Removal / Inst. One side After removing crawler shoe - ditto One side - ditto One side Include attaching hose's tag and plug - ditto One side - ditto One side O/H One side - ditto One side

1.0 0.1 0.6 0.2 0.1 2.5

See section n°12 Removal / Inst. 1 pc. After removing upper flame - ditto 0.6 1 pc. Cleaning 1 pc. Degreasing / Replenishment 0.3 Removal / Inst. 1 pc. 0.1 Removal / Inst. - ditto - ditto - ditto - ditto - ditto O/H Preparation

See section n°12 1 pc. 1 pc. 2 pcs. 2 sets 2 sets Include adjusting length 1 pc. 1 pc. 1 set Removal / Inst. position

(Secure working space) Removal / Inst. 1 pc. Under cover

6-7

2.5 0.1 0.2 0.2 0.2 1.5 2.0 0.5 0.1

STANDARD MAINTENANCE TIME TABLE

00104 9-88670 GB

NOTES:

6-8

CX16B and CX18B

SECTION 7

MAINTENANCE STANDARDS AND TEST PROCEDURES

INDEX How to use maintenance standards and precuations .......................................................7-1 Performance inspection standard table .............................................................................7-2 Measuring engine speed ...................................................................................................7-4 Measuring hydraulic oil pressure ......................................................................................7-5 Measuring travel performances .........................................................................................7-8 Measuring slew performances ........................................................................................7-10 Measuring attachment operating performances ..............................................................7-12 Measuring slew bearing performances ...........................................................................7-14

00104 9-88670 GB

Measuring crawler tension ..............................................................................................7-15

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