Ammann ASC Series Instruction manual

Workshop manual E
ASC 70 / ASC 90 / ASC 110 / ASC 150 / ASC 200 / ASC 250
Cummins Tier II © 7 / 2004
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Verdichtung AG, CH-4900 Langenthal
0041 (0)62 916 63 56 FAX: [phone]
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CONTENTS
INTRODUCTION ............................................................................................................................. 4
SAFETY PRECAUTIONS .................................................................................................................. 5
REPAIR SAFETY INSTRUCTIONS .................................................................................................. 38
ENVIRONMENTAL MEASURES AND HEALTH PRECAUTIONS .......................................................... 42
1 - A SUMMARY OF APPLICATIONS ............................................................................................. 45
2 - DESCRIPTION OF THE MACHINE ............................................................................................. 46
3 - REMOVING THE ENGINE .........................................................................................................68
4 - DRUM REMOVAL.................................................................................................................... 92
5 - ARTICULATED JOINT ............................................................................................................133
6 - REMOVAL OF PUMPS, CENTO CLUTCH .................................................................................149
7 - STEERING CYLINDERS .........................................................................................................159
8 - CONTROLS ........................................................................................................................... 163
9 - THE DRIVER‘S STATION ASSEMBLY ......................................................................................167
10 - DISASSEMBLY OF HEATER..................................................................................................173
11 - ELECTRICAL INSTALLATION................................................................................................181
12 - REMOVAL OF ROPS FRAME................................................................................................197
13 - ASSEMBLY OF SEGMENTS ..................................................................................................199
14 - DISASSEMBLY OF WHEEL...................................................................................................207
15 - REMOVAL OF HYDRAULIC MOTORS ...................................................................................209
16 - REPLACING PRESSURE FILTER OF HYDRAULICS ................................................................215
17 - FILLING HYDRAULIC OIL ....................................................................................................218
18 - DISASSEMBLY OF LEVEL GAUGE ........................................................................................219
19 - DISASSEMBLY OF THE FLOATER .........................................................................................221
20 - ELECTRIC SCHEMATA ........................................................................................................223
21 - HYDRAULIC .......................................................................................................................256
22 - DIAGNOSTICS OF HYDRAULIC SYSTEM DEFECTS ...............................................................268
23 - TROUBLESHOOTING ...........................................................................................................281
24 - TIGHTENING TORQUES ...................................................................................................... 310
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INTRODUCTION
Data and figures from this manual must not be copied or distributed in any way, since they are protected by copyright.
INTRODUCTION
Vibration roller ASC 70/250 series is suitable for compaction of all kinds of ground and for large- and mid-scale groundwork
in highway construction (construction of motorways, railways, airports), in hydro-engineering (construction of dams), in building
construction (industrial areas, ports), and the like.
The roller should be used under conditions defined in the Czech Standard (CSN) IEC 721-2-1 (038900): WT, WDr, MWDr, i. e.
in mild, dry warm and dry hot weather in the range of temperatures from -15 °C (5 °F) to 45 °C (113 °F).
This STA machine is manufactured to the latest developments and standards, which secure its safe function.
If the machine is used incorrectly, by untrained operators or for other purpose than stipulated above, there is a danger of an
accident or damage to the equipment.
The main purpose of this manual is to give information necessary for carrying out assembly and disassembly of the machine as
well as service repairs of main assemblies of the equipment. It contains technical and installation data, instructions how to adjust
the machine and how to use special tools, fixtures and aids.
The manufacturer continuously improves the products on the basis of experience and latest developments in the field.
For this reason, the manufacturer may make some changes in drawings, descriptions and designs in this manual.
Some expressions are used in the manual for better orientation, i. e. right, left, forward, backward – in the sense of the machine
moving forward.
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SAFETY PRECAUTIONS
GENERALITIES
Read the Operation and Maintenance Instruction Ma-
nual 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 star-
ting, 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 ATTENTION 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 conside-
rably decreases operating hazards and accidents.
Do not allow unauthorised personnel to operate or
service this machine.
Do not wear rings, wrist watches, jewellery, loose or
hanging garments, such as ties, torn clothing, scarves,
unbuttoned or unzipped jackets that can get caught in
moving parts. Wear certified safety clothes such as:
hard hat, no-slip footwear, heavy gloves, ear protecti-
on, 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. 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, telepho-
ne 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.
STARTING
Never start or operate a failed machine. Walk all
around the machine before mounting.
Before operating the machine, make sure that any possi-
ble dangerous condition has been properly removed.
Before starting machine, check that steering and at-
tachment 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 operating area before
starting the machine 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 perfor-
mance or responds abnormally, have the machine chec-
ked for air in the system.
Air in these circuits may cause incorrect movements with
consequent accident hazard. Refer to the Operation and
Maintenance Instruction Manual about corrective action
to be taken.
OPERATING
Do not run the engine of this machine in closed buildings
without proper ventilation capable to remove harmful
exhaust gases which concentrate in the air. Keep the
operator’s compartment free of foreign objects, especi-
ally 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 opera-
ting the attachment. Sound the horn.
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SAFETY PRECAUTIONS
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 obsta-
cles to ensure required visibility conditions. Always
give way to loaded machines.
Maintain a clear vision of the surroundings of the travel
or work area at all times.
Keep cab windows clean and repaired.
When pulling loads or towing through a cable or chain,
do not start suddenly at full throttle. Take-up slack
carefully.
Avoid kinking or twisting chains or cables.
Carefully inspect cables or chains for flaws or problems
before proceeding.
Do not pull through a kinked chain or cable as the high
anomalous stresses existing in this condition may in-
duce 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 enou-
gh to withstand the expected load.
Keep anyone clear of anchor points and cables or
chains.
Do not pull or tow unless the operator’s compart-
ments of the machines involved are properly protec-
ted against possible backlash in case of cable or
chain failure or detachment.
Be alert of soft ground conditions close to newly con-
structed 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 ac-
tion. 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 machi-
ne control could result.
If noise level is high and exceeds 90 dB(A) over 8 hours
at the operator’s ear, wear approved ear protection in
compliance with local regulations.
Do not operate the machine if you are extremely tired
or feel ill.
Be especially careful towards the end of the working
shift. Where removable counterweights are provided,
do not operate the machine if they have been removed.
When operating the machine, keep in mind height
limits of overhead doors, arches, overhead cables and
lines as well as width limits of corridors, roads and
narrow passages. Also, get to know load limits of the
ground and paving type of the ramps you are to work on.
Beware of fog, smoke or dust that obscure visibility.
Always inspect the working area to identify potential
risks such as: inclines, overhangs, trees, demolition
rubble, fires, ravines, steep slopes, rough terrain, dit-
ches, 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 redu-
ce 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 experien-
ce 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. Remem-
ber 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 dis-
continue adherence or traction with the ground, especi-
ally 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.
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.
Ground speed should be adequate to ground condi-
tions.
- Nobody should be allowed to stand within the machine
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 features capacities are referred to the machine on
a level surface and should be disregarded when wor-
king on a slope.
Avoid travelling across slopes. Proceed from uphill
downhill and vice-versa.
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SAFETY PRECAUTIONS
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.
We recommend to work on slopes after checking machi-
ne stability.
Properly judge ground conditions with particular atten-
tion to consistency of the area you are going to work on.
Keep the machine sufficiently far from the ditch edge.
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 obser-
ving the machine, any part of it and/or the load appro-
aching the gas mains from a standpoint more favou-
rable than the Operator’s. This signal man (flagman)
must be in direct communication with the Operator and
the Operator must pay undivided attention to the sig-
nals 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 (in any position) may reach the
minimum safety distance established by local or inter-
national 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 regulati-
ons concerning work near electric lines are observed.
Prior to beginning the work near electric lines:
- Contact the Company owner of the electric lines or its
nearest branch before starting the work.
Look up the in the telephone directory.
- Define together with the Company representative
which precautions should be taken to guarantee work
safety.
- All electric lines should be considered as operative
live lines even though it might be well known that the
line in question is out of work and visibly connected to
the ground.
- The Electric Power Company, if previously advised
and involved in the work, as well as machine Operator,
Owner and/or any natural person or legal entity having
rent or leased the machine or being responsible at the
time by contract or by law, are liable for the adoption of
the necessary precautions.
- Decrease work speed. Reaction time could be too slow
and distance evaluation wrong.
- Warn all ground personnel to keep clear of the machine
at all times.
- Appoint a person in charge of signalling duties.
This person will have the responsibility of observing II
the machine approaching the electric lines from a I
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.
Always check ground conditions and conditions of the
material to be removed. Support everywhere it is requi-
red to prevent possible cave-ins or landslides:
- near previous trenches filled with material, - in bad
ground conditions,
- when working trenches subject to vibration from rail-
roads, working machines or highway traffic.
STOPPING
When the machine is to be stopped for whatever reason,
always check that all controls are in the neutral position
and that the safety lever is on the lock position to
guarantee risk-free start-up.
Never leave the machine unattended with the engine
running.
Prior to leaving the driver’s seat, and after making sure
that all people are clear of the machine, slowly lower the
attachment until resting it safely to the ground. Retract
possible auxiliary tools to the closed safety position.
Check that all controls are in the neutral position. Move
engine controls to the shut-down position. Switch off the
key-start switch. Consult the Operation and Maintenan-
ce 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.
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SAFETY PRECAUTIONS
Securely block and lock the machine every time you
leave it unattended. Return keys to the safe place
previously agreed upon. Perform all necessary opera-
tions for stopping as detailed in the Operation and
Maintenance Instruction Manual.
Drive the machine far from pits, trenches, rocky han-
ging walls, areas with overhead electric lines, and
slopes before stopping it at the end of the working day.
Move all controls to the position specified for machine
stopping. Refer the Operation and Maintenance In-
struction Manual.
Never park on an incline without accurately blocking
the machine to prevent unexpected movement.
Follow stopping instructions contained in the Operati-
on and Maintenance Instruction Manual.
MAINTENANCE
GENERALITIES
Carefully read the Operation and Maintenance Instruc-
tion 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, ope-
rating, repairing, fuelling or servicing the machine. Do
not allow unauthorised personnel to repair or service
the machine.
Follow all recommended maintenance and service
procedures.
Do not wear rings, wrist watches, jewellery, loose or
hanging garments, such as ties, torn clothing, scarves,
unbuttoned or unzipped jackets that can get caught in
moving parts. Wear certified safety clothes such as:
hard hat, no-slip footwear, heavy gloves, ear protecti-
on, 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 oper-
ator 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, espe-
cially if these are not secured.
Should it be necessary to move the attachment for
maintenance purposes, do not raise or lower the at-
tachment 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 abso-
lutely 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 necessa-
ry guards, unless they are suitably and safely locked.
Never lubricate, repair or adjust the machine with the
engine running, except when this is specifically requi-
red by the Operation and Maintenance Instruction Ma-
nual.
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 avai-
lable, 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 requi-
rements.
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 genera-
tion of sparks due to static electricity.
Use a trailer to haul a failed machine. Should it be
necessary to tow it, provide for suitable danger signals
as required by the local norms and regulations and
observe recommendations given in the Operation and
Maintenance Instruction Manual. Load/unload the ma-
chine on firm level ground providing safe support. 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.
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.
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SAFETY PRECAUTIONS
Lift and handle heavy components using hoisting devi-
ces of appropriate capacity. Ensure the parts are sup-
ported 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 regulati-
ons 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 mate-
rials.
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 mu-
shroomed or damaged heads. Always wear eye prote-
ctions 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 driver’s seat at all times while the mechanic is at
work.
Keep hands and clothes far OFF moving parts.
Stop the engine and move the safety lever to the lock
position before starting adjusting or repairing an as-
sembly.
Do not carry out any work on the attachment without
prior authorisation. Observe recommended mainte-
nance 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 at-
tachments. Move the machine to level ground as soon
as possible. Do not twist chains and cables. Never use
a twisted chain or cable for lifting or pulling. Always
wear safety gloves to handle chains or cables. Be sure
chains and cables are firmly fastened and that
the anchor point is strong enough to withstand the
expected load. Keep all bystanders clear of the anchor
point, cables or chains. Do not pull or tow unless the
operator’s compartments of the machines involved
are fitted with proper guards against cable or chain
backlash.
Keep the maintenance area clean and dry at all times.
Clean immediately all water and oil spillage.
Do not pile up oily or greasy rags as they represent a
major fire hazard. Always store them in closed metal
containers.
Before starting the machine or its attachment, check,
adjust and lock the operator’s seat. Also ensure that
nobody is within the machine or attachment operating
range before starting or operating the machine and/or
its attachments. Sound the horn.
Rust inhibitors are volatile and flammable. Prepare
parts in well ventilated areas. Keep open flames away.
Do not smoke. Store containers in a cool well ventilated
place where they could not be reached by unauthorised
people.
Do not carry loose objects in your pockets that might fall
unnoticed into open compartments.
Wear appropriate safety clothing such as hard hat,
safety shoes and gloves, safety glasses when splinters
or other particles may be ejected.
Wear the appropriate welder’s equipment such as dark
safety glasses or mask, hard hat, protective clothing,
safety gloves and footwear always while welding or arc-
cutting. Wear dark safety glasses when you are near a
welding in progress.
Do not look the welding arc without proper eye prote-
ction.
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 possi-
ble 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 produ-
ce steel splinters. Always wear certified protection clo-
thes 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 In-
struction 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 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 possi-
ble hazard. Always support the load onto appropriate
blocking means as a safety measure before proceeding
with service or maintenance work, in compliance with
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SAFETY PRECAUTIONS
local or national safety regulations. Metal cables pro-
duce steel splinters. Always wear certified protection
clothes such as safety gloves and glasses while han-
dling 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 In-
struction Manual for correct maintenance procedure.
Areas near articulated cutting edges where mechani-
cal 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 rea-
son.
Always install the safety stays for the hood and other
hinged covers before performing any maintenance or
repair work in the engine compartment.
TRANSFERS AND TRANSPORTATION
Before moving or transporting the machine, block it to
prevent accidental movement.
Pay particular attention during transfer on inclines,
both uphill and downhill.
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 dimensional limits during transfer or
transportation. Rough terrain may cause the machine
to sway and roll. Cross obstacles at a right angle at low
speed. Pay attention to machine shaking when the
centre of gravity overcomes the obstacle.
Drive with the lights on and use appropriate signals and
flags.
Get to know and respect local and national regulations.
Consider machine dimensions while turning.
Use a ramp to load the machine on a trailer. If a ramp
is not available, fabricate one using blocks. The ramp
should be sufficiently strong to support machine weight.
Always load and unload on level surface.
Tow the machine following the instructions contained in
the Operation and Maintenance Instruction Manual.
ENGINE
Do not run the engine in closed buildings without proper
ventilation capable to remove harmful exhaust fumes.
Do not place head, body, limbs, feet, hands or fingers
near rotating fans or belts. Be especially careful near
blower fans.
Loosen the radiator cap very slowly to relieve system
pressure before removing it. Always top-up coolant
level with the engine off or idling if hot. See the Operation
and Maintenance Instruction Manual.
Keep the exhaust manifold and tube free from combus-
tible matters. Fit the machine with shields and guards
when working in the presence of combustible matter free
in the air.
Do not refuel with the engine running, especially if hot,
as this increases fire hazard in case of fuel spillage.
Never attempt to check or adjust fan belt tensions when
the engine is running.
Do not adjust the fuel injection pump when the machine
is operating.
Do not lubricate the machine with the engine running. Do
not run the engine with the air intakes open and not
protected. If this cannot be avoided for service reasons,
place protection meshes on all intakes before servicing
the engine.
ELECTRICAL SYSTEM
Pay attention to connect connecting cables to correct
poles(+ to +) and(- to -) atboth ends. Do notshort-circuit
terminals. Thoroughly follow instructions given in Ope-
ration and Maintenance Instruction Manual.
Always move the key-start switch in the lock position
before servicing or repairing the machine.
Batteries contain SULPHURIC ACID. Protect the eyes
when working near the batteries against possible sprays
of the acid solution. Should acid contact skin, eyes, or
clothes, RINSE IMMEDIATELY IN WATER FOR AT
LEAST 15 MINUTES. Immediately seek medical
attention.
Battery released gas is highly flammable. Leave the
battery compartment cover open during recharging to
improve ventilation. Never check battery charge by
placing metal objects across the posts. Keep sparks or
open flames away from batteries. Do not smoke near the
battery to prevent explosion hazard.
Before any maintenance or repair, make sure that there
are no fuel or electrolyte leaks from the batteries. If 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 char-
ging.
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SAFETY PRECAUTIONS
Disconnect batteries before working on the electrical
system or carrying out any other type of work.
HYDRAULIC SYSTEM
Pressure fluid escaping from a very small hole can be
almost invisible and still have sufficient force to pene-
trate 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 Maintenan-
ce Instruction Manual.
Always use gauges of adequate capacity for pressure
testing. Refer to the Operation and Maintenance In-
struction Manual or Repair Manual.
TOOLS
Always keep head, body, limbs, feet, hands, and fingers
away from the bucket and attachments, when in the
raised position.
Prior to any maintenance or repair work, install all
supports necessary to this aim according to local and
national safety regulations.
In case the attachment is to be operated for maintenan-
ce or repair purposes, do so exclusively while sitting in
the driver’s seat. Sound the horn before starting the
machine or moving the attachment. Require that nobo-
dy remain near the machine. Raise the attachment
slowly.
Do not use the machine to transport loose objects,
unless proper securing devices are provided.
TYRES AND WHEELS
Make sure that the inflation pressure of the tyres is
according to the specifications issued by the Manu-
facturer and check it periodically.
Should the pressure be changed, stand on the side of
the tyre at a safe distance.
Pressure check operations must be performed with
unloaded machine and cold tyres.
Never use reconditioned tyre rims, since eventual wel-
dings, heat-treatments or repairs not performed cor-
rectly can weaken the wheel, thus causing subsequent
damages or dangers.
Do not perform torch cutting or welding operations on
rims with tyres installed.
Spare tyres must be inflated only as far it is necessary
to keep the rim components assembled; remember that
when not installed on the disc, a tyre inflated to maximum
pressure can explode.
Before operating on tyres, block all wheels, front and
rear. After lifting the machine with the cylinders, block it
with stands according to current safety rules and regu-
lations.
Deflate the tyres before removing them.
Before removing objects from the tyre tread, deflate it.
Do not inflate tyres with flammable gas: they may cause
explosions and serious personal injuries.
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SAFETY PRECAUTIONS
RIRECOGNISE SAFETY INFORMATION
This is your SAFETY SYMBOL ALERT
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
practises.
UNDERSTAND SIGNAL WORDS
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.
DANGER
WARNING
CAUTION
IMPORTANT
NOTE
ENVIRONMENTAL PROTECTION
This Manual also contains this symbol accompanying
instructions for correct behaviour as regards
environmental protection.
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13
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 safety.
Allow only trained, qualified, authorized personnel to
operate the machine.
Keep your machine in proper working condition.
Unauthorized modifications to the machine may impair
the function and/or safety and affect machine life.
The safety messages in this SAFETY PRECAUTIONS
chapter are intended to illustrate basic safety procedures
of hydraulic excavators. However it is impossible for
these safety messages to cover every hazardous
situation you may encounter.
If you have any questions, you should first consult your
supervisor before operating and servicing the machine.
PREPARE FOR EMERGENCIES
Be prepared if a fire starts or an accident occurs.
Keep the first-aid kit and fire extinguisher on hand.
Thoroughly read and understand the label attached to
the fire extinguisher to use it properly.
Establish emergency priority procedures to cope with
fires and accidents.
Keep emergency numbers for doctors, ambulance
service, hospitals and fire department posted near the
telephone.
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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 safety requires the full attention
of one operator. Do not wear radio or music headphones
while operating machine. Wear close fitting clothing and
safety equipment appropriate for the job.
Standard safety equipment includes:
- A hard hat
- Safety shoes
- Safety glasses, goggles, or face shield
- Heavy gloves
- Hearing protection
- Reflective clothing
- Wet weather clothing
- Respirator or filter mask.
Do not take chances. Wear whatever is needed for the
job at hand.
PROTECT AGAINST NOISE
Prolonged exposure to loud noise can cause impairment
or loss of hearing.
Wear a suitable hearing protective device such as earmuffs
or earplugs to protect against constant or uncomfortably
loud noised.
FASTEN SEAT BELT
Should the machine overturn, the operator may become
injured and/or thrown from the cab. Not only, the operator
may be crushed by the overturning machine resulting in
serious injury or oven 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 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.
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SAFETY PRECAUTIONS
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 handholds.
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.
ADJUST THE SEAT
Adjust the seat whenever changing operators. Be sure
that the operator can fully depress the pedals with his
back against the seat back.
If not, move the seat forward and check again.
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”.
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SAFETY PRECAUTIONS
OPERATE ONLY FROM OPERATOR’S SEAT
Avoid possible injury or machine damage. Do not start
the engine by shorting across started terminals.
NEVER start the engine while standing on ground. Start
the engine only from operator’s seat.
KEEP RIDERS OFF MACHINE
Only allow the operator on the machine. Keep riders off.
Riders on machine are vulnerable to injury such as being
struck by foreign objects or being thrown off the machine.
Riders also obstruct the operator’s view, resulting in
unsafe operation.
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SAFETY PRECAUTIONS
AVOID INJURY FROM BACK-OVER AND
SWING ACCIDENTS
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.
Keep travel alarm in working condition (if equipped).
Always be alert for bystanders moving into the work
area. Use horn or other signal to warm 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.
Use a signal person when backing up if you view is
obstructed. Always keep signal person in view.
Use hand signals when work conditions require signal
person.
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.
When operating in potential dangerous areas, or in
areas with low visibility, use a person for machine shifts.
Before starting machine shifting, warm people near the
working area by means of the horn.
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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SAFETY PRECAUTIONS
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.
WORK 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.
RULES FOR ROAD TRANSFER
The machine is equipped with safety locks to be used
for road transfer.
When transferring the machine:
- Locate cylinders as shown in homologation confi-
guration.
- Lock cylinders (cocks, reference marks).
- Lift dozing blade (if equipped).
- Unlock equipment control levers shifting safety
device lever to lock position.
On the road follow the rules regulating traffic.
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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 R.O.P.S.
(Roll Over Protective Structure) cab before working in
areas where there is the possibility of falling stones or
landslides.
WORKING ON SLOPES
Never go down on slopes with gearbox in neutral. You
might loose control and cause serious injuries or death.
When going down on slopes, use a low gear. In this
way the engine is used as brake and holds the machine
without overloading brakes.
When working on a slope and the warning light for fuel
insufficient level lights up, fill the tank immediately.
Due to machine inclination, the engine can suct air and
stop suddenly, causing a serious danger to the
operator and the persons behind the machine.
If the engine stops suddenly, apply brakes and lower
immediately the blade to the ground.
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20
SAFETY PRECAUTIONS
AVOID TIPPING
When operating on a slope, keep blade low to ground
and close to machine.
To avoid tipping:
- Be extra careful before operating on a grade.
- Prepare machine operating area flat by grading.
- Keep the blade low to the ground and close to
the machine.
- Reduce machine operating speed to avoid tipping
or slipping.
- Never attempt to travel across a grade steeper
than 15 degrees.
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 levers.
Before moving the machine, confirm which way to move
pedals/levers for the corresponding direction you wish
to go.
When traveling up or down a grade, keep the blade in
the direction of travel, approximately 20 to 30 cm (A)
above the ground.
BEWARE OF EXHAUST FUMES
Engine exhaust fumes can cause sickness or death.
If you must operate in a building, be sure there is
adequate ventilation.
Either use an exhaust pipe extension to remove the
exhaust fumes or open doors and windows to bring
enough outside air into the area.
A
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