New Holland Kobelco E215b E245b Workshop Manual Compress 1

E215B
E245B
Workshop
Manual
Workshop
Manual
Print No. 87677762A

English - Printed in Italy
E215B
E245B PROVEN PERFORMANCE
E215B
E245B
WORKSHOP MANUAL
M0103
All the information and data contained in this manual are based upon most recent information available at the
time of its publication.
NEW HOLLAND KOBELCO has the right to implement, at any time, any modification without providing any
communication.
NEW HOLLAND KOBELCO CONSTRUCTION MACHINERY S.p.A. - Product Support

Print No. 87677762A
Edition - June 2007
INTRODUCTION E215B-E245B
TO THE READER
• This manual is written for an experienced - If you have any questions or comments, or if you
technician to provide technical information found any errors regarding the contents of this
needed to maintain and repair this machine. manual, please contact:
- Be sure to thoroughly read this manual for NEW HOLLAND KOBELCO

correct information concerning the service CONSTRUCTION MACHINERY S.p.A.
procedures. Strada Settimo, 323
San Mauro Torinese (TO)
10099 ITALIA
PRODUCT SUPPORT
Fax. ++39 011 0077357
ADDITIONAL REFERENCES
• Please refer to the materials listed below in

addition to this service manual:
- Operation and Maintenance Instruction

Manual
- Parts Catalog
WORKSHOP MANUAL COMPOSITION
• The Workshop Manual consists of five parts: - The “Operational Performance Test” part includes
- “Safety Precautions” the information needed to carry out the machine
operational performance test.
- “Operational Principle”
- “Operational Performance Test”
- The “Troubleshooting” part includes the technical
- “Troubleshouting”
information needed for troubleshooting and
- “Repair Instructions” malfunction detection.
- The “Safety Precaution” part includes the - The “Repair Instruction” part includes information
recommended procedures that, if followed, can needed for maintenance and repair of the
avoid the risk of accident for operator and for staff machine, tools and devices needed for
related to the work and maintenance machine maintenance and repair, maintenance standards,
operations. removal/installation and assembly/disassembly
procedures.
- The “Operational Principle” part includes the
technical information concerning the operation of
main devices and systems.
IN - 1
E215B-E245B INTRODUCTION
PAGE NUMBER
• Each page has a number, located on the external upper corner of the page. Each page number contains the
following information:
Example: T 1-2-3
Consecutive page number for each group
Group number (if exist))
Section number
T: Technical Manual
W: Workshop Manual
SYMBOLS
In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential
for personal injury or machine damage.
This is the safety alert symbol.

When you see this symbol, be alert to the potential for personal injury.
Never fail to follow the safety instructions prescribed along with the safety alert symbol.
The safety alert symbol is also used to draw attentio in to component/part weights.
To avoid injury and damage, be sure to use appropriate lifting techniques and equipment when lifting
heavy parts.
UNITS USED
SI Units (International System of Units) are used in this manual.

MKSA system units and English units are also indicated in parentheses just behinds SI units.
Example: 24.5 MPa (250 kgf/cm2)
A table for conversion from SI units to other system units is shown below for reference purposes.
Quantity To convert from Into Multiply by Quantity To convert from Into Multiply by
(SI) (Others) (SI) (Others)
Lenght mm in 0.03937 Pressure MPa kgf/cm2 10.197
mm ft 0.003281 MPa psi 145.0
Volume L US gal 0.2642 Power kW CV-PS 1.360
L US qt 1.057 kW HP 1.341
m3 yd3 1.308 Temperature °C °F °C x 1.8 + 32
Mass kg lb 2.205 Velocity km/h mph 0.6214
Force N kgf 0.10197 min-1 rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque N.m kgf.m 0.10197 mL/rev cc/rev 1.0
N.m lbf.ft 0.7375
IN - 2
INDEX E215B-E245B
MANUAL INDEX
SAFETY PRECAUTIONS Page
Section 1 GENERALITIES ..................................................................... S1

Section 2 SAFETY PRECAUTIONS ..................................................... S2
Section 3 SAFETY PLATES .................................................................. S3
OPERATIONAL PRINCIPLE
Section 1 GENERAL
Group 1 Specifications................................................................................. T1-1
Group 2 Component Layout ........................................................................ T1-2
Section 2 SYSTEM
Group 1 Mechatro control system................................................................ T2-1
Group 2 Hydraulic System........................................................................... T2-2
Group 3 Electrical System ........................................................................... T2-3
Section 3 COMPONENT OPERATION

Group 1 Hydraulic Pump Assy..................................................................... T3-1
Group 2 Pilot Valve ...................................................................................... T3-2
Group 3 Control Valve ................................................................................. T3-3
Group 4 Swing Device ................................................................................. T3-4
Group 5 Travel Device ................................................................................. T3-5
Group 6 Swivel Joint.................................................................................... T3-6
Group 7 Cylinders........................................................................................ T3-7
Group 8 Air Conditioner system................................................................... T3-8
OPERATIONAL PERFORMANCE TEST

Section 4 OPERATIONAL PERFORMANCE TEST
Group 1 Introduction ................................................................................... T4-1
Group 2 Standard Performances ................................................................. T4-2
Group 3 Test Procedures ............................................................................ T4-3
Group 4 Mechatro Controller ....................................................................... T4-4
TROUBLESHOOTING
Section 5 TROUBLESHOOTING
Group 1 Troubleshooting (by error codes)................................................... T5-1
Group 2 Troubleshooting (by trouble) .......................................................... T5-2
Group 3 Troubleshooting (trouble diagnosis mode)..................................... T5-3
E215B-E245B INDEX
REPAIR INSTRUCTIONS
Section 1 GENERAL INFORMATION

Group 1 Precautions for Disassembly and Assembly.................................W1-1
Group 2 Tightening Torque ........................................................................W1-2
Section 2 UPPERSTRUCTURE
Group 1 Upperstructure ..............................................................................W2-1
Group 2 Pump Device.................................................................................W2-2
Group 3 Control Valve ................................................................................W2-3
Group 4 Swing Device ...............................................................................W2-4
Group 5 Pilot Valve .....................................................................................W2-5
Section 3 UNDERCARRIAGE
Group 1 Swing Bearing ..............................................................................W3-1
Group 2 Travel Device ...............................................................................W3-2
Group 3 Swivel Joint ..................................................................................W3-3
Group 4 Track Adjuster ..............................................................................W3-4
Group 5 Front Idler .....................................................................................W3-5
Group 6 Upper and Lower Roller ...............................................................W3-6
Group 7 Tracks ...........................................................................................W3-7
Section 4 FRONT ATTACHMENT

Group 1 Front attachment...........................................................................W4-1
SAFETY PRECAUTIONS
M0103
SAFETY PRECAUTIONS E215B-E245B
INDEX
Section 1 GENERALITIES
Section 2 SAFETY PRECAUTIONS
Section 3 SAFETY PLATES

