Case 21D 121D 221D & 221D Small Wheel Loaders Operator’s Manual 6-84230 - PDF DOWNLOAD

Small Wheel Loaders 21D, 121D, 221D and 221D

Operator’s Manual

6-84230 EN

Ber 6-84230 EN

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D

The operating manual is in 5 sections; the sections are designed for different target groups:

Operating manual

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS

2261175

Target group Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel

Part 2 OPERATION

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

Inspection and servicing personnel

Part 3 INSPECTION AND SERVICING

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

Repair personnel

Part 4 REPAIR WORK

Part 5 ANNEX

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

Operating personnel + Inspection and servicing personnel + Repair personnel

PART 1 - INTRODUCTION Preface After-sales service .................................................................................................................................. 3 Warranty .................................................................................................................................................. 3 Warnings and symbols ............................................................................................................................ 4 Designated use ........................................................................................................................................ 4 Organizational measures ........................................................................................................................ 5 Selection and qualification of personnel ................................................................................................ 6 OPERATING SAFETY INSTRUCTIONS Standard operation .................................................................................................................................. 6 MAINTENANCE SAFETY INSTRUCTIONS .............................................................................................. 7 WARNING OF SPECIAL DANGERS Electric energy ........................................................................................................................................ 8 Gas, dust, steam and smoke .................................................................................................................. 8 Hydraulic and pneumatic equipment ...................................................................................................... 9 Noise ...................................................................................................................................................... 9 Oil, grease and other chemical substances ............................................................................................ 9 TRANSPORTING AND TOWING - RECOMMISSIONING ........................................................................ 9

PART 2 - OPERATION Operation, safety instructions .............................................................................................................. 13 DESCRIPTION OF THE MACHINE Layout of the machine .......................................................................................................................... 15 Basic unit .............................................................................................................................................. 16 Chassis.................................................................................................................................................. 16 Drive unit .............................................................................................................................................. 16 Axles...................................................................................................................................................... 16 Brakes .................................................................................................................................................. 16 Hydraulic system .................................................................................................................................. 16 Electrical system .................................................................................................................................. 16 Working equipment .............................................................................................................................. 16 Noise emissions Outside the machine ............................................................................................................................ 17 Inside the cab ........................................................................................................................................ 17 Vibration level Vertical vibration at the operator’s seat ................................................................................................ 17 Vibrations in the hands and arms .......................................................................................................... 17 CE Mark.................................................................................................................................................... 17 Warning and instruction signs / Europe .............................................................................................. 18 Warning and instruction signs / North America Machine number.................................................................................................................................... 22 Engine number ...................................................................................................................................... 22 Axle number .......................................................................................................................................... 22 Travel pump number ............................................................................................................................ 23 Travel motor number ............................................................................................................................ 23 Attachments .......................................................................................................................................... 23 DRIVER’S CAB Entering and leaving the machine - Safety instructions ........................................................................ 24 Driver’s cab door Opening the door .................................................................................................................................. 25 Closing the door .................................................................................................................................... 25 Side window ............................................................................................................................................ 26 Emergency exit ...................................................................................................................................... 26 Documentation ........................................................................................................................................ 27

Sun visor.................................................................................................................................................. 27 Cab interior lighting ................................................................................................................................ 27 Adjusting the operator’s seat Adjusting the weight-oriented suspension ............................................................................................ 28 Weight adjustment ................................................................................................................................ 28 Height adjustment ................................................................................................................................ 28 Fore-and-aft adjustment ........................................................................................................................ 29 Backrest adjustment .............................................................................................................................. 29 Switches and pushbuttons .................................................................................................................... 34 PUTTING THE MACHINE INTO OPERATION ........................................................................................ 38 Refuelling Refuelling, safety instructions ................................................................................................................ 38 Fuel ...................................................................................................................................................... 38 Filling in fuel .......................................................................................................................................... 38 Switching the electrical system on and off Battery main switch .............................................................................................................................. 39 Starting and stopping the engine Starting the engine ................................................................................................................................ 40 Engine does not start ............................................................................................................................ 41 Stopping the engine .............................................................................................................................. 41 Ventilation and heating Ventilation.............................................................................................................................................. 42 Heating .................................................................................................................................................. 43 Blower .................................................................................................................................................. 43 Air conditioner Activation / deactivation ........................................................................................................................ 43 Switching on the air conditioner ............................................................................................................ 43 Adjusting the conditioner air temperature .............................................................................................. 43 Signal horn, turn signal, main beam and screen wiper / washer........................................................ 44 Lighting .................................................................................................................................................... 46 Rear screen wiper / washer .................................................................................................................... 46 Socket outlet .......................................................................................................................................... 47 DRIVING .................................................................................................................................................. 47 Driving, safety instructions .................................................................................................................... 47

Adjustment of steering column Steering column - Safety instructions .................................................................................................... 48 Adjusting the steering column .............................................................................................................. 48 Seat belt Seat belt - Safety instructions ................................................................................................................ 48 Control lever - Travelling / Working ...................................................................................................... 49 Driving Warming up the machine ...................................................................................................................... 50 Engine .................................................................................................................................................. 50 Steering and working hydraulics .......................................................................................................... 50 Front and rear axle ................................................................................................................................ 50 Braking and stopping ............................................................................................................................ 50 Setting off .............................................................................................................................................. 51 Travel direction and working mode........................................................................................................ 51 High-speed model Activating the high-speed function ........................................................................................................ 52 Switch off high-speed function .............................................................................................................. 53 Load stabilization system ...................................................................................................................... 54 Monitoring the indicators and instruments Hydraulic oil temperature ...................................................................................................................... 55 Engine oil pressure................................................................................................................................ 55 Alternator .............................................................................................................................................. 55 Air filter .................................................................................................................................................. 55 Engine oil temperature .......................................................................................................................... 56 Brake pressure monitoring .................................................................................................................... 56 Brake pressure monitoring in high-speed gear...................................................................................... 56 Driving on public roads .......................................................................................................................... 57 Recovering / towing of the machine Recovery and towing, safety instructions .............................................................................................. 58 Towing lug ............................................................................................................................................ 59 Towing .................................................................................................................................................. 60 Transport Transport - Important information .......................................................................................................... 61 Loading by crane .................................................................................................................................. 61 Blocking the articulated joint .................................................................................................................. 62 WORKING OPERATION .......................................................................................................................... 63 Working operation, safety instructions

Before starting work .............................................................................................................................. 63 Driving the machine on the public highway .......................................................................................... 64 Road travel ............................................................................................................................................ 64 Loading bucket equipment control lever Floating position of loading bucket ........................................................................................................ 65 Using combined functions .................................................................................................................... 66 Control lever additional function ............................................................................................................ 66 Quick tool coupler.................................................................................................................................. 66 Control lever locking mechanism .......................................................................................................... 67 Locking the control levers ...................................................................................................................... 67 Unlocking the control levers .................................................................................................................. 67 OPTIONAL EQUIPMENT Bottom-dump bucket ............................................................................................................................ 68 After daily operation Securing the machine............................................................................................................................ 69 Cleaning and refuelling of machine ...................................................................................................... 69 Carry out visual inspection .................................................................................................................... 69 Chock .................................................................................................................................................... 69 WORKING EQUIPMENT .......................................................................................................................... 70 Assembling working equipment, safety instructions .......................................................................... 70 TOOLS AND EQUIPMENT ...................................................................................................................... 72 Quick tool coupler .................................................................................................................................. 72 Bucket Attaching the bucket .............................................................................................................................. 73 Checking the locked condition .............................................................................................................. 74 Detaching the bucket ............................................................................................................................ 74 Bottom-dump bucket Attaching the bottom-dump bucket ........................................................................................................ 75 Detaching the bottom-dump bucket ...................................................................................................... 75 Carrier with lifting forks Attaching the carrier .............................................................................................................................. 76 Detaching the carrier ............................................................................................................................ 76 Lifting forks ............................................................................................................................................ 76 Working with lifting forks ........................................................................................................................ 77 Taking up loads .................................................................................................................................... 77 Transporting loads ................................................................................................................................ 77 Depositing loads .................................................................................................................................... 77

Front working floodlamps ...................................................................................................................... 78 Rear working floodlamps ...................................................................................................................... 78 Rotary beacon ........................................................................................................................................ 79 Acoustic reversing signal ...................................................................................................................... 79