GENERALITIES E215B-E245B
SAFETY PRECAUTIONS
GENERALITIES
Read the Operation and Maintenance Instruction Do not leave the machine until it has come to a
Manual carefully before starting, operating, complete stop.
maintaining, fuelling or servicing the machine. Always check height, width and weight limitations
Carefully read the explanation to each and all safety which may be encountered in the working site and
signs in the special section of this Manual before ensure the machine does not exceed them.
starting, operating, maintaining, fuelling or servicing Assess exact paths of gas ducts, water mains,
the machine. telephone lines, sewers, overhead and underground
Machine-mounted safety plates are colour coded electric lines and all other possible obstacles.
yellow with black borders when they refer to points Such paths should be opportunely defined by
where special ATTENTION must be paid and failure competent Authorities. If necessary, require that the
to observe them may cause a serious DANGER to service is interrupted or said installations are moved
the integrity of machine operators. They are white prior to starting the work.
with red borders and black lettering when they refer
You must know the working capacity of the machine.
to a FORBIDDEN practice.
Define the rear upperstructure swing area and
It is fundamental that all machine operators know
provide for opportune barriers to prevent access into
very well the meaning of each safety plate as this
it.
considerably decreases operating hazards and
accidents. Never exceed machine lifting capacity.
Do not allow unauthorised personnel to operate or Remain within the limits shown in the loading
service this machine. capacity chart which located on the 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 STARTING
caught in moving parts. Wear certified safety clothes Never start or operate a failed machine. Walk all
such as: hard hat, no-slip footwear, heavy gloves, ear around the machine before mounting.
protection, safety glasses, reflector vests, respirators Before operating the machine, make sure that any
every time the job requires it. Ask your employer possible dangerous condition has been properly
about safety regulations in force and protective removed. Before starting machine, check that
equipment. steering and attachment controls are in the neutral
Always keep the operator’s compartment, step position and the safety lever is in the LOCK position.
plates, grab-rails and handles clean and clear of Immediately report any malfunction of parts or
foreign objects, oil, grease, mud or snow to minimise systems to the maintenance managers for proper
the danger of slipping or stumbling. Remove mud or action.
grease from your shoes before operating the Prior to starting the engine, check, adjust and lock the
machine. driver’s seat for maximum riding comfort and control
Do not jump on or off the machine. Always keep both accessibility. Prior to operating the machine and/or
hands and one foot, or both feet and one hand in its attachments, check that bystanders are outside
contact with steps and/or grab rails. the machine operating range. Sound the horn.
Do not use controls or hoses as hand holds. Hoses Obey all hand signals, safety indications and signs.
and controls are movable parts and do not provide Due to the presence of flammable fluids, never
solid support. Besides, controls may be inadvertently check fuel level, refuel, charge the batteries in the
moved and cause unexpected movement of the presence of smoking materials, open flames or
machine or its attachments. sparks.
Never operate the machine or its attachments from Ensure that nobody is within the excavator operating
any position other than sitting in the driver’s seat. area before starting the machine, swinging the upper
Keep head, body, limbs, hands and feet inside the structure or moving in any direction.
operator’s compartment at all times to reduce Adjust all rear-view mirrors for maximum visibility of
exposure to external hazards. the area behind the machine.
Be careful of possible slippery conditions of the steps Ensure that engine speed is appropriate to the job to
and hand rails as well as of the ground around the be carried out.
machine. Wear protective boots or shoes with the
soles made of highly no-slip rubber
S1 - 1
E215B-E245B GENERALITIES
If any hydraulic control or system exhibits erratic properly protected against possible backlash in
performance or responds abnormally, have the case of cable or chain failure or detachment.
machine checked for air in the system. Be alert of soft ground conditions close to newly
Air in these circuits may cause incorrect movements constructed walls. The fill material and machine
with consequent accident hazard. Refer to the weight may cause the wall to collapse under the
Operation and Maintenance Instruction Manual machine.
about corrective action to be taken. In darkness, check area of operation carefully before
moving in with the machine. Use all lights provided.
Do not move into low visibility areas.
OPERATING 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
Do not run the engine of this machine in closed proper action.
buildings without proper ventilation capable to
Do not operate the machine until this condition is
remove harmful exhaust gases which concentrate in
corrected. Regularly check all exhaust system
the air.
components, as exhaust fumes are toxic for the
Keep the operator’s compartment free of foreign operator.
objects, especially if not firmly secured. Never use
Operators must know the performance of the
the machine to transport objects, unless proper
machine they are driving. When working on slopes or
securing points are provided.
near sudden level drops in the terrain, pay attention
Do not carry riders on the machine. Study and not to lose adherence and avoid loose soft ground
familiarise with escape routes alternative to normal since overturn or loss of machine control could result.
exit routes. For your personal safety, do not climb on
If noise level is high and exceeds 90 dB (A) over 8
or off the machine while it is in motion.
hours at the operator’s ear, wear approved ear
Make sure that bystanders are clear of the machine protection in compliance with local regulations.
operating range before starting the engine and
Do not operate the machine if you are extremely tired
operating the attachment. Sound the horn.
or feel ill. Be especially careful towards the end of the
Obey all hand signals, safety indications and signs. working shift.
When backing, always look to where the machine is Where removable counterweights are provided, do
to be moved. not operate the machine if they have been removed.
Be alert of the position of bystanders. Should When operating the machine, keep in mind height
someone enter the work area, stop the machine. limits of overhead doors, arches, overhead cables
Maintain a safe distance from other machines or and lines as well as width limits of corridors, roads
obstacles to ensure required visibility conditions. and narrow passages.
Always give way to loaded machines. Also, get to know load limits of the ground and
Maintain a clear vision of the surroundings of the paving type of the ramps you are to work on.
travel or work area at all times. Keep cab windows Beware of fog, smoke or dust that obscure visibility.
clean and repaired.
Always inspect the working area to identify potential
When pulling loads or towing through a cable or risks such as: inclines, overhangs, trees, demolition
chain, do not start suddenly at full throttle. Take-up rubble, fires, ravines, steep slopes, rough terrain,
slack carefully. Avoid kinking or twisting chains or ditches, crowns, ridge trenches,diggings in traffic
cables. areas, crowded parking lots, crowded service areas,
Carefully inspect the towing items for flaws or fenced zones. In such conditions, proceed with
problems before proceeding. Do not pull through a extreme care.
kinked chain or cable as the high anomalous stresses Whenever possible, avoid crossing over obstacles
existing in this condition may induce failures in the such as very rough terrain, rocks, logs, steps,
kinked portion. ditches, railroad tracks.
Always wear heavy gloves when handling chains or When obstructions must be crossed, do so with
cables. extreme care and at a square angle, if possible. Slow
Chains and cables should be securely anchored down.
using suitable hooks. Anchor points should be strong Ease up to the break-over point, pass the balance
enough to withstand the expected load. point slowly and ease down the other side also using
Keep anyone clear of anchor points and cables or the attachment, if necessary.
chains. To overcome deep trenches or sinking ground, place
Do not pull or tow unless the operator’s the machine perpendicular to the obstacle, drastically
compartments of the machines involved are reduce ground speed and start crossing using also
S1 - 2
the attachment if necessary, only after assessing that The load must always be properly arranged in the
ground conditions allow the traverse safely and bucket; move with extreme care when transporting
without risks. oversize loads.
The gradient you may attempt to overcome is limited Do not lift and move the bucket overhead where
by factors such as ground conditions, load being persons are standing or working, nor downhill when
handled, machine type and speed, and visibility. working on a slope as this would decrease machine
There is no substitute for good judgement and stability. Load the bucket from the uphill side.
experience when working on slopes. Loads to be raised using the machine should be
Avoid operating the attachment too close to an exclusively hooked to the hitch specially provided.
overhang or high wall, either above or below the The excavator is no lifting and transportation means,
machine. Beware of caving edges, falling objects therefore it should not be used to position loads
and landslides. Remember that such hazards are accurately. Should it be exceptionally used to lift and
likely to be concealed by bushes, undergrowth and lay building components, special caution must be
such. taken as follows:
Avoid faggots, bushes, logs and rocks. Never drive
over them, nor over any other surface irregularities
- The machine must be equipped compulsorily with
that discontinue adherence or traction with the
the appropriate variant provided upon request.
ground, especially near slopes or drop-offs.
- Secure the loads to be raised using cables or
Be alert to avoid changes in adherence conditions
chains fastened with appropriate hooking
that could cause loss of control. Work with extreme
mechanisms.
care on ice or frozen ground and on stepped slopes
or near drop-offs. - Nobody should be allowed to remain under the
raised load or within the excavator operating range
The word “bulldozing” generally refers to work in
for any reason whatever.
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 Never exceed specified loading capacity. Incorrect
tree limbs (possibly falling on the machine) and large fastening of slings or chains may cause boom/arm
roots (which may act as a leverage under the failure or failure of the lifting means with consequent
machine when up-rooted and cause the unit to bodily injuries and even death.
overturn). Always ensure that slings and chains used for lifting
Position the machine dependent upon the loading are adequate to the load and in good condition.
and unloading areas in order to swing leftwards to All loading capacities are referred to the machine
load to obtain best visibility. on a level surface and should be disregarded
Never use the bucket or attachment as a man lift when working on a slope.
or carry riders. Never use the machine as a work Avoid travelling across slopes. Proceed from uphill
platform or scaffolding. The machine must not be downhill and vice-versa. If machine starts slipping
improperly used for works not consistent with its sideways when on a slope, lower the bucket and
features (such as pushing railway cars, trucks or thrust bucket teeth into the ground.
other machines).
Working on slopes is dangerous. Grade the working
Always pay attention to people within the machine area if possible. Reduce work cycle time if it is not
operating range. possible to grade the working area.
Never move or stop the bucket, other loads or the Do not move full bucket or a load from uphill downhill
attachment above ground personnel or truck cabs. as this would reduce machine stability. Do not work
Ensure the truck driver is in a safe place before with the bucket turned to the uphill side.
loading the truck. Do not work with the bucket turned uphill as
Load trucks from side or rear. counterweights protruding downhill would reduce
Use only the type of bucket recommended machine stability on the slope and increase risk of
considering machine type, materials to be handled, overturning.
material piling up and loading characteristics, ground We recommend to work on slopes with the bucket
type and other typical conditions of the work to be downhill, after checking machine stability with the
performed. bucket empty and attachment retracted, by slowly
When transporting a loaded bucket, keep it as swinging the upper structure by 360°.
rolled-back as possible. Keep boom and arm as low Position the carriage at a right angle relative to
as possible. slopes, hanging walls, etc. to exit the working area
Ground speed should be adequate to the load and easily.
ground conditions. Standard use, provides for the travel controls at the
front and travel motors at the back. Should travel
S1 - 3
motors be positioned at the front with regard to the - Look up the in the telephone directory.
actual travel direction. Remind relative to travel - Define together with the Company representative
direction that controls are reversed. which precautions should be taken to guarantee
Always check travel motor position before moving off. work safety.
Properly judge ground conditions with particular - All electric lines should be considered as operative
attention to consistency of the area you are going to live lines even though it might be well known that
work on. the line in question is out of work and visibly
Keep the machine sufficiently far from the ditch connected to the ground.
edge. - The Electric Power Company, if previously advised
Never dig under the machine. and involved in the work, as well as machine
Operator, Owner and/or any natural person or legal
Should it be necessary to dig under the machine,
entity having rent orleased the machine or being
always ensure that digging walls are opportunely
responsible at the time by contract or by law, are
propped up against landslide to prevent the machine
liable for the adoption of the necessary
from falling into the trench.
precautions.
Do not swing the upperstructure, raise the load or
- Decrease work speed. Reaction time could be too
brake abruptly if not required. This may cause
slow and distance evaluation wrong.
accidents.
- Warn all ground personnel to keep clear of the
Prior to beginning the work near gas distribution
machine and/or load at all times. If the load has to
mains or other public utilities:
be guided down for laying, consult the Electric
- Contact the company owner of the gas mains or its Power Company to know which precautions should
nearest branch before starting the work. Look up be taken.
the number in the telephone directory.
- Appoint a person in charge of signalling duties.
- Define together which precautions should be taken This person will have the responsibility of observing
to guarantee work safety. the machine, any part of it and/or the load
- Decrease work speed. Reaction time could be too approaching the electric lines from a standpoint
slow and distance evaluation wrong. more favourable than the Operator’s. This signal
- When working near gas mains or other public man (flag-man) must be in direct communication
utilities installations, appoint a person in charge of with the Operator and the Operator must pay
signalling duties. This person will have the undivided attention to the signals supplied.
responsibility of observing the machine, any part of When working in or near pits, in ditches or very high
it and/or the load approaching the gas mains from walls, check that the walls are sufficiently propped up
a standpoint more favourable than the Operator’s. to avoid cave-in hazards.
This signal man (flag-man) must be in direct Pay the utmost attention when working near
communication with the Operator and the Operator overhang walls or where landslides may take place.
must pay undivided attention to the signals Make sure that the support surface is strong enough
supplied. to prevent landslides.
- The gas distributing Company, if previously When digging, there is the risk of cave-ins and
advised and involved in the work, as well as landslides.
machine Operator, Owner and/or any natural
Always check ground conditions and conditions of
person or legal entity having rent or leased the
the material to be removed. Support everywhere it is
machine or being responsible at the time by
required to prevent possible cave-ins or landslides
contract or by law, are liable for the adoption of the
when:
necessary precautions.
- Digging near previous trenches filled with material.
Working near electric lines can be very dangerous,
therefore some special precautions must be - Digging in bad ground conditions.
observed. - Digging trenches subject to vibration from
Within this Manual, “work near electric lines” means railroads, working machines or highway traffic.
when the attachment or load raised by the excavator
(in any position) may reach the minimum safety
distance established by local or international Safety
STOPPING
Regulations.
To work without risks, keep maximum possible
distance from electric lines and never trespass When the machine is to be stopped for whatever
minimum safety distance. reason, always check that all controls are in the
neutral position and that the safety lever is on the lock
- Contact the Company owner of the electric lines or
position to guarantee risk-free start-up.
its nearest branch before starting the work.
S1 - 4
Never leave the machine unattended with the engine Read all safety plates mounted on the machine and
running. observe instructions they contain before starting,
Prior to leaving the driver’s seat, and after making operating, repairing, fuelling or servicing the
sure that all people are clear of the machine, slowly machine.
lower the attachment until resting it safely to the Do not allow unauthorised personnel to repair or
ground. Retract possible auxiliary tools to the closed service the machine.
safety position. Follow all recommended maintenance and service
Check that all controls are in the neutral position. procedures.
Move engine controls to the shut-down position. Do not wear rings, wrist watches, jewellery, loose or
Switch off the key-start switch. Consult the Operation hanging garments, such as ties, torn clothing,
and Maintenance Instruction Manual. scarves, unbuttoned or unzipped jackets that can get
Park the machine in a non-operating and no-traffic caught in moving parts. Wear certified safety clothes
area. Park on firm level ground. If this is not possible, such as: hard hat, no-slip footwear, heavy gloves, ear
position the machine at a right angle to the slope, protection, safety glasses, reflector vests, respirators
making sure there is no danger of uncontrolled when required. Ask your employer about safety
sliding. regulations in force and protective equipment.
If parking in traffic lanes cannot be avoided, provide Do not use controls or hoses as hand holds. Hoses
appropriate flags, barriers, flares and other signals as and controls are movable parts and do not provide
required to adequately warn the oncoming drivers. solid support. Besides, controls may be inadvertently
Always switch off the key-start switch before moved and cause unexpected movement of the
cleaning, repairing, or parking the machine to prevent machine or its attachments.
accidental unauthorised start-up. Do not jump on or off the machine. Always keep both
Never lower the attachment or auxiliary tools other hands and one foot, or both feet and one hand in
than from sitting in the operator’s seat. Sound the contact with steps and/or grab rails.
horn. Make sure that nobody is within the machine Never service the machine with someone sitting in
operating range. Lower the attachment slowly. the driver’s seat, unless this person is an authorised
Securely block and lock the machine every time you operator assisting in the maintenance being carried
leave it unattended. Return keys to the safe place out.
previously agreed upon. Perform all necessary Keep the operator’s compartment, step plates, grab
operations for stopping as detailed in the Operation rails and handles clear of foreign objects, oil, grease,
and Maintenance Instruction Manual. mud orsnow to minimise the danger of slipping or
Drive the machine far from pits, trenches, rocky stumbling.
hanging walls, areas with overhead electric lines, and Clean mud or grease from your shoes before
slopes before stopping it at the end of the working climbing on the machine or driving it.
day. Never attempt to operate the machine or its
Align the upperstructure to the tracks in order to allow attachments from any position other than sitting in the
to easily get on and off the driver’s compartment. operator’s seat.
Move all controls to the position specified for machine Keep the driver’s seat free from foreign objects,
stopping. Refer the Operation and Maintenance especially if these are not secured.
Instruction Manual. Should it be necessary to move the attachment for
Never park on an incline without accurately blocking maintenance purposes, do not raise or lower the
the machine to prevent unexpected movement. attachment from any other position than sitting in the
Follow stopping instructions contained in the operator’s seat. Before starting the machine or
Operation and Maintenance Instruction Manual. 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
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
GENERALITIES
attachment. If you are not absolutely sure about your
safety, do not stay or walk under a raised attachment.
Carefully read the Operation and Maintenance Do not place head, body, limbs, hands, feet or fingers
Instruction Manual before starting, operating, near articulated cutting edges deprived of the
maintaining, fuelling or servicing the machine in any necessary guards, unless they are suitably and
manner. safely locked.
S1 - 5
Never lubricate, repair or adjust the machine with the flammable fluids to clean parts. Use proprietary
engine running, except when this is specifically certified non-flammable, non-toxic solvents only.
required by the Operation and Maintenance When using compressed air to clean parts, wear
Instruction Manual. safety glasses with side shields. Limit pressure to
Do not wear loose clothing, jewellery near rotating max. 2 bars, in accordance with local and national
parts. safety regulations in force.
When service or maintenance require access to Do not run the engine of this machine in closed
areas that cannot be reached from the ground, use a buildings without proper forced ventilation capable to
ladder or step platform conforming to local or national remove toxic exhaust gases concentrating in the air.
regulations to reach the working area. If such means Do not smoke, nor allow open flames or sparks
are not available, use machine grab rails and steps. nearby while refuelling the unit or handling highly
Always perform all service or maintenance work with flammable materials.
the greatest care and attention.
Do not use open flames as light sources to look for
Shop and/or field service platforms or ladders should leaks or inspect anywhere on the machine.
be manufactured and maintained in accordance with
Make sure that all mechanical tools provided are in
local or national safety regulations in force.
good condition at all times. Never use tools with
Disconnect batteries and label all controls to warn mushroomed or damaged heads. Always wear eye
that service work is in progress, according to local protections with side shields.
and national safety regulation requirements.
Move with extreme care when working under, on or
Block the machine and all attachments to be raised near the machine or its attachments.
according to local and national safety regulation
In case of attachment tests during which the engine
requirements.
should be kept running, a qualified operator must sit
Do not check or fill fuel tanks or install batteries near in the driver’s seat at all times while the mechanic is
burning or smoking materials and open flames due to at work.
the presence of flammable vapours.
Keep hands and clothes far off moving parts.
The fuel filler pipe nozzle must be constantly kept in
Stop the engine and move the safey lever to the lock
contact with the filler neck and this even before fuel
position before starting adjusting or repairing an
starts flowing in. Keep this contact from the beginning
assembly.
to the end of the fuelling operation to avoid possible
generation of sparks due to static electricity. Do not carry out any work on the attachment without
prior authorisation. Observe maintenance and repair
Use a truck or trailer to haul a failed machine. Should
procedures.
it be necessary to tow it, provide for suitable danger
signals as required by the local norms and In case of field service, move the machine to level
regulations and observe recommendations given in ground and block it. If work on an incline cannot be
the Operation and Maintenance Instruction Manual. avoided, securely block the machine and its
Load/unload the machine on firm level ground attachments. Move the machine to level ground as
providing safe support to the wheels of the truck or soon as possible.
trailer. Use strong access ramps, with adequate Do not twist chains and cables. Never use a twisted
height and angle. Keep the trailer flatbed free of mud, chain or cable for lifting or pulling. Always wear safety
oil or slippery materials. Tie the machine securely to gloves to handle chains or cables.
the trailer and block carriages and upperstructure. Be sure chains and cables are firmly fastened and
Never align holes or slots using your fingers; that the anchor point is strong enough to withstand
alwaysuse appropriate aligning tools. the expected load.
Remove all sharp edges and burrs from re-worked Keep all bystanders clear of the anchor point, cables
parts. or chains. Do not pull or tow unless the operator’s
Use only approved and effectively grounded auxiliary compartments of the machines involved are
power sources for heaters, battery chargers, pumps fitted with proper guards against cable or chain
and similar equipment to reduce electrical shock backlash.
hazard. Keep the maintenance area clean and dry at all
Lift and handle heavy components using hoisting times.
devices of appropriate capacity. Ensure the parts are Clean immediately all water and oil spillage.
supported by appropriate straps and hooks. Do not pile up oily or greasy rags as they represent a
Use lifting eyes provided to this aim. major fire hazard. Always store them in closed metal
Pay attention to bystanders near the lifting area. containers.
Never pour gasoline or diesel fuel into open Before starting the machine or its attachment, check,
containers. Never use gasoline, solvents or other adjust and lock the operator’s seat. Also ensure that
nobody is within the machine or attachment
S1 - 6
operating range before starting or operating the injuries are most likely to occur. Pay attention to
machine and/or its attachments. prevent possible part movements by means of
Sound the horn. blocks or by keeping clear of such zones when
motion may take place during maintenance or repair.
Rust inhibitors are volatile and flammable.
Move the hydraulic system lock safety lever to the
Prepare parts in well ventilated areas. Keep open
lock position when stopping the machine for
flames away.
whatever reason.
Do not smoke.
Always install the safety stays for the hood and other
Store containers in a cool well ventilated place where hinged covers before performing any maintenance or
they could not be reached by unauthorised people. repair work in the engine compartment.
Do not carry loose objects in your pockets that might
fall unnoticed into open compartments.
Wear appropriate safety clothing such as hard hat,
TRANSFERS AND TRANSPORTATION
safety shoes and gloves, safety glasses when
splinters or other particles may be ejected.
Wear the appropriate welder’s equipment such as Before moving or transporting the machine, block
dark safety glasses or mask, hard hat, protective upperstructure swing to prevent accidental
clothing, safety gloves and footwear always while movement.
welding or arc-cutting. Wear dark safety glasses Pay particular attention during transfer on inclines,
when you are near a welding in progress. both uphill and downhill. Keep the bucket in a position
Do not look the welding arc without proper eye to provide a possible anchor point into the ground in
protection. case of slipping.
Become acquainted with all your jacking equipment During transfers on inclines, both uphill and downhill,
and their capacity. keep the upperstructure aligned with the carriages.
Do not travel across the slope.
Ensure that the jacking point on the machine is
appropriate for the load applied. Also, be sure the Never transfer the machine in the working site, in a
supports under the jack and between the jack and the crowded area, or near people without having at least
machine are appropriate and stable. one person charged with hand-signals who could
guide the Operator.
Any equipment supported by a jack represents a
possible hazard. Always support the load onto Sound the horn to inform that you are about to move
appropriate blocking means as a safety measure off.
before proceeding with service or maintenance work, It is necessary to know load limits of bridges and
in compliance with local or national safety dimensional limits of tunnels. Such limits must never
regulations. be exceeded. You should also know machine height,
Metal cables produce steel splinters. Always wear width, and weight. Have a signal-man help you when
certified protection clothes such as safety gloves and clearances are limited.
glasses while handling them. Check distance between boom/arm and dimensional
Do not use makeshift jacks to adjust track sag. Follow limits during transfer or transportation.
instructions given in the Repair Manual. Rough terrain may cause the machine to sway and
Handle all parts carefully. Keep hands and fingers roll to such an extent that boom/arm could get to
away from gaps, gears, and similar. Always use and contact electric lines or other obstacles. Cross
wear certified safety clothes such as safety glasses, obstacles at a right angle at low speed. Pay attention
gloves and footwear. to machine shaking when the centre of gravity
overcomes the obstacle.
The attachment is kept constantly in position by an oil
column trapped into the high pressure circuit. Lower Keep the bucket down at all times during transfers.
the attachment to the ground and relieve pressure Drive with the lights on and use appropriate signals
from all circuits prior to carrying out any type of and flags.
maintenance or repair work. Get to know and respect local and national
Do not service or repair the machine if it is parked regulations.
downhill. If this is unavoidable, in case of emergency, Consider boom/arm and upperstructure dimensions
block the carriages to prevent unexpected while turning.
movement, particularly if the work is to be carried out
Use a ramp to load the machine on a trailer. If a ramp
on the final reduction units or travel motors.
is not available, fabricate one using blocks. The ramp
Consult the Operation and Maintenance Instruction should be sufficiently strong to support machine
Manual for correct maintenance procedure. weight. Always load and unload on level surface.
Areas near articulated cutting edges where
mechanical parts are in motion are where personal
S1 - 7
Tow the machine following the instructions contained Before any maintenance or repair, make sure that
in the Operation and Maintenance Instruction there are no fuel or electrolyte leaks from the
Manual. 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
ENGINE explosive gas released during charging.
Disconnect batteries before working on the electrical
Do not run the engine in closed buildings without system or carrying out any other type of work.
proper ventilation capable to remove harmful exhaust
fumes.
Do not place head, body, limbs, feet, hands or fingers
HYDRAULIC SYSTEM
near rotating fans or belts. Be especially careful near
blower fans.
Loosen the radiator cap very slowly to relieve system Pressure fluid escaping from a very small hole can be
pressure before removing it. Always top-up coolant almost invisible and still have sufficient force to
level with the engine off or idling if hot. See the penetrate the skin. Always check any suspected
Operation and Maintenance Instruction Manual. pressure leaks using a piece of cardboard or wood.
Keep the exhaust manifold and tube free from Do not use hands. If injured by escaping fluid, obtain
combustible matters. Fit the machine with shields medical attention immediately or serious infection or
and guards when working in the presence of reaction may develop.
combustible matter free in the air. Stop the engine and ensure pressure is relieved from
Do not refuel with the engine running, especially if all systems before removing side panels, housings,
hot, as this increases fire hazard in case of fuel guards and covers. See the Operation and
spillage. Maintenance Instruction Manual.
Never attempt to check or adjust fan belt tensions Always use gauges of adequate capacity for
when the engine is running. pressure testing. Refer to the Operation and
Maintenance Instruction Manual or Repair Manual.
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 TOOLS
before servicing the engine.
Always keep head, body, limbs, feet, hands, and

ELECTRICAL SYSTEM fingers away from the bucket and attachments, when
in the raised position.
Pay attention to connect connecting cables to correct Prior to any maintenance or repair work, install all
poles (+ to +) and (- to -) at both ends. Do not short- supports necessary to this aim according to local and
circuit terminals. Thoroughly follow instructions given national safety regulations.
in Operation and Maintenance Instruction Manual. In case the attachment is to be operated for
Always move the key-start switch in the lock position maintenance or repair purposes, do so exclusively
before servicing or repairing the machine. while sitting in the driver’s seat. Sound the horn
Batteries contain SULPHURIC ACID. Protect the before starting the machine or moving the
eyes when working near the batteries against attachment. Require that nobody remain near the
possible sprays of the acid solution. Should acid machine. Raise the attachment slowly.
contact skin, eyes, or clothes, RINSE IMMEDIATELY Do not use the machine to transport loose objects,
IN WATER FOR AT LEAST 15 MINUTES. unless proper securing devices are provided.
Immediately seek medical attention. Never use gases other than nitrogen to charge the
Battery released gas is highly flammable. Leave accumulators.
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.
S1 - 8
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.
UNDERSTAND SIGNAL WORDS
• In this Manual you will find the following words

referring to different hazard risks:
- DANGER;
- WARNING;
- CAUTION.
These words are always accompanied by the safety DANGER
alert symbol.
DANGER: indicates an imminent hazardous

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

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

which, if not avoided, may result in minor or
moderate injury.
NOTE
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.
S2 - 1
E215B-E245B SAFETY PRECAUTIONS
FOLLOW SAFETY PRECAUTIONS
• Carefully read and observe all safety signs on the

machine and read all safety precautions in this
Manual.
• Safety signs should be installed, maintained, and
replaced when necessary.
- If a safety sign or this Manual are damaged or
missing, obtain a replacement from your Dealer
in the same way you order a spare part (be sure
to detail machine model and serial number upon
ordering).
• Learn how to operate the machine and its controls
correctly and safely.
• Allow only trained, qualified, authorised personnel
to operate the machine.
• Keep the machine in proper working conditions.
- Unauthorised changes to the machine may
impair function and/or safety and affect machine
life.
• Safety messages in this Chapter “SAFETY
PRECAUTIONS”, are intended to illustrate basic
safety procedures of the machine. However, it is
impossible for these safety messages to cover
every hazardous situation you may encounter. If
you have any doubts, consult your direct
supervisor prior to operating or 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.
S2 - 2
WEAR PROTECTIVE CLOTHING
• Wear close-fitting clothing and safety equipment

appropriate to the job.
You need:
- A hard hat;
- Safety shoes;
- Safety glasses or face shield;
- Heavy gloves;
- Ear protection;
- Reflective clothing;
- Waterproof clothing;
- Respirator or filter mask;
Be sure to correctly wear equipment and clothing
for the job.
- Do not take any chances.
- Avoid wearing loose clothing, jewellery, or other
items that can catch on control levers or other
parts of the machine.
• Operating equipment safely requires the full
attention of the operator. Do not wear radio or
music headphones while operating the machine.
PROTECT AGAINST NOISE
• Prolonged exposure to loud noise can cause

impairment or loss of hearing.
- Wear a suitable hearing protection such as
earmuffs or earplugs to protect objectionable or
uncomfortably loud noise.
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.
S2 - 3
USE HAND HOLDS AND STEPS
• Falling is one of the major causes of personal

injury.
- When you get on and off the machine, always

face the machine and maintain a three-point
contact with the steps and handrails.
- Prior to climbing or leaving the machine, check
that the fasteners of stepping points and the
handrails are tightened and are undamaged.
Repair them as required.
- Keep the access to the machine clear of foreign
objects and clean. Remove grease or mud from
stepping points and rails to minimise the danger
of slipping or stumbling.
- Do not use the controls or the safety lever as
hand holds when climbing on or off the machine.
- Do not climb or leave the machine running. Do
not jump on or off the machine.
- Do not climb or leave the machine while holding
tools or other objects in your hands.
- Do not climb or leave the machine while it is
moving.
ADJUST THE OPERATOR'S SEAT
• A seat poorly adjusted for operator or work

requirements may quickly fatigue the operator
leading to improper operations.
- The seat should be adjusted whenever machine

operator changes.
- The operator should be able to fully press the
pedals and correctly move the control levers
with his back resting against the seat back.
- If not, move the seat fore and aft, and check
again.
S2 - 4
FASTEN SEAT BELT
• Should the machine overturn, the operator may

become injured and/or thrown from the cab. Not
only, the operator may be crushed by the
overturning machine resulting in serious injury or
even death.
- Prior to operating the machine, thoroughly

examine belt webbing, buckle, and attaching
hardware. If any item is damaged or worn,
replace the seat belt or component before
operating the machine.
- Be sure to remain seated with the seat belt
securely fastened at all times when the machine
is in operation to minimise injury hazard in case
of accident.
- After a significant accident, replace the seat
belts even though they do not look damaged.
MOVE AND OPERATE MACHINE SAFELY
• Bystanders can be run over.
- Pay the utmost attention not to run over

bystanders.
- Be sure exposed personnel in the area of
operation are clear of the machine before
moving it or its attachments. Sound horn to
inform bystanders that the machine is going to
be operated.
- When operating, swinging, or moving the
machine in a congested area use a signal man.
S2 - 5
OPERATE ONLY FROM THE DRIVER'S SEAT
• Inappropriate engine starting procedures may

cause the machine unexpected movement,
possibly resulting in serious injury and even
death.
- Start the engine only from the operator’s seat.
- NEVER start the engine while standing on the
track or on the ground.
- Do not start the engine by shorting across
starter motor terminals.
- Before starting the engine, ensure that all
control levers are in the neutral position.
DO NOT CARRY PERSON ON THE MACHINE
• Riders on the machine are exposed to serious

injuries.
- DO NOT carry riders on the machine. Besides

precluding a full vision by the operator, there is
the possibility of serious bodily harm or death
due to accidental falls from the machine.
CONFIRM DIRECTION WHERE THE

MACHINE IS TO BE DRIVEN
• Incorrect travel controls operation may result in

serious injury and even death.
- Before driving the machine, be aware of the

undercarriage position relative to the operator’s
position. If travel motors are located at the front of
the cab, the machine will move reverse when
travel controls are moved towards cab front.
S2 - 6
AVOID INJURY FROM BACK-OVER AND

SWING ACCIDENTS
• If any person is present near the machine when

backing or swinging the upperstructure, the
machine may hit or run over that person, resulting
in serious injury or death.
• To avoid back-over and swing accidents:

- Always look around BEFORE YOU BACK UP
AND SWING THE MACHINE. BE SURE THAT
ALL BYSTANDERS ARE CLEAR.
- ALWAYS BE ALERT FOR BYSTANDERS

MOVING INTO THE WORK AREA. USE THE
HORN OR OTHER SIGNAL TO WARN
BYSTANDERS BEFORE MOVING MACHINE.
- USE A SIGNAL PERSON WHEN BACKING

UP IF YOUR VIEW IS OBSTRUCTED.
ALWAYS KEEP THE SIGNAL PERSON IN
VIEW.
- Use hand signals, which conform to your local

regulations, when work conditions require a
signal person.
- No machine motions shall be made unless

signals are clearly understood by both
signalman and operator.
- Learn the meanings of all flags, signs, and

markings used on the job and confirm with the
person in charge of signalling.
- Always make sure that rear mirrors are clean

and correctly adjusted.
- Dust, heavy rain, fog, etc., can reduce visibility.

As visibility decreases, reduce speed and use
proper lighting.
S2 - 7
DRIVE MACHINE SAFELY
• Before moving the machine, confirm which way to

move travel pedals/levers for the corresponding
direction you wish to go.
- Pushing down on the front of the travel pedals or

pushing the levers forward moves the machine
towards the idlers.
• Traveling on a grade may cause the machine to

slip or to overturn, possibly resulting in serious
injury or death.
- When traveling up or down a grade, keep the

bucket in the direction of travel, approximately
20 to 30 cm (A) above the ground.
- If machine starts to skid or becomes unstable,

lower the bucket immediately.
- Traveling across the face of a slope may cause

the machine to skid or to overturn. When
travelling (ascending/descending) on a slope,
be sure to point the tracks uphill/downhill.
- 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.
- Do not travel on slopes with an angle exceeding

30°. Do not travel across hill on slopes
exceeding an angle of 15°.
S2 - 8
AVOID OVERTURNING
• When working on a slope or on unstable terrain,

the danger of tipping over is present with the
possibility of subsequent serious damages or fatal
injuries.
- Pay the utmost attention when working on a
slope. If possible, level first the work area.
- Avoid swing or steering the machine on a slope.
- Decrease the operating speed and actuate the
controls carefully, to prevent sudden
movements that could result in slipping or
tipping over.
- In case the engine is cut-off, lower the bucket to
the ground, move the controls in neutral and
restart the engine.
• Pay the utmost attention when operating the

machine on frozen ground or in snowy conditions.
- Frozen ground, when the ambient temperature
increases, tends to be less firm jeopardising the
stability of the machine.
- Operate carefully when in snowy conditions.
The snow could hide invisible dangerous spots.
- Actuate the controls slowly and carefully to
prevent the machine from making unwanted
slippery manoeuvres or movements.
- Even on minor slopes, when snow is present
and on frozen ground, unwanted slippery
manoeuvres or movements of the machine
could occur.
PARK MACHINE SAFELY
• To avoid accidents:
- Park machine on a level surface.
- Lower bucket to the ground.
- Pull the safety lever (pilot-control shut-off lever)
to the LOCK position.
- Turn auto-idle switch off.
- Run engine at slow idle speed without load for 5
minutes.
- Turn key-start switch to OFF to stop engine.
- Remove the ignition key from the key switch.
- Prior to leaving the machine, close the windows,
the cab door and all panels.
S2 - 9
INVESTIGATE JOB SITE BEFORE

OPERATING THE MACHINE
• Explore the working area to identify potential risks

before starting and operating the machine. Make
sure that the structure and the conditions of the
ground are safe before starting operations.
- Make sure that the digging area is sufficiently
stable and firm to support the weight of the
machine during the work operations.
- Working near edges and ditches presents a risk
for the stability of the machine. Check first that
edges and the walls of the digging are
sufficiently strong. If necessary, prop the edges
appropriately to prevent caving-ins.
- DO NOT dig too near the machine.
- Always position the tracks perpendicular to the
edge of the digging with the travel motors on the
rear side.
- When working on a slope or near the edge of the
road, have a flagman available.
PROTECTING AGAINST THE FALL OF

ROCKS AND LANDSLIDES
• When operating in zones where the possibility of
falling rocks or landslides exists or when there is
the risk for front impacts with objects that could
penetrate the cab, make sure that protection
structures are installed: F.O.P.S. (Falling Object
Protection Structure) and FRONT GUARD.
- DO NOT install any cab lifting device to the
protection structures.
- DO NOT weld, drill or modify protective
structures. Any type of modification could
weaken the structural integrity of the safety
system, with serious consequences for the
operator, in case of collision, falling objects or
landslides.
- After an accident, DO NOT try to straighten or
repair protective structures. Contact a Dealer to
verify the functionality, to repair or to completely
or partially replace the protective structures.
S2 - 10
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.
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.
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 5 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.
S2 - 11
KEEP PERSONNEL CLEAR FROM

WORKING AREA
• A person may be hit severely by the swinging front

attachment or counterweight and/or may be
crushed against an other object, resulting in
serious injury or death.
- Keep all persons clear from the area of

operation and machine movement.
- Before operating the machine, set up barriers to
the sides and rear area of the bucket swing
radius to prevent anyone from entering the work
area.
NEVER MOVE THE BUCKET OVER

ANY ONE
• Never lift, move, or swing bucket above anyone or

a truck cab. Serious injury or machine damage
may result due to bucket load spill or due to
collision with the bucket.
SP0030
DO NOT OPERATE IN TUNNELS
• DO NOT operate the machine in enclosed spaces

or, in any case, without appropriate ventilation.
Operations in tunnels or underground sites where
potential explosive conditions exist are not
allowed. There is a danger for explosions and
potentially deadly injuries. Please comply with the
ATEX regulation relative to devices to be used in
a potentially explosive environment.
S2 - 12
NEVER UNDERCUT A HIGH BANK
• The edges could collapse or a land slide could

occur causing serious injury or death.
SAFETY LOADS MOVING
• The excavator is a machine designed specifically

to perform digging/loading works, thus it must not
be used to handle suspended loads. In the event,
under exceptional conditions, it becomes
necessary to handle materials, the following
indications must be strictly implemented:
- The machine must be equipped compulsorily
with the appropriate variant provided upon
request. Also, totally comply with the safety
precautions for the operation of the excavator as
a lifting equipment.
- Secure the loads to be raised using cables or
chains fastened with appropriate hooking
mechanisms.
- Never hook cables or chains to the bucket teeth.
- 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.
- In any case, comply with the current national or
local regulations on this matter.
S2 - 13
AVOID EXCESSIVE DIGGING EFFORTS
• Operate the machine complying with the load

limits in accordance with the "table of lifting loads"
located inside the cab.
- Do not exceed the prescribed load limits.
- Do not use the strength of the attachment to
travel or move the machine.
- Do not try digging exploiting the mass of the
machine.
PAY ATTENTION WHEN DIGGING DEEPLY
• When digging deeply, pay special attention to

prevent contacts of the attachment and the
relevant hydraulic hoses with the ground.
• DO NOT swing the turret or the undercarriage
when the attachment boom is fully lowered. Under
these conditions there is the danger that the boom
collides with the track chains.
DO NOT USE THE TRACTION FORCE OF

THE MACHINE FOR DIGGING
• Do not travel the machine to dig. In doing this, an

excessive stress on the front attachment could
results in damages to the structure. Use the
undercarriage for travelling only.
DO NOT USE THE TURRET SWING FOR

DIGGING
• Do not use the turret swing for digging or moving

rocks. An excessive stress on the front
attachment could results in damages to the
structure reducing the operating life of the swing
system. Also, this inappropriate use of the
machine could cause serious injuries or fatalities.
S2 - 14
DO NOT USE THE BUCKET AS A HAMMER
• The use of the bucket as a hammer or for piling

operations could cause serious damages to the
bucket itself and the components of the front
attachment. Also, this inappropriate use of the
machine could cause serious injuries or fatalities.
AVOID OPERATING THE CYLINDERS TO

FULL STROKE
• Do not extend repeatedly the bucket and the arm

cylinders full stroke with the purpose of cleaning
the bucket from residual materials. This could
cause damages to the cylinders. To remove
residues from the bucket, use water under
pressure or remove them manually.
Tolerance A ≥ 50 mm
PROVIDE SIGNALS FOR JOBS INVOLVING

A NUMBER OF MACHINES
For jobs involving several machines, provide signals

commonly known by all personnel involved. Also,
appoint a signal person to co-ordinate the job site.
Make sure that all personnel obey the signal
person’s directions.
TRANSPORTING THE MACHINE UNDER

SAFE CONDITIONS
• During loading or unloading operations of the

machine on a truck or trailer the danger for tipping
over is always present.
- Use a truck or trailer appropriate for transporting
the machine.
- Secure safely the machine to the trailer with
appropriate chains or cables. Please refer to the
chapter "TRANSPORTATION" of this Manual
for the safe loading and unloading procedures.
- Make sure that you comply with National and
local regulations when transporting the machine
on open roads.
S2 - 15
SAFE MAINTENANCE
• To avoid accidents:
- Understand maintenance procedure before
starting the work.
- Keep the working area clean and dry.
- Do not spray water or steam inside the cab.
- Do not lubricate or service the machine when it
is in motion.
- Keep hands, feet and clothes far from moving
parts.
Prior to service in the machine:
1. Park the machine on the level ground.
2. Lower the bucket to the ground.
3. Move the safety lever (pilot-control shut-off
lever) to the LOCK position.
4. Switch off the Auto-Idle.
5. Let the engine idle with no load for at least
five minutes until it has cooled down.
6. Move the key-start switch to the OFF
position to stop the engine.
7. Remove the ignition key from the start
switch.
8. Apply the "Maintenance in progress" tag
(see SAFETY PLATE in this Chapter).
This tag can be applied o the left-hand
control lever, safety lever or cab door.
9. Let the engine cool down.
- Do not leave the machine unattended if
servicing requires the engine running.
- If the machine is to be raised, place boom and
arm at an angle 90 to 110°. Lock machine
components which should be raised for
maintenance or repair using suitable supporting
means.
- Never work under a machine kept raised by the
boom.
- Inspect certain component regularly, repair or
replace as necessary. Refer to the Chapter
MAINTENANCE in this Manual.
- Keep all components in good condition and
properly install. Immediately repair any fault.
- Immediately repair any damage.Replace worn
or failed components. Remove grease, oil,
debris build-ups.
- Disconnect the negative cable (-) from the
battery before carry out any work on he
electrical sysem or arc-welding on he machine.
S2 - 16
WARN OTHERS OF SERVICE WORK
• Unexpected machine movement can cause

serious injury.
- Before performing any work on the machine,

attach a maintenance in progress tag (see also
SAFETY PLATES in this Chapter) . This tag can
be applied o the left-hand control lever, safety
lever or cab door.
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.
STOP THE ENGINE PRIOR TO PERFORMING
• DO NOT perform any maintenance operation with

the engine running. Trapping by moving parts
could cause serious injuries. Stop the engine and
wait that it cools-off prior to performing
maintenance operations.
In case it is indispensable to perform maintenance
operations with the engine running, have a person
co-operating with you sitting in the operator's seat,
to cut-off the engine immediately in case of
necessity.
S2 - 17
DISPOSE OF WASTE IN THE APPROPRIATE

MANNER
• Waste improperly disposed of represents a

danger for the envinronment. Potentially
dangerous waste used on the excavators
includes lubricants, fuel, coolant, brake fluid,
filters and batteries.
- Used sealed containers when discharging

fluids. Do not use containers for food or
beverages which may induce drinking.
- Do not spill waste over the ground, into drains,

or water beds.
- Obtain information about the correct methods to

recycle or dispose of waste from local
Authorities, collection centres or your Dealer.
WORK IN A CLEAN AREA
- Before starting an operation, clean the working

area. Clear the area from all the objects that can
be dangerous for mechanics or people in the
working area.
PROPERLY LIGHT THE WORKING AREA
• Properly and safely light the working area.

- Use safe portable lamps in order to work inside
and under the machine.
- Make sure that the lamp is shielded by a cage;
the incandescent filament of a lamp,
accidentally broken, can cause fuel or oil fire.
S2 - 18
KEEP CLEAN THE MACHINE
• Keep clean the engine compartment, radiator,

batteries, hydraulic pipes, fuel tank and operator's
position.
- The engine compartment temperature can
quickly rise, after stopping the engine. IN
THESE CASES, BE CAREFUL TO POSSIBLE
FIRES.
Open the access doors in order to quicken the
engine cooling process and clean the
compartment.
• Remove all the traces of grease, oil and deposits,
in order to avoid people accidents or damages to
things.
- Do not spray water or steam in the cab.
PREVENT ACID SCALDS
• The sulphuric acid, contained in the battery, is

poisonous. It is strong enough to scald the skin,
corrode clothes and cause blindness, if it is
sprayed into the eyes.
To avoid dangers:
- Fill the batteries in airy areas.
- Wear eye protections and rubber gloves.
- Avoid breathing the electrolyte vapours when
topping up.
- Avoid spilling or dripping the electrolyte.
- Use proper emergency starting techniques.
If you are touched with acid sprays:
- Rinse your skin well with water.
- Put on your skin sodium bicarbonate or clay to
help the acid neutralization.
- Rinse your eyes with water for 10-15 minutes.
- Immediately see a doctor.
If you have swallowed the acid:
- Immediately see a doctor.
S2 - 19
STARTING THE ENGINE WITH BOOSTER

BATTERIES
• 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 use batteries that have been stored in
the cold for a long time.
- Mistakes in following procedures detailed for
starting the engine with slave batteries may
cause the batteries to explode or machine to
move unexpectedly
PREVENT BATTERY EXPLOSIONS
• Battery gas can explode.
- Keep sparks, lighted matches, and flames away

from the top of battery.
- Never check battery charge by placing a metal

object across the posts. Use a voltmeter or
hydrometer.
- Do not charge a frozen battery; it may explode.

Warm battery to 16 °C.
• Battery electrolyte is poisonous. If the battery

should explode, battery electrolyte may be
splashed into eyes, possibly resulting in
blindness.
- Be sure to wear eye protection when checking

electrolyte specific gravity.
S2 - 20
PREVENT BURNS
Hot spraying fluids:
• After operation, engine coolant is hot and under

pressure. Hot water or steam is contained in the
engine, radiator and heater lines. Skin contact
with escaping hot water or steam can cause
severe burns.
- To prevent possible injury from hot spraying

water. Do not remove the radiator cap until the
engine is cool. When opening, turn the cap
slowly to the stop. Allow all pressure to be
released before removing the cap.
- The hydraulic oil tank is pressurized. Again, be

sure to release all pressure before removing the
cap.
Hot fluids and surfaces:
• Engine oil, reduction 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 down

before starting any maintenance or inspection
work.
STORE ATTACHMENTS SAFELY
• Stored attachments such as buckets, hydraulic

breakers and blades can fall and cause serious
injury or death.
- Securely store attachments and implements to
prevent falling.
- Keep bystanders away from storage areas.
S2 - 21
AVOID HIGH-PRESSURE FLUIDS
• Fluids such as diesel fuel or hydraulic oil under

pressure can penetrate the skin or eyes causing
serious injury, blindness or death.
- Avoid this hazard by relieving pressure before

disconnecting hydraulic or other lines.
- Tighten all connections before applying

pressure.
- Search for leaks with a piece of cardboard; take

care to protect hands and body from high-
pressure fluids. Wear a face shield or goggles
for eye protection.
- In an accident occurs, see a doctor familiar with

this type of injury immediately. Any fluid injected
into the skin must be surgically removed within
a few hours or gangrene may result.
PREVENT 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.
SP0047
- 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.
S2 - 22
PROTECT AGAINST FLYING DEBRIS
• If flying debris hit eyes or any other part of the

body, serious injury may result.
- Guard against injury from flying pieces of metal

or debris; wear goggles or safety glasses.
- Keep bystanderds away from the working area
before striking any object.
HANDLE FLUIDS SAFELY - AVOID FIRES
• Handle fuel with care: it is highly flammable. If fuel

ignites, an explosion and/or a fire may occur,
possibly resulting in serious injuty or death.
- Do not refuel the machine while smoking or

when near open flame or sparks.
- Always stop the engine before refuelling the

machine.
- Fill the tank outdoors.
• All fuels, most lubrificants, and some antifreeze

fluids are flammable.
- Store flammable fluids well away from fire

hazards.
- Do not burn or puncture pressurized containers.
- Do not store oily rags; they can ignite and burn

spontaneously.
S2 - 23
PREVENT FIRES
• Check for Oil Leaks:
- Fuel, hydraulic oil and lubricant leaks can lead to
fires.
- Check for missing or loose clamps, kinked hoses,
lines or hoses that rub against each other, damage
to the oil-cooler, and loose oil-cooler flange bolts
which may cause 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.
• Check for Shorts:
- Short circuits can cause fires.
- Clean and tighten all electrical connections.
- Check before each shift or after about ten (10)
hour operation for loose, kinked, hardened or
frayed electrical cables and wires.
- Check before each shift or after about ten (10)
hour operation for missing or damaged terminal
caps.
- DO NOT OPERATE MACHINE if cable or wires
are loose, kinked, etc..
• Clean up Flammables:
- Spilled fuel and lubricans, and trash, grease,
debris, accumulated coal dust, and other
flammables may cause fires.
- Prevent fires by inspecting and cleaning the
machine daily and by removing spilled or
accumulated flammables immediately.
• 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:
1. Start the engine and run it at slow idle.
2. Turn the key-start switch to the OFF
position to confirm that the engine stops.
- If any abnormalities are found, be sure to repair
them before operating the machine.
• Check Heat Shields:
- Damaged or missing heat shields may lead to
fires.
- Damaged or missing heat shields must be
repaired or replaced before operating the
machine.
S2 - 24
EVACUATING IN CASE OF FIRE
• If a fire breaks out, evacuate the machine in the

following way:
- Stop the engine by turning the key-start switch

to the OFF position if there is time.
- Use a fire extinguisher if there is time.
- Exit the machine.
BEWARE OF EXHAUST FUMES
• Prevent asphyxiation. 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.
SP0062
USE APPROPRIATE TOOLS
• Use tools appropriate for the job to be performed.
- Inappropriate tools, parts and procedures might

generate dangerous conditions.
- Use tools of correct size to tighten or loosening

securing elements, in order to avoid injuries
caused by a wrench getting out of control.
- Do not use U.S. Standard or British Standard

tools on metric fasteners and vice versa.
• Use only genuine spare parts (please refer to the

Spare Parts Catalogue).
S2 - 25
AVOID HEATING NEAR PRESSURIZED

FLUID LINES
Flammable spray can be generated by heating 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 lines 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 welding, soldering, etc.
AVOID APPLYING HEAT TO LINES

CONTAINING FLAMMABLE FLUIDS
- Do not weld or flame cut pipes or tubes that

contain flammable fluids.
- Clean them thoroughly with non-flammable
solvent before welding or flame cutting them.
REMOVE PAINT BEFORE WELDING OR

HEATING
• Hazardous fumes can be generated when paints

is heated by weiding, soldering, or using a torch. If
inhaled, these fumes may cause sickness.
- Avoid breathing potentially toxic fumes and
dust.
- Do all such work outside or in a well-ventilated
area.
- Dispose of paint and solvents properly.
- Remove paint before welding or heating:
1. If you sand or grind paint, avoid breathing
the dust. Wear an approved respirator.
2. 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.
S2 - 26
WELDING REPAIR INTERVENTIONS
• Welding repair interventions must be performed

only by a certified welder with sufficient
experience. Also, appropriate safety rules must be
implemented by all the personnel involved in the
operations. The duration through time of the
welding depends upon the quality and the
accuracy with which the operation is performed.
- Identify first all the fracture points and the zones
in which welding is required.
- Clean accurately the zones involved.
- Remove all paint and inspect the parts with
penetrating liquid or a magnetic particle tester.
- Move the starter switch into position "OFF" and
wait for 4 seconds to cut-off electricity from the
system.
- Disconnect the negative terminal (-) from the
battery.
- Connect the ground cable of the welder at least
1 m from the component to be welded.
- Make sure that the ground cable is NOT
connected to a seal or bearing and that there
are noo seals or bearings between the ground
cable and the part to be welded.
- Avoid welding pieces at low temperature i. e.
below 16 °C. If necessary, warm-up the part
involved prior to welding it.
- Remove paints from all surfaces prior to
warming-up or welding. Painted surfaces, when
warmed-up or when welded, can generate toxic
fumes.
- Use appropriate masks or protective glasses.
- Wear gloves and adequate clothing to protect
the skin.
S2 - 27
NOTE:
S2 - 28
SAFETY PLATES E215B-E245B
SAFETY PLATES
Triple articulation version
Triple articulation version
1. Attachment operating range safety plate.

2. Track adjuster plate.
S3 - 1
E215B-E245B SAFETY PLATES
3. Counterweight operating range safety plate. 9. Controls lock/unlock plate (safety lever).
4. Read-your-manual plate. 10. Hydraulic oil pressurised tank warning plate.
5. Boom and arm movement warning plate 11. Burns warning plate.
(Triple articulation version). 12. Safety distance plate.
6. Open windscreen warning plate aperta 13. No-stepping warning plate.
(inside the cab).
14. Special equipment movement warning plate
7. Tag indicating maintenance in progress.
8. Engine hood warning plate.
S3 - 2
SAFETY PLATES E215B-E245B
1 - Attachment operating range safety plate
Ensure that any person near the working site is

outside the machine operating range before
starting the machine or operating the
attachments. Sound the horn.
Background: yellow
Border and icons: black
2 - Track adjuster plate
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
3 - Counterweight operating range safety plate
Ensure that any person near the working site is

outside the machine operating range before
starting the machine or operating the
attachments. Sound the horn.
Background: yellow
S3 - 3

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E215B

Print No. 87677762A

NEW HOLLAND KOBELCO CONSTRUCTION MACHINERY S.p.A. - Product Support

- Be sure to thoroughly read this manual for NEW HOLLAND KOBELCO

• Please refer to the materials listed below in

- Operation and Maintenance Instruction

WORKSHOP MANUAL COMPOSITION

Consecutive page number for each group

Group number (if exist))

This is the safety alert symbol.

SI Units (International System of Units) are used in this manual.

Example: 24.5 MPa (250 kgf/cm2)

mm ft 0.003281 MPa psi 145.0

Volume L US gal 0.2642 Power kW CV-PS 1.360

m3 yd3 1.308 Temperature °C °F °C x 1.8 + 32

Mass kg lb 2.205 Velocity km/h mph 0.6214

Force N kgf 0.10197 min-1 rpm 1.0

N lbf 0.2248 Flow rate L/min US gpm 0.2642

Torque N.m kgf.m 0.10197 mL/rev cc/rev 1.0

N.m lbf.ft 0.7375

SAFETY PRECAUTIONS Page

Section 1 GENERALITIES ..................................................................... S1

Section 3 COMPONENT OPERATION

OPERATIONAL PERFORMANCE TEST

Section 1 GENERAL INFORMATION

Section 4 FRONT ATTACHMENT

Section 2 SAFETY PRECAUTIONS

Section 3 SAFETY PLATES

Always keep head, body, limbs, feet, hands, and

RECOGNISE SAFETY INFORMATION

• This is your SAFETY ALERT SYMBOL

- When you see this symbol on your machine or

UNDERSTAND SIGNAL WORDS

• In this Manual you will find the following words

DANGER: indicates an imminent hazardous

WARNING: indicated a potential hazardous

CAUTION: indicates a potential hazardous situation IMPORTANT

NOTE: indicates an additional explanation for

• This Manual also contains this symbol

FOLLOW SAFETY PRECAUTIONS

• Carefully read and observe all safety signs on the

PREPARE FOR EMERGENCIES

• Be prepared if a fire starts or an accident occurs.

WEAR PROTECTIVE CLOTHING

• Wear close-fitting clothing and safety equipment

PROTECT AGAINST NOISE

• Prolonged exposure to loud noise can cause

INSPECT THE MACHINE

• Inspect the machine carefully every day or work-

USE HAND HOLDS AND STEPS

• Falling is one of the major causes of personal

- When you get on and off the machine, always

ADJUST THE OPERATOR'S SEAT

• A seat poorly adjusted for operator or work

- The seat should be adjusted whenever machine

FASTEN SEAT BELT

• Should the machine overturn, the operator may

- Prior to operating the machine, thoroughly