PART 3 - INSPECTION AND SERVICING Inspection and Servicing, Safety Instructions .................................................................................... 83 MAINTENANCE WORK Securing the machine............................................................................................................................ 87 Opening the engine compartment ........................................................................................................ 87 Draining hose for oil changes ................................................................................................................ 88 Operating hours indicator ...................................................................................................................... 88 Inspection and servicing plans, instructions Intervals ................................................................................................................................................ 89 Warranty ................................................................................................................................................ 89 Engine oil change .................................................................................................................................. 89 Oils / greases ........................................................................................................................................ 89 Cleaning ................................................................................................................................................ 89 Servicing material .................................................................................................................................. 89 Plan V - once prior to initial commissioning .......................................................................................... 90 Plan N - after initial commissioning ...................................................................................................... 91 Plan T - every 10 OH or each working shift .......................................................................................... 92 Plan W - every 50 OH or weekly .......................................................................................................... 92 Plan B - after every 500 OH .................................................................................................................. 94 Plan C - after every 1000 Bh ................................................................................................................ 94 Plan D - after every 3000 OH ................................................................................................................ 94 LUBRICATING CHART - GREASE Lubricating chart - Grease .................................................................................................................... 97 Joints and hinges .................................................................................................................................. 97 INSPECTION PLAN - OIL Inspection plan - oil .............................................................................................................................. 99 Refilling quantities - oil .......................................................................................................................... 99 Refilling quantities - Other .................................................................................................................... 99 LUBRICANTS ........................................................................................................................................ 100 Oils for internal combustion engines.................................................................................................. 100 Oils for hydraulic systems, mineral .................................................................................................... 102 Oils for hydraulic systems, synthetic ................................................................................................ 103 Oils for axles and gearboxes .............................................................................................................. 104 Greases for bearing points and slewing rings .................................................................................. 105 ENGINE .................................................................................................................................................. 107

Engine, safety instructions for inspection and servicing Checking the engine oil level / topping up oil ...................................................................................... 107 Changing the engine oil ...................................................................................................................... 108 Changing the engine oil filter .............................................................................................................. 109 AIR INTAKE SYSTEM Dust discharge valve .......................................................................................................................... 110 Removing, cleaning and checking the main filter element .................................................................. 111 Cleaning the main filter element .......................................................................................................... 112 Checking / replacing the safety filter.................................................................................................... 112 Check the air intake lines .................................................................................................................... 113 FUEL SYSTEM Fuel filter.............................................................................................................................................. 114 Fuel pre-filter ...................................................................................................................................... 115 Cleaning the fuel tank .......................................................................................................................... 115 Injection nozzles .................................................................................................................................. 116 Air conditioner - Inspection and servicing work Location of components inside the machine. ...................................................................................... 117 Work to be performed every month .................................................................................................... 117 In the cab ............................................................................................................................................ 117 In the engine compartment.................................................................................................................. 118 Work to be performed every 6 months ................................................................................................ 119 Work to be performed every 2 years .................................................................................................. 119 AIR CONDITIONER................................................................................................................................ 120 ELECTRICAL SYSTEM Safety instructions .............................................................................................................................. 121 Alternator, instructions ........................................................................................................................ 121 WORKING EQUIPMENT ........................................................................................................................ 122 Assembling working equipment, safety instructions ........................................................................ 122 Battery Battery - checking the fluid level .......................................................................................................... 123 Battery - checking the charge .............................................................................................................. 124 Removing and installing the battery .................................................................................................... 125 HYDRAULIC SYSTEM Hydraulic oil level ................................................................................................................................ 126 Return-flow filter .................................................................................................................................. 127 Replacing the filter .............................................................................................................................. 127 Breather filter ...................................................................................................................................... 128 Hydraulic reservoir

Hydraulic oil change ............................................................................................................................ 128 Filling oil into the hydraulic reservoir .................................................................................................. 128 Bleeding the working and steering hydraulics Working hydraulics .............................................................................................................................. 129 Steering hydraulics .............................................................................................................................. 129 Environmentally compatible hydraulic fluid (biodegradable) Environmentally compatible hydraulic fluid, operating instructions...................................................... 130 Environmentally compatible hydraulic fluid, conversion ...................................................................... 130 Environmentally compatible hydraulic fluid, sampling ........................................................................ 131 AXLES, GEARBOXES .......................................................................................................................... 132 Axles and gearboxes, safety instructions .......................................................................................... 132 Front axle .............................................................................................................................................. 132 Rear axle ................................................................................................................................................ 133 Distributor gearbox .............................................................................................................................. 133 Planetary gearbox ................................................................................................................................ 134 BRAKES Working on brakes, safety instructions ................................................................................................ 136 Parking brake ........................................................................................................................................ 137 Reducing braking pressure ................................................................................................................ 137 Bleeding the brake system Bleeding .............................................................................................................................................. 138 WHEELS AND TYRES Tyre pressure - Safety instructions ...................................................................................................... 139 Checking the tyre inflation pressure - Refilling the tyre ...................................................................... 140 Tyre pressure ...................................................................................................................................... 140 Tyre pressures and approved tyres for................................................................................................ 142 141 Tyres and wheels - Safety instructions ................................................................................................ 143 Changing a wheel................................................................................................................................ 144 Fastening of the wheels ...................................................................................................................... 144 Position of tyre tread .......................................................................................................................... 144 Lubricating the greasing points .......................................................................................................... 145 CAB VENTILATION Filter .................................................................................................................................................... 145 PUTTING THE LOADER OUT OF OPERATION

Preserving the engine ........................................................................................................................ 146 Battery storage .................................................................................................................................... 146 RECOMMISSIONING Removal of engine preserving agents ................................................................................................ 147

PART 4 - REPAIR WORK Repair, safety instructions .................................................................................................................. 151 ENGINE .................................................................................................................................................. 153 Engine, repair information Replacing V-belts ................................................................................................................................ 153 Replacing alternator / coolant pump V-belts........................................................................................ 153 Assisted starting (jump-starting) - Safety instructions Assisted starting (jump-starting) .......................................................................................................... 154 Prior to assisted starting ...................................................................................................................... 154 Connecting the jumper cables ............................................................................................................ 154 Starting the engines ............................................................................................................................ 154 ELECTRICAL SYSTEM Fuses .................................................................................................................................................. 155 Replacing a fuse.................................................................................................................................. 155 Fuses in the cab .................................................................................................................................. 155 Fuse in the engine compartment ........................................................................................................ 156 Replacing bulbs .................................................................................................................................. 156 Lighting Headlamp ............................................................................................................................................ 157 Turn signal .......................................................................................................................................... 157 Tail light / stop light / turn signal .......................................................................................................... 158 Interior lamp ........................................................................................................................................ 159 Working floodlamp .............................................................................................................................. 159 OPTIONAL EQUIPMENT Rotary beacon .................................................................................................................................... 160 Rotary beacon - replacing the reflector .............................................................................................. 160 WELDING OPERATIONS Welding operations - safety instructions .............................................................................................. 161 HYDRAULIC SYSTEM Replacing hydraulic hoses, safety instructions .................................................................................... 162 Lifting cylinder - installation ................................................................................................................ 162 BRAKES ................................................................................................................................................ 163 Working on brakes - safety instructions Checking the braking pressure ............................................................................................................ 164 Checking the accumulator pressure .................................................................................................... 165 Checking the precharging pressure of the accumulator ...................................................................... 166

Pressure accumulator Pressure accumulator, safety instructions .......................................................................................... 167 Replacing the accumulator .................................................................................................................. 167 EQUIPMENT Working equipment - replacing a tooth ................................................................................................ 168 Bucket limit stops ................................................................................................................................ 169 Upper dumping position ...................................................................................................................... 169 Rearward tilt position .......................................................................................................................... 169 Lifting forks Lifting forks, instructions ...................................................................................................................... 170 Fork prongs Types .................................................................................................................................................. 170 Marking................................................................................................................................................ 171 Inspection interval .............................................................................................................................. 171 Cracking test ...................................................................................................................................... 171 Deformation check .............................................................................................................................. 172 Wear check ........................................................................................................................................ 172

PART 5 - ANNEX TROUBLESHOOTING .......................................................................................................................... 175 Instructions for troubleshooting ........................................................................................................ 175 Fault table layout Fault .................................................................................................................................................... 175 Possible causes .................................................................................................................................. 175 Remedial action .................................................................................................................................. 175 Chapter reference .............................................................................................................................. 175 Steering system .................................................................................................................................... 176 Working equipment .............................................................................................................................. 177 Travel drive ............................................................................................................................................ 178 Brake system ........................................................................................................................................ 180 Air conditioner, troubleshooting ........................................................................................................ 181 ABBREVIATIONS .................................................................................................................................. 186 KHD engine operating instructions .................................................................................................... 188

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D PART 1 - INTRODUCTION

Operating manual

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS Part 2 OPERATION

2261176

Target group Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel The operating personnel must have know-how relevant to the operation and the application of this or comparable machines.

Inspection and servicing personnel

Part 3 INSPECTION AND SERVICING

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

Repair personnel

Part 4 REPAIR WORK

Part 5 ANNEX

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

Operating personnel + Inspection and servicing personnel + Repair personnel

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OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D

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OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Preface

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This Owner’s Manual is designed to familiarize the operator with the machine and its designated use.

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

The Owner’s Manual must be supplemented by the respective national rules and regulations for accident prevention and environmental protection.

The Owner’s Manual must always be available in the operator’s cab of the machine.

The Owner’s Manual must be read and applied by any person authorized to carry out work with / on the machine, e.g.

- operation, including setting-up, troubleshooting in the course of work, care, disposal of fuels and consumables, - maintenance ( inspection, servicing, repair) and / or - transport.

In addition to the Owner’s Manual and the mandatory rules and regulations for accident prevention and environmental protection in the user’s country and at the location where the machine is to be used, the generally recognized technical rules for safe and proper working must be observed. [1]

After-sales service

30000160

Our after-sales service will be pleased to deal with any queries you may have after reading through the Owner’s Manual.

The Owner’s Manual does not comprise working instructions for carrying out major repairs . Such work is willing done for you by our after-sales service .

For maintenance work that cannot easily be done by the owner, please contact your dealer or other after-sales service centres that have trained staff and appropriate tools, equipment and original spare parts at their disposal.

The after-sales service staff and technicians will be pleased to provide explanations and to make recommendations. They will also carry out any necessary special work for you if the loader is not functioning satisfactorily.

Warranty

30000161

One of the preconditions for our granting the warranty is that the following mandatory servicing work is carried out by our after-sales service or at a workshop authorized by us in writing: 1.

Mandatory servicing N 30 - 50 operating hours after commissioning.

2.

Mandatory servicing B 500 operating hours after commissioning.

The proper implementation of the mandatory servicing work must be documented in the service checklists.

The Owner’s Manual is directed to the construction machine specialist. It cannot provide basic know-how. This can be acquired, for example, in several days’ instruction by a qualified O&K mechanic or by attending an O&K training course for operators or maintenance personnel

[1] Complies with VDMA recommendation "Operating Instructions"

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OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D

Warnings and symbols

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

Warning against serious dangers which might result in death or in extremely severe injuries.

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

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

Using the wheel-mounted loader for purposes other than or extending beyond those stated above, e.g.: -

for lifting or transporting persons, as a working platform, for lifting or transporting loads, unless the attachment is designed for this purpose,

is considered contrary to the designated use.

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

Designated use

2732494

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

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

The wheel-mounted loader is designed for excavating, loading, transporting and dumping materials such as soil, rock and other bulk materials.

Using other attachments, the wheel-mounted loader can also be used for special applications.

Clear-cut data are provided in the technical specifications.

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

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

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

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

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Organizational measures The operating instructions must always be at hand at the place of use of the machine, e.g. by stowing them in the tool compartment or tool-box provided for such purpose.

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

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

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

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

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

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

2800456

Observe all safety instructions and warnings attached to the machine.

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

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

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

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

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

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

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

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

Observe all fire-warning and fire-fighting procedures.

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

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OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Selection and qualification of personnel

OPERATING SAFETY INSTRUCTIONS

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

Standard operation

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

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

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

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

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

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

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

Avoid any operational mode that might be prejudicial to safety.

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

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

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

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

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

Start the machine from the driver’s seat only.

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

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

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

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

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

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

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OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Persons accompanying the driver must be seated on the passenger seats provided for this purpose.

MAINTENANCE SAFETY INSTRUCTIONS

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

Observe the adjusting, maintenance and inspection activities and intervals set out in the operating instructions, including information on the replacement of parts and equipment. These activities may be executed by skilled personnel only.

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

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

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

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

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

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

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

Ensure that the maintenance area is adequately secured.

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

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

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

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

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

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OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Wear a safety harness when carrying out maintenance work at greater heights.

WARNING OF SPECIAL DANGERS

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

Electric energy

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

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

Use only original fuses with the specified current rating. Switch off the machine immediately if trouble occurs in the electrical system.

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

If your machine comes into contact with a live wire - do not leave the machine

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

- drive the machine out of the hazard zone - warn others against approaching and touching the machine - have the live wire de-energized

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

- do not leave the machine until the damaged line has been safely de-energized.

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

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

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

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

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

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

Observe the regulations in force at the respective site.

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

Before carrying out welding, flame-cutting and grinding operations, clean the machine and its surroundings from dust and other inflammable substances and make sure that the premises are adequately ventilated. RISK OF EXPLOSION.

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OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Hydraulic and pneumatic equipment Check all lines, hoses and screwed connections regularly for leaks and obvious damage. Repair damage immediately. Splashed oil may cause injury and fire.

TRANSPORTING AND TOWING RECOMMISSIONING The machine must be towed, loaded and transported only in accordance with the operating instructions.

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

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

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

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

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

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

Always wear the prescribed ear protectors.

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

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

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OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D

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OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D PART 2 - OPERATION

Operating manual

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS Part 2 OPERATION

2261177

Target group Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel The operating personnel must have know-how relevant to the operation and the application of this or comparable machines.

Inspection and servicing personnel

Part 3 INSPECTION AND SERVICING

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

Repair personnel

Part 4 REPAIR WORK

Part 5 ANNEX

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

Operating personnel + Inspection and servicing personnel + Repair personnel

11

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D

12

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Operation, safety instructions

30000230

Operating instructions

Safety belt

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

For machines with a safety belt for operating personnel:

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

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

Apply the safety belt before starting work.

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

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

State of the machine

Keep the operating instructions with the machine at all times.

Always have inspection and maintenance work carried out on schedule.

Operating personnel

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

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

The necessaryy know-how can be acquired in several days’ instruction, e.g. by attending an operators’s training course.

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

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

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

Never install other equipment and component combinations without the manufacturer having first inspected and approved the project.

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

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

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

13

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D

Entering and leaving the machine

Marshallers

Always face the machine when entering and leaving.

The marshaller must keep outside the hazard zone.

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

Have a marshaller to assist you:

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

-

when you have no clear overview over the hazard zone, when reversing,

-

when shunting.

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

-

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

Keep in constant contact with the marshaller.

Stop the machine immediately, if you loose contact with the marshaller.

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

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

Securing the machine Secure the machine as described in the section "Securing the machine" before: -

mounting or dismantling the attachment,

-

parking the machine after daily operation, carrying out any servicing or repair work.

-

14

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D DESCRIPTION OF THE MACHINE

30000141

Fig. 1

Layout of the machine (Fig. 1) 1

-

Bucket

10

-

Battery

2

-

Tilting cylinder

11

-

Rear axle

3

-

Lifting cilinder

12

-

Transfer gearbox

4

-

Fuel tank

13

-

Travel motor

5

-

Driver’s cab

14

-

Steering cylinder

6

-

Hydraulic reservoir

15

-

Front axle

7

-

Air filter

16

-

Lifting frame

8

-

Engine

17

-

Quick-change device

9

-

Travel pump

15

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Basic unit

Hydraulic system

The basic unit accomodates all drive units and the control equipment.

The loader is equipped with two hydraulic systems:

Chassis

• the hydrostatic transmission

The articulated chassis frame consists of two parts. Front andrear frame are linked by a pinand-bearing connection enabling the frame to swivel about a vertical axis.

Drive unit The drive unit consists of an internal combustion engine and a hydrostatic transmission with travel pump and travel motor.

• the hydraulic steering and working system.

Steering is assisted by an hydrostatic power steering system. The working control commands are given by hand and are transmitted via control circuits.

The hydraulic system is equipped with pressurerelief valves.

Electrical system

Axles

The electrical system operates on 12 volts.

Front and rear axle are planetary gear-driven axles. The frontaxle is equipped with a limited-slip differential and the rearaxle with a conventional differential. The rear axle can also beequipped with a limited-slip differential (optional equipment).

The front axle is a rigid axle fixed to the front chassis section and the rear axle is a fully floating axle.

Working equipment

Brakes

30000142

The service brake is actuated by means of the brake / inching pedal. When the brake / inching pedal is depressed, the travel drive is cut out. If the brake / inching pedal is depressed further, the disk brake in the front axle and also the multiplate brake of the high-speed model (option) is actuated by braking pressure.

When the engine speed is reduced, the travel drive acts additionally as a service brake.

The parking brake acts equally on the disk brake of the front axle.

16

30000143

30000144

The loading equipment consists of the lifting frame with integrated hydraulic quick-change device, lifting and tilting cylinders and the bucket.

Further equipment, such as e.g. bottom-dump bucket, fork carrier with lifting forks or sweeper, can also be attached to the loader.

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Noise emissions

30000231

Outside the machine The sound intensity level LWA in operation is 98 dB(A).

CE Mark

1946704

The CE sign (Fig. 1) certifies that the machine has been built in accordance with the EG-directives 89/392, 91/368, 93/44, 93/68 and 98/37.

CE is short for "Communauté Européenne".

Measured in identical machines in acc. with Directive 2000/14/EC.

Inside the cab The sound pressure level LpA inside the cab is 77 dB(A).

Vibration level

30000145

Vertical vibration at the operator’s seat Following investigations on identical machines in driving and working operation through cycles of various lengths, the average vibration level is assumed to be EQUAL TO or LESS THAN 2:0 m/s2 (weighted effective value using the "broad-band method" in conformity with ISO 2631-1).

Fig. 1

Vibrations in the hands and arms Nach Following investigations on identical machines in driving and working operation through cycles of various lengths, the average vibration level is assumed to be LESS THAN 1.4 m/s2 (weighted effective value using the "broad-band method" in conformity with ISO 2631-1).

Through his personal driving behaviour, the operator has a substantial influence on the vibrations at his workplace.

To keep vibrations at a low level, the driving speed must be adapted to the respective ground.

Travelling at high speed on uneven ground should be avoided.

17

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Warning and instruction signs / Europe

Fig. 1

18

30000270

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Key to Fig. 1 Observe the warning and instruction signs attached to the machine.

10 - DANGER IN FRONT AREA OF THE MACHINE

Keep signs clean and legible.

11 - DANGER IN REAR AREA OF THE MACHINE

Replace signs immediately when they are no longer legible.

New warning and instruction signs can be ordered from the spare-parts service. The part number for ordering can be found in the spare-parts catalogue of your machine.

12 - DANGER IN AREA OF ARTICULATED JOINT 13 - ENGINE MUST BE STOPPED 14 - WHEEL FASTENING NUTS 15 - BATTERY MAIN SWITCH 16 - SUSPENSION POINT lifting 17 - SUSPENSION POINT tying 20 - FUEL filling 21 - SCREEN WASHER WATER reservoir 23 - OPERATOR’S MANUAL 24 - OPERATION INSTRUCTION SIGN lifting, lowering, back-tipping, opening 25 - HAND BRAKE RELEASE 26 - QUICK TOOL COUPLER BOLT 27 - TRANSPORT POSITION BUCKET 29 - FUSE BOX 40 - AXLE FASTENING NUT 53 - SIGN ether 67 - JOYSTICK 69 - STEERING COLUMN adjustable 70 - TOWING BOLT 71 - HANDBOOK operating instructions 72 - FRESH AIR FILTER 73 - HYDR. RESERVOIR VENTING 80 - GLASS BREAKAGE WARNING 90 - EMERGENCY EXIT 91 - ROTARY BEACON 92 - FIRE EXTINGUISHER 93 - ROAD TRAVEL BLOCKING 94 - FUSE/RELAYS

19

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Warning and instruction signs / North America

Fig. 2

20

30000233

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Key to Fig. 2 Observe the warning and instruction signs attached to the machine.

13 - ENGINE STOPPED 15 - BATTERY MAIN SWITCH

Keep the signs clean and legible.

16 - FIXING POINT LIFTING

Replace signs immediately if they are no longer legible.

17 - FIXING POINT TIE-DOWN

New warning and instruction signs can be obtained from the spare-parts service. The part number for ordering is given in the spare-parts list of your machine.

21 - SCREEN WASHER WATER

20 - FUEL 24 - BOPERATION INSTRUCTION SIGN LIFTING, LOWERING, BACK-TIPPING, OPENING 25 - PARKING BRAKE RELEASE 26 - QUICK TOOL COUPLER LOCKING PIN 27 - BUCKET TRANSPORT POSITION 29 - FUSE BOX 40 - AXLE FASTENING NUT 50 - QUICK TOOL COUPLER LOCKING PIN 51 - HYDRAULIC RESERVOIR BLEEDING 52 - BATTERY EXPLOSION HAZARD 53 - ETHER 54 - HAZARD ZONE AROUND ARTICULATED JOINT 55 - HAZARD ZONE IN FRONT 56 - ARTICULATED JOINT LOCKING DEVICE 57 - BRAKE PRESSURE ACCUMULATOR 58 - FAN MOTOR 59 - V-BELT 60 - STARTER 62 - OPERATING MANUAL 64 - SAFETY BELT 65 - HAZARD ZONE AT THE REAR 67 - JOYSTICK OPERATION INSTRUCTION SIGN 69 - STEERING COLUMN ADJUSTABLE 70 - TOWING PIN 71 - MANUAL 72 - FRESH-AIR FILTER 74 - HAZARD ZONE IN FRONT 80 - GLASS BREAKAGE WARNING 90 - EMERGENCY EXIT 91 - ROTARY BEACON 92 - FIRE EXTINGUISHER 93 - ROAD TRAVEL LOCK 94 - FUSE/RELAY 95 - START INDICATOR

21

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Machine number

30000147

The MACHINE NUMBER is engraved on the nameplate (Fig. 3).You will also find this number stamped into the chassis frame above the nameplate.

Axle number

30000245

The axle number is engraved on the type identification plate on the axle tube.

Fig. 5 Fig. 3

Engine number

30000202

The engine number is indicated on the type identification plate of the engine (Fig 4).

The type identification plate (Fig. 5) contains details about the axle.

The individual fields contain the following data: A = Axle type B = Number of customer C = Serial number D = Gearbox transmission ratio E = Type of differential F = Quantity of oil in differential G = Differential oil specification H = Quantity of oil in planetary gearbox I = Planetary gearbox oil specification J = Input speed

Fig. 4

22

K = Current number

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Travel pump number

30000156

Attachments

30000158

The nameplate with the travel pump number is located on the travel pump’s control unit (Fig. 6).

The loader attachments are equipped with an identification plate. Fig. 8 shows the identification plate of the bucket.

Fig. 6

Fig. 8

Travel motor number

30000157

The travel motor number can be found on the nameplate of the travel motor (Fig. 7).

Fig. 7

23

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D DRIVER’S CAB Entering and leaving the machine 30000148 Safety instructions

Clean off oil, grease, soil, mud, snow, iceand other substances from shoes, grab handles and steps.

Keep steps, platforms and grab handles in a non-slipperycondition.

Risk of injury due to slipping.

30000201

For driver safety, the wheel-loader is equipped with a ROPS/FOPS cab.

The plate (Fig. 2) shows detailed information about the cab. The plate is located on the left under the driver’s seat.

For entering and leaving use only the steps, platforms andgrab handles provided (see illustrations).

Always face the machine when entering or leaving it.

Fig. 2

The individual fields provide the following information.

A = Serial number Fig. 1

B = Cab year of construction C = Manufacturer’s logo D = Test structure ROPS/FOPS E = Machine type F = Operative weight G = Approval standards ROPS/FOPS H = Machine manufacturer

24

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Driver’s cab door

30000150

Opening the door

Fig. 1

Fig. 3

• Unlock door with key (Fig. 1).

To open the door from inside, press the lever (Fig. 3) down.

• Depress lock button and swing door sideways.

• The cab door engages in its limit position.

Closing the door

Always close the cab door before driving on the highway.

Fig. 2

To release, pull handle (1, Fig. 2) or press unlock button (2). The door can then be closed.

25

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Side window

30000234

For admission and evacuation of fresh air, the cab is equipped on the right-hand side with a hinged window.

Emergency exit If the cab door is unusable, get out through the side window.

Fig. 2 Fig. 1

• Pull the handle forwards (Fig.1).

• Swing the window open into blocking position.

• Open the window as described.

• Pull the handle backwards (Fig.2) and unblock the window.

• The window can now be opened completely.

Open the window completely only in an emergency as it cannot be blocked in fully open position Persons might be injured by the swinging window or the window itself may be damaged.

26

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Documentation

30000153

The documentation can be stored in the compartment on the left of the driver’s seat (Fig. 1).

Cab interior lighting 30000185

The interior lighting is switched on and off directly at the lamp (1, Fig. 3).

• To switch on, press on the left or right side of the lamp (1).

• To switch off, press the middle of the lamp (1).

Fig. 1

Sun visor

30000271

The sun visor (Fig. 2) is installed above the front screen.

Fig. 3

The lamp remains connected to the power supply even after the electrical system key-switch has been turned off.

For this reason, turn off the interior lighting when you leave the machine. The batteries may be discharged if the lamp remains on for a long time.

Fig. 2

27

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Adjusting the operator’s seat The operator’s seat can be adjusted in height and in fore-and-aft position. The seat suspension can be adjusted to suit the operator’s weight.

2905352

Weight adjustment The respective operator’s weight should be set by turning the weight adjustment lever (1, Fig. 1) while the operator’s seat is unloaded. The set weight can be read off at the window (2, Fig. 1).

Never adjust the seat while driving. Concentrate on the road to avoid accidents.

Before adjusting the seat: - stop the machine -

set travel direction lever to "0" apply parking brake.

The locking levers for fore-and-aft adjustment and for backrest adjustment must engage in the required position.

Once locked, the operator’s seat and the backrest must not be movable into another position.

Fig. 1

Adjusting the weight-oriented suspension

Height adjustment The height can be adjusted in several stages.

To avoid injury to the back, the suspension should be adjusted to suit the operator’s specific weight at each change of operator.

Raise operator’s seat as far as required until engagement is audible. If the seat is raised beyond the last stage, it drops back to the lowest position.

Fig. 2

28

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Fore-and-aft adjustment

Backrest adjustment

The fore-and-after adjustment is performed with the locking lever (3, Fig. 3).

The backrest inclination can be adjusted with the locking lever (4, Fig. 4).

Lift lever upwards in direction of arrow, move seat to required position and release lever. The lokking lever must engage in the required position.

Once locked, the operator’s seat must not be movable into another position.

Sit on seat and lean back lightly against backrest.

Pull locking lever (4) upwards in direction of arrow.

Adjust backrest by leaning back or forward, and release lever when backrest is in required position.

Fig. 3

Fig. 4

29

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D 30000235

Indicator and warning lamps

Fig. 1

30

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Indicator and warning lamps(Fig. 1) No. Designation

Seite 1 von 2

Function

1

Warning lamp

Alternator

Lights up when the battery is not charged.

2

Warning lamp

Engigne oil pressure

Lights up when the engine oil pressure is too low.

Shut off the engine and rectify the fault.

3

Warning lamp

Brake pressure

Lights up when the brake pressure is too low.

Stop the machine immediately and rectify the fault.

4

Preheating indicator lamp

5

Indicator lamp

Parking brake

Lights up when the parking brake is applied.

6

Warning lamp

Engine oil temperature

Lights up when the engine oil temperature is too high.

Shut off the engine and rectify the fault.

7

Warning lamp

Hydraulic oil temperature

Lights up when the hydraulic oil temperature is too high.

Shut off the engine and rectify the fault.

8

Warning lamp

Air filter

Lights up when the air filter is contaminated.

9

Indicator lamp

Main beam

Lights up when the headlamps are on main beam.

10

Indicator lamp

Turn signal

Flashes when the turn signal is activated.

11

Indicator lamp

Forward travel

Lights up when forward travelling is selected.

12

Indicator lamp

Creep speed

Lights up when creep speed is activated.

13

Indicator lamp

Reversing

Lights up when reverse travelling is selected.

Symbol

Lights up during automatic preheating.

31

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Indicator and warning lamps

Fig. 2

32

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Indicator and warning lamps(Fig. 2) No. Designation 14

Fuel gauge

15

Speedometer

16

Operating hours meter

17

Temperature indicator

Page 2 of 2

Function

Symbol

Indicates the fuel tank filling level.

(option)

indicates the travelling speed in km/h and mph. (only with high-speed option)

km/h mph

Indicates the working hours of the machine.

Engine oil

Indicates the engine oil temperature.

33

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Switches and pushbuttons

Fig. 3

34

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Switches and pushbuttons (Fig. 3) No. Designation 20

Function

Steering column lever switch

Symbol

Signal horn, travel direction, main beam, front screen wiper / washer.

21a Signal lamp

Fast speed (option)

Indicates that fast driving speed has been selected.

21b Signal lamp

Emergency steering (option)

Monitors the emergency steering system

22

Switch

Fast speed (option)

Preselects fast driving speed Fast speed active lamp 21a ON

24

3-position switch

Lighting

Parking lamp ON - depress switch down to 1st notch.

Dipped beam ON - depress switch down to 2nd notch.

Parking lamp / dipped beam OFF depress switch face without symbol.

25

Rocker switch / Rear screen wiper / pushbutton washer

To activate the wiper - depress symbol side of switch.

To activate the washer - depress and hold symbol face of switch.

To deactivate the wiper - depress switch face without symbol.

26

Rocker switch

Working floodlamp, front (option)

To activate the floodlamp - depress symbol face of switch.

To deactivate the floodlamp - depress switch face without symbol.

27

Rocker switch

Working floodlamp, rear (option)

To activate the floodlamp - depress symbol face of switch.

To deactivate the floodlamp - depress switch face without symbol.

28

Rocker switch

Load stabilization

Activates and deactivates the load stabilization

29

Rocker switch

Acoustic reversing signal (option)

Activates and deactivates the acoustic reversing signal

30

Rocker switch

Rotary beacon reversing alarm shut-off (option)

Rotary beacon ON depress symbol face of switch Rotary beacon OFF depress switch face without symbol

31

Optional

32

Optional

35

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Switches and pushbuttons

Fig. 4

36

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Switches and pushbuttons(Fig. 4) No. Designation

Function

33

Switch

Air conditioner (option)

34

Locking

Road travel

35

Socket outlet

12V

36

Lever

Steering column lock

Adjusts the steering column.

37

Foot-switch

Quick tool coupler release

Activates the hydraulic circuit of the quick tool coupler.

38

Service brake and inching

Depress pedal - machine is braked gently.

Depress pedal fully - machine is braked with service brake.

39

Accelerator pedal

Controls the travelling speed.

Symbol

Activates and deactivates the air conditioner.

40a 3-position switch

Travelling / working

Switches the travelling functions forwards neutral - reversing

40b Control lever

Working

Lifting/lowering - bucket dumping

40c Switch

Working gear/ creep speed

Switches between two different speeds.

41

Lever

Auxiliary hydraulic function

Activates an additional hydraulic function (bottom-dump bucket, broom, etc.)

A simultaneous press on the release foot-switch (37) activates the quick tool coupler.

42

3-stage blower switch

43

Rotary switch

Heating

Controls the heating power.

44

Switch / Indicator lamp

Hazard warning system

Activates and deactivates the hazard warning system.

Flashes when hazard warning is active.

45

Armrest

46

Key-switch

Electrical system ignition lock

Activates and deactivates the electrical system.

Starting / Stopping the engine.

F N R

1, 2, 3 = blower intensity stages 0 = OFF

37

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D PUTTING THE MACHINE INTO OPERATION Prior to starting up the machine each day, carry out the works listed in maintenance schedule T (see Section 3 "Inspection and Servicing").

Refuelling Refuelling, safety instructions

Explosion hazard Do not smoke and do not use open flames.

Diesel fuel may be harmful to the skin.

Wear protective gloves or apply a barrier cream.

Stand the working equipment on the ground.

Shut off the engine.

Apply the parking brake.

Do not spill fuel and do not let it penetrate into the ground. This constitutes an environmental hazard.

Soak up spilt fuel immediately with rags or binding agents. Then discard without polluting the environment.

Report accidents involving fuels without delay to the machine owner or his agent.

30000277

Fuel

Read and observe the engine operating instructions.

Use commercial-grade diesel fuels with a sulphur content of less than 0.5%.

The following fuel specifications are approved: • DIN EN 590 • BS 2869 • ASTM D 975-96; 1-D and 2-D

Filling in fuel

Fig. 1

• Open the tank lock.

• Unlock the tank cap (1, Fig. 1) by turning the key 90˚ counterclockwise and remove the cap.

• Fill in fuel through the filler neck.

If possible, use a microfilter in the filling line.

38

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Switching the electrical system 30000163 on and off Battery main switch (option) The battery main switch (1, Fig. 1) is located on the right under the engine hood

Never set battery main switch to OFF when the engine is running. The voltage spikes produced during shut-off may cause irreparable damage to electrical component.

The battery main switch (1) serves the purpose of disconnecting the electrical system as a whole from the battery. The switch positions shown in Fig. 1 have the following meaning: I = ON II = OFF In the OFF position, the battery main switch (1) prevents • unauthorized starting of the engine • unintentional discharging of the battery.

Fig. 1

39

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Starting and stopping the engine

30000246

Starting the engine

Exhaust gases from the engine are a health hazard.

Start the engine only in the open or on premises equipped with an exhaust gas evacuation system.

Fig. 2

Fig. 1

• Apply the parking brake with lever (7, Fig. 3).

• Release the key. The key returns to position 1 .

Increase the engine speed briefly by depressing the accelerator pedal.

The alternator (1, Fig. 2) and engine oil pressure (2) warning lamps go out.

If the machine is started after a downtime, it may take up to 45 s until the emergency steering accumulator (option) is charged and the indicator lamp goes out.

The indicator lamp of the parking brake (5) continues to be lit up.

• Switch off the travel direction.

To do so, set switch (40c, Fig. 4) to neutral position.

• Deactivate the immobilizer(option).

• Turn key in key-switch (Fig. 1) to position 1 .

All warning and indicator lamps light up briefly (self-test).

After the self-test, the alternator (1, Fig. 2) and the engine oil pressure warning lamps (2) are lit up.

At low temperatures, the preheating indicator (4) is on.

When the brake pressure is too low, warning lamp (3) is on.

When the parking brake is applied, indicator lamp (5) is on.

• Hold key in position 1 until the preheating indicator (4) and the brake pressure warning lamp (3) go out.

• Turn switch to position X. The engine starts up.

40

If the warning and indicator lamps do not go out when the engine is running, shut off the engine immediately.

Locate the cause of the fault and rectify before restarting the engine.

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Engine does not start

Do not use additional starting aids, for instance, by injecting starting-aid fluid.

Risk of accident due to uncontrolled deflagrations.

Stopping the engine

Do not stop the engine out of full load, but let it run for another 3 minutes at idling to allow for cooling.

If the engine does not start, repeat the starting procedure. If the engine does not start after 10 seconds of uninterrupted starting, turn the keyswitch (Fig. 1) back to position 1 and wait one minute.

Turn key-switch to position 0 and start again.

For starting in winter or in the event of engine faults, observe the instructions in the engine manual.

The engine cannot be started by towing the loader as the wheels are blocked by the hydrostatic travel drive.

Fig. 3

• Stand the working equipment on the ground.

• Switch off the travel direction. To do so, set switch (40c, Fig. 4) to neutral position. Indicator lamps (11 and 13, Fig. 2) must go out.

• Set control lever (40b, Fig. 4) to position 0.

• Apply the parking brake with lever (7, Fig. 3).

Indicator lamp (5, Fig. 2) is on.

Fig. 4

• Turn the key-switch (Fig. 1) to position 0 . The engine is shut off.

• Withdraw the key.

• Secure the loader against inadvertent movements and unauthorized starting.

41

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Ventilation and heating

30000236

The cab is ventilated through the right side window and by a blower. The blower mixes fresh air with recirculated air.

Ventilation The rotary slats of the air outlets (Fig. 1, 2 and Fig. 3) direct the air flow towards the front and rear window, the side windows and into the leg area.

Fig. 3

Ventilation / fresh air The air is sucked into the cab through the filter (Fig. 4).

Keep the suction openings clean.

Fig. 1

Fig. 4

Fig. 2

42

The filter is located on the right side of the vehicle below the side window and accessible after opening the right service flap.

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Heating The heating efficiency depends on the temperature of the engine. Full heating performance is therefore available only after the engine has reached its operating temperature.

Adjusting the heating performance The heating intensity is controlled by means of rotary switch (43, Fig. 5).

Air conditioner (option)

30000167

Activation / deactivation Switching on the air conditioner • Start the engine (see operating instructions) • Switch on the air conditioner with switch (33, Fig.2).

• Set the blower (42, Fig.1) to level 1 or higher.

Fig. 1 Fig. 5

Turn switch (43, Fig. 5) to the right - heating off.

Turn switch (43) to the left - heating on.

Even if it is not needed during longer periods, the heating should be switched on at least once a week for about 5 minutes at full performance to mix the oil in the engine and the heating.

Adjusting the conditioner air temperature The temperature of the air blown into the cab can be steplessly adjusted with knob (43).

Settings: • fully to the left (min) = cooled air.

Blower

• fully to the right (max) = mixed air.

The blower for heating and/or ventilation is switched on with rotary switch (42).

For higher cooling or heating performance, the blower can be switched to levels 2 and 3.

Turn switch (42) to the left - blower off.

Prerequisites for good cooling performance:

Turn switch (42) to the right - blower on.

• The suction opening for fresh air on the right side of the cab must not be covered up or soiled.

• Filter, cooler/heater and the ribs of the evaporator and the heat exchanger must be clean.

• Doors and windows of the cab must be closed.

Important: More information (e.g. adjustment of the air outlets) is provided in the "Ventilation and heating" chapter.

43

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Signal horn, turn signal, main beam and screen wiper / washer

30000025

Fig. 2

Fig. 1

The following functions can be selected with lever (20, Fig. 1):

Position Function

44

Symbol

Remarks

1

Signal horn

Depress lever button towards position 1

2

Turn signal left

Pull lever towards position 3. Indicator lamp (10, Fig. 2) is lit up.

3

Turn signal right

Move lever towards position 2. Indicator lamp (10, Fig. 2) is lit up.

4

Main beam

Pull lever towards position 4. Main beam when dipped beam is on.

Indicator lamp (9, Fig. 2) is lit up.

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D The rotary handle of the lever selects the following functions: 0 = wiper off J = intermittent wiping I = wiper on • To switch on the screen wiper:

The fluid reservoir (Fig. 4) for the screen washer is located in the engine compartment.

After opening the engine hood, the reservoir is accessible in the right sidewall For topping up, remove cap and fill in water.

In winter, add antifreeze to the water.

- turn handle to position J (intermittent wiping) - turn handle to position I (wiper) • To switch off the screen wiper: - turn handle to position 0 • To switch on the screen washer: - move lever (20, Fig. 3) to position 6 and maintain in this position.

- set screen wiper to position I .

• To switch off the screen washer: - release lever (20).

- set screen wiper to position 0 .

Fig. 4

Fig. 3

45

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Lighting

30000026

The lighting can be switched on and off with rocker switch (24, Fig. 1).

Fig. 1

Fig. 3

• To switch on the sidemarker lamps

• To switch off the main beam

- Press the symbol face of rocker switch (24) until the switch engages in the 1st notch.

- Raise lever (20) again to position 4 and release.

Rear screen wiper / washer

30000187

Fig. 2

• To switch on the dipped-beam headlamps - Press symbol face of rocker switch (24) until it engages in the 2nd notch.

• To switch off the dipped-beam headlamps / sidemarker lamps - Press the blank face of rocker switch (24).

• To switch on the main-beam headlamps - The main beam is activated and deactivated with lever (20, Fig. 3).

Raise lever (20) to position 4 and release.

Indicator lamp (9, Fig. 2) is lit up.

The headlamps can be switched to main beam only when the dipped-beam lamps are on.

46

Fig. 1

• To switch on the wiper - Press symbol face of rocker switch (25, Fig. 1) down to the 1st notch.

• To switch on the washer - Press symbol face of rocker switch (25) further down and hold.

• To switch off - Press blank face of switch.

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Socket outlet

30000169.01

DRIVING Driving, safety instructions

30000237

Raise the working equiment only to such an extent that the machine can pass under overhead power lines without risk.

Adjust the driver’s seat, the steering column and the rear-view mirrors before setting off.

Fig. 2

The socket outlet 12 V (Fig.2) can be used for connection of a hand lamp, for instance.

The machine is equipped with a retaining belt for the operator. Put on the belt before setting off.

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

Never drive across slopes.

Risk of battery discharge when the engine is stationary.

Take the utmost care on on slippery and greasy ground.

Make sure the wheels have adequate grip.

Only then are the steering and braking properties assured.

When driving on the road, install the transport safety locks and close the cab door.

Give the engine 2 to 3 minutes’ time to warm up before setting off and before running the engine at full load.

47

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Adjustment of steering column

Seat belt

2905762

Steering column - Safety instructions

Do not adjust the steering column during driving. Concentrate on the road to avoid accidents.

Before adjusting the steering column: - Stop the machine - Stand working equipment on the ground - Set the travel direction to "0" -

Apply the parking brake.

2905416

Seat belt - Safety instructions

Always belt up before driving.

Never run belt over rigid or fragile objects such as bunches of keys or spectacles.

This may result in injury.

The belt must always be flat and firm against the body and must not be jammed.

The buckle opening must not be locked, e. g. with paper, as the buckle can then not engage.

Damaged seat belts and those stretched in an accident must be replaced.

Adjusting the steering column

30000173

Adjust the position of the steering column to suit your height and posture.

The driver’s seat is fitted with a lap-type seat belt (Fig. 2).

• Press lever (39, Fig. 1) downwards; the steering column moves into front position.

• Pull steering column back into the desired position.

• Release the lever to lock the steering column.

Fig. 4

Fig. 3

48

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Control lever - Travelling / Working The wheel loader is equipped with a lever (25, Fig. 1) for controlling the travelling and working operations.

The control operations for the working equipment are described in the "Working" chapter.

30000170

Switch (40c, Fig. 1) switches from creep speed to working speed and vice versa.

When the creep gear is engaged, indicator lamp (12, Fig.2) is on.

Fig. 1

Fig. 2

Switch (40a, Fig. 1) is the selector switch for forward / reverse travel with the following positions.

When the creep speed is active, the wheel loader is limited to the maximum speed that can be reached in this gear. This is important for work requiring low working speeds.

• Switch (40a, Fig. 1) in middle position (position N) - no travel direction selected.

Indicator lamps (11 and 13, Fig. 2) are off.

When the working speed is active, the creep gear range can be included automatically as required.

• Switch(40a, Fig. 1) forwards (position F) - forward travel activated.

Indicator lamp (11, Fig. 2) is on.

• Switch (40a, Fig. 1) backwards (position R) reverse travel activated.

Switch (13, Fig. 2) is on.

As long as the parking brake is applied, the forward and reverse functions can only be preselected, but not activated.

The forward (11) or Reverse (13) directions are indicated only after the parking brake has been released.

The gears can be shifted only after the the parking brake has been released.

49

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Driving

2800716

Warming up the machine

Braking and stopping

Warm-up is necessary:

To brake the machine during travelling, it is generally sufficient to take the foot off the accelerator pedal (39, Fig. 1). In this case, the driving speed is efficiently reduced by the hydrostatic travel drive.

• after prolonged downtimes of the machine • at temperatures around and below freezing.

30000171

Warming up should be performed with the machine being stationary or driven at very low speed.

Engine

Allow the engine to warm up for 2 - 3 minutes before setting off.

Do not operate the engine at full load unless it has reached operating temperature.

Fig. 1

Steering and working hydraulics During engine warm-up, turn steering wheel several times fully clockwise and counter-clockwise.

Extend and retract all hydraulic cylinders several times.

Do not warm up the steering and working hydraulic systems by maintaining the steering wheel or the control lever in the limit stop position.

Front and rear axle Drive the machine at low speed for a few minutes forwards, backwards and round.

50

To stop the wheel loader completely, depress brake pedal (38). The disk brake on the front axle is applied. The power output of the hydrostatic drive is automatically decreased at the same time even if pedal (39) is not released.

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Driving Setting off

Before setting off, observe the indicators (12 - 15, Fig. 1) for driving.

30000238

Travel direction and working mode Working speed - creep speed The functions can be engaged under load, i.e. the machine must not be stationary before switching the function. Switching over to opposite driving direction - even in position N - should, however be avoided, as the machine is then braked abruptly.

Reduce speed beforehand.

The brake pedal (38, Fig. 3) fulfills two functions.

Fig. 1

• Check that the steering column is locked.

• Raise the working equipment slightly.

• Release the parkin brake.

Fig. 3

• Give a signal with the horn.

When the pedal is depressed slightly, the travel pump is swivelled back to low output and the travelling speed reduced (inching).

When the press on the pedal is increased, the machine is being braked by means of the disk brake in the front axle.

• Select the travel direction with switch (40a, Fig. 2) in control lever (40b) and, if desired, shift into the other gear with button (40c).

The pedal thus offers the possibilty to perform precision maneuvers such as soft starting, precise shunting and controlled braking independent of the engine speed.

During inching (slow driving), the travel drive needs less power than without inching, so that more power is available to the working hydraulics.

Fig. 2

With switch (40c, Fig. 2), the machine can be switched between normal working speed and creep speed. In creep gear, the travelling speed is limited. The creep speed is particularly useful for precision work such as levelling or sweeping operations.

Regulate the speed with accelerator pedal (39, Fig. 3).

51

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D High-speed model (option)

30000174

Activating the high-speed function The wheel loader with high-speed option is designed for a maximum speed of 35 km/h (22mph). Exceeding the maximum speed may cause damage.

If the maximum speed of 35 km/h (22mph) is exceeded during driving (red range of speedometer), release the accelerator pedal to reduce the driving speed. During downhill drives, brake the machine with the brake pedal to bring the machine back into the admissible range.

If the machine reaches a speed of more than 35 km/h (22mph) also on level terrain, contact the Technical Service to have the hydrostatic travel drive readjusted.

Fig. 1

• Switch on or start the machine • The engine is running, working or creep speed is engaged.

• Preselect the high-speed gear with rocker switch/button (22, Fig. 1). Set switch to middle position.

• Press brake pedal fully down until indicator lamp (22) is ON.

It is absolutely necessary that the machine is stationary

• Press symbol face of button (22).

• Indicator lamp (12, Fig. 2) is OFF. Lamp (21a, Fig.1) is ON. • Release the brake pedal - Indicator lamp (22) is OFF. • Set rocker switch (22) to OFF position. Highspeed remains active.

• Set off slowly.

52

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Switch off high-speed function

Fig. 2

• The machine is running, the high-speed function is on.

It is absolutely necessary that the machine is stationary

• Set rocker switch to middle position (22, Fig.1).

• Press brake pedal strongly until indicator lamp (22) is ON. • press symbol face of button (22).

• Indicator lamp (21a) is OFF. • When creep speed is active, indicator lamp (12, Fig.2) is ON. • Release brake pedal. Indicator lamp (22, Fig.1) is off.

• Set rocker switch (22) to OFF. • The high-speed function is deactivated when the machine is shut off (engine off) and the working speed is engaged.

• Set off slowly (working or creep speed is engaged).

53

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Load stabilization system (option)

The load stabilization system cannot be used together with the pipe break option.

30000239

The load stabilization system is deactivated when a factory-adjusted lifting height is exceeded (1, Fig.2).

The load stabilization system must not be used for driving on the public highway. Observe the country-specific highway code and other regulations.

The load stabilization option is a hydraulic damping system for the loading and lifting mechanism of the wheel loader.

The system helps to relieve the bearings, axles and tyres when the machine is being driven over rough ground and on bumpy roads.

The load stabilization system provides very high driving safety and excellent driving comfort.

Fig. 1

The system is switched on and off with rocker switch (28, Fig.1).

• When the load stabilization system is active, indicator lamp (28) is on.

54

Fig. 2

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Monitoring the indicators and instruments Watch the warning lamps (Fig. 1) during driving.

The wheel loader works troublefree as long as no warning lamp is on and no acoustic warning is heard.

30000176

Engine oil pressure When the engine oil pressure is too low, warning lamp (2) lights up and a warning signal is sounded.

Stop the wheel loader, shut off the engine, locate the cause and rectify or contact the Technical Service.

Alternator In the event of an Alternator malfunction, only warning lamp (1) lights up.

Fig. 1

If the warning lamp (1) does not go out after increasing the engine speed, shut off the engine, locate the cause and rectify.

Stop the loader immediately when a warning lamp lights up and and acoustic warning signal is heard.

If necessary, shut off the engine, locate the cause and rectify or contact the Technical Service.

Hydraulic oil temperature

Air filter When the air filter is contaminated, warning lamp (8) lights up and a warning signal is sounded.

When warning lamp (8) is on, the filter must be cleaned or replaced even if the maintenance interval has not yet elapsed.

When the hydraulic oil temperature is too high, warning lamp (7) lights up and a warning signal is sounded.

Stop the wheel loader, shut off the engine, locate the cause and rectify or contact the Technical Service.

55

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Engine oil temperature

Brake pressure monitoring

The engine is cooled by oil. The engine oil is cooled in the combined radiator and returned to the lubricating oil circuit of the engine.

The circulation of the engine oil is controlled by a thermostat.

The maximum admissible temperature is approx.

135˚C. The engine oil temperature is monitored by an indicating instrument (17, Fig. 2).

If the brake pressure drops sharply during driving, the wheel loader will be stopped immediately.

At the same time, warning lamp (3) lights up and the acoustic warning signal is sounded.

Secure the machine as described under "Securing the machine".

Locate the cause of the pressure drop and rectify or contact the Technical Service before putting the loader back into operation.

Brake pressure monitoring in high-speed gear (option)

Fig. 2

When the engine oil temperature is in the green range, the machine works troublefree.

When the oil temperature indication (17) is in the red range, warning lamp (6) is lit up and an acoustic signal is heard, the engine oil temperature is too high.

When the brake pressure drops sharply during driving, the wheel loader will be stopped immediately if the loader speed is less than 5km/h (3.1 mph). At the same time, warning lamp (3) lights up and the acoustic warning signal is sounded.

If the speed is higher than or equal to 5 km/h (3.1 mph), only warning lamp (3) is lit up and the acoustic warning signal is sounded.

Secure the machine as described under "Securing the machine".

Stop the wheel loader immediately and let the engine run at idling for cooling.

Turn the heater control to warm.

If the warning lamp (6) continues to be on after several minutes of idling and if the oil temperature indication (17) remains in the red range and if the acoustic warning is still sounding, stop the wheel loader immediately and shut off the engine.

Secure the machine, locate the cause and rectify or contact the Technical Service.

56

Locate the cause of the pressure drop and rectify or contact the Technical Service before putting the loader back into operation.

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Driving on public roads Observe the highway code and the safety regulations in force in the country of use.

30000240

Before driving on public roads • Empty the bucket and tip fully backwards. Bring loading equipment into transport position (see marking on the left, Fig. 1).

When driving on public roads, the loader must be equipped with a first-aid kit (1, Fig. 3), a warning triangle (2), a fire extinguisher (4, Fig. 4) and a warning beacon (3, Fig. 3).

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

Have the fire extinguisher inspected at the prescribed intervals by authorized workshops.

Fig. 1

• Cover up the front edge of the bucket with a guard strip.

• Check brakes, steering, tyres and lighting.

• Protect the control lever for loading bucket equipment and auxiliary function (40b and 41, Fig. 2) against inadvertent activation with lokking mechanism (34) (see section "Control lever locking mechanism"), • Switch off the working floodlamps.

• Switch off the load stabilization system (option).

• Check whether the steering column is locked.

• Close the cab door.

• Check the settings and locks of the driver’s seat.

• Attach the safety belt.

• Adjust the mirrors.

57

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Recovering / towing of the machine

1946670

Recovery and towing, safety instructions

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

Fig. 2

The first-aid kit (1, Fig. 3) and the warning triangle (2) are to be stowed away on the left side of the driver’s seat.

The rod or the rope must not be damaged. They must be dimensioned in such a way that their theoretical breaking load is equal to three times the tractive power of the towing machine.

The towing pin is designed for a maximum towing force of 5800 kgs.

The towing vehicle must have sufficient tractive power. Drive slowly and carefully.

Nobody must stand near the towing rod or rope.

Tow away only if the breaks and the steering of the machine are functional and if the machine cannot be transported with other means.

Tow non-functioning machines as far as needed to remove the machine from the hazard area.

After recovery, the machine must be secured against rolling away and inadvertent starting.

Fig. 3

A holder for a fire extinguisher (4, Fig. 4) can be installed in front at the right beside the accelerator pedal.

Fig. 4

58

Before long transports, repair the machine or load onto a transport vehicle.

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Towing lug The towing lug (Fig. 1) is located at the rear of the machine.

2905421

Never use the towing lug to tow trailers.

Unlocking Lift catch (2, Fig. 2); bolt (1) can be pulled up (Fig. 3).

Fig. 1

Fig. 2

Fig. 3

Locking Lower bolt (1); catch (2) is automatically locked.

59

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Towing

30000188

The machine must be towed only with a low speed of approx. 2 km/h (1.2 mph) and over a maximum distance of 0.5 km to prevent irreparable to the travel motor from overheating.

Do not tow longer than necessary to recover the machine from the hazard zone. and damaged.

Remove the protective caps (1, Fig. 1) from the valves for forward (3) or reverse travel (2).

Fig. 1

Slacken the hex nut (6 or 7) by 1 1/2 to 2 turns.

Hold the hex nut with a fork wrench and turn down setscrew (4 or 5) with an Allan key until it is flush with hex nut (6 or 7). Retighten the hex nut.

Do not turn down the setscrew (4 or 5) further than described above. Risk of damaging essential parts of the valves.

After towing, slacken hex nut (6 or 7). Turn out setscrew (4 or 5) completely and retighten hex nut (6 or 7).

For towing over longer distances remove the cardan shaft between both axles and either tow with the rear axle in the air or or transport the loader on a low-bed trailer.

Block the articulated joint

60

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Transport

2904991

Transport - Important information

Never load and transport the machine unless all safety regulations are fulfilled.

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

The responsibility for loading and transport is with the transport company or its representative.

Loading by crane

If the machine is to be lifted with a crane, the articulated joint must be blocked (Fig. 3).

Loading by crane requires loading gear. The fastening points are marked on the machine (Fig. 2).

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

Ensure that lashing gear has sufficient strength (machine-relevant weights are given under "Technical data").

Drive wheeled loader onto low-bed trailer and lower working equipment.

Fig. 2

Block the articulated joint.

Never actuate the steering when the articulated joint is blocked.

Remove articulated-joint catch after transport but before unloading the machine (Fig. 3).

Secure machine with appropriate means (lifting tackle, wire cables, chains, tensioners, chocks) (Fig. 1).

Fig. 1

61

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Blocking the articulated joint Drive loader into such a position that the boreholes of the holders (1 and 2, Fig. 3) are aligned one above the other. Then secure with the pin (3). The pin (3) is located in a support (4, Fig. 4) on the frame.

When the pin (3) is not in use, push it into the support (4, Fig. 4) and press into the spring clip (5) as far as the limit stop.

Fig. 3

Fig. 4

62

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D WORKING OPERATION Working operation, safety instructions

Read the chapters "Fundamental safety instructions" and "Operation, safety instructions" thoroughly and observe the information provided in these chapters.

Inspect the site for underground gas, electricity and water lines before starting work. Any damage to these lines is a lifethreatening risk.

Clean off any earth, mud, snow, ice, grease and oil adhering to your working footwear before operating the machine. There is otherwise a risk of slipping off the steps and pedals and thus of initiating inadvertent working movements.

Sound the hooter to warn persons in the immediate vicinity before starting work.

30000178

At low temperatures, warming up of the hydraulic system is necessary (depending of the vicosity of the oil used, see "Inspection and servicing, lubricants"). To warm up, actuate all hydraulic control elements for about 10 minutes.

Lower the working equipment immediately and shut off the engine as soon as the warning lamps for engine oil temperature, hydraulic oil temperature and alternator light up and an acoustic warning signal is sounded.

The working equipment can be lowered while the engine is stationary.

Never operate the hydraulic pump at maximum pressure when the engine is running at low speed.

Stop work if anyone is in the hazard range of the machine. Make sure they have left the hazard range before resuming work.

Always use and operate the wheel loader in such a way as to guarantee its stability.

Bear the load capacity of the machine in mind (see "Technical Data").

Trenches and buildinging pits may give way. Keep well clear of them.

Before starting work

2487659

Before starting work, the operator must check all controlelements for proper functioning.

He must also extend and retract the piston rods of allhydraulic cylinders several times at increased engine speed(pedal pressed down by abt.

2/3) and with the parking brake applied - toeliminate existing voids in the cylinders.

63

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Driving the machine on the public highway 30000179

Read and observe the chapter "Driving on the public highway" carefully and observe the instructions provided there.

For drives on the public highway, the loading bucket must be empty. Lock the control levers in neutral position.

Make sure the toggle lever and the bucket cannot move as a result of inadvertent actuation of the control levers.

Check the levels of all consumables and the tyre pressure beforehand.

The working equipment must be kept within the machine dimension limits and be brought into transport position to permit troublefree driving on the road.

If the loader starts swinging up and down due to road conditions, the travelling speed must be reduced by braking.

Continue to travel with a lower speed.

Caution - When driving on the public highway the prescriptions of the Motor Vehicle Safety Standards must be observed. The lighting system of the machine must be in perfect condition. Defective lamps and fuses must be replaced immediately.

N.B.- The prescriptions mentioned may differ depending on the traffic standards in force in other countries. Observe all adaptations and modifications.

Road travel

Check all signal lamps, lamps and the hooter for perfect condition.

Some tyre types and treads are not suited for road travel.

Ask your tyre supplier.

Always observe the braking distances and adapt the travelling speed of the machine accordingly.

Observe all traffic regulations! In the event of traffic jams, drive the loader on the lay-by and give other vehicles the right of way.

After two hours of travelling, stop the machine for half an hour to allow for cooling down of the tyres.

The tyre pressure rises during travelling. Correction is, however, not necessary as this is normal.

Check the instrument panel frequently to make sure the loader is in a perfect state of operation.

It is recommended to have another vehicle accompany the loader which can draw the attention of other drivers by corresponding signals (flashing beacons, signs, etc.) to a slow-moving machine.

Fig. 1

1 - Locking lever for working functions 3 - Headlamps 4 - Rotary beacon 5 - Rear light 6 - License plate lighting 7 - Bucket teeth guard strip

64

30000180

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Loading bucket equipment control lever

Floating position of loading bucket 30000181

The control lever (40b, Fig. 1) is used for initiating the working movements.

Never activate the floating function when the working equipment is in lifted position as the equipment would otherwise sink too fast.

In machines with pipe break protection, the floating position is not operational. The control lever cannot be moved into position 2a.

Floating position 2a permits levelling a subgrade while the machine is reversing.

Fig. 1

Control layout (Fig. 1): 0 = holding position 1 = lifting 2 = lowering 2a = floating position (lock position) 3 = back-tipping 4 = dumping

For levelling, stand the bucket on the ground.

Then, set control lever (25) to position 2a and engage. The bucket now rests freely on the ground, loaded only by its own weight. After setting back the control lever to position 2, the floating position function is cancelled.

Pull the control lever by hand back from position 2a into position 2. From all other positions, the lever goes back to neutral automatically .

Fig. 2

65

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Using combined functions

Control lever additional function Control lever (41, Fig. 4) can be used switching additional hydraulic functions, e.g. hydraulic quick tool coupler, bottom-dump bucket, sweeper attachment.

In the foremost position, control lever (41) has a lock facility, e.g. for sweeper operation.

Fig. 3

To combine two functions (Fig. 3): 1/4 = lifting + dumping 2/4 = lowering + dumping 2/3 = lowering + back-tipping If two functions are combined, e.g. 1/4, 2/3 or 2/4, the two movements of the bucket will be performed simultaneously depending on the loading of the hydraulic circuits lifting / lowering and and back-tipping / dumping.

Fig. 4

Quick tool coupler

Thus, it is possible in position 1/4 to raise the lifting frame during dumping. This is useful when loading material onto lorries.

The wheel loader is equipped with a hydraulic quick tool coupler. Lever (41, Fig. 4) controls the following functions:

After emptying the bucket, select combined function 2/3, for lowering and back-tipping at the same time so that the bucket already has the required digging angle when it reaches the ground.

Control lever (41) forwards - quick tool coupler unlock

When two bucket movements are combined, the respective hydraulic circuits are connected in series and the movements themselves are executed one after another.

The quick tool coupler can only be activated if the enable button (37, Fig. 5) is pressed at the same time.

Control lever (41) backwards - quick tool coupler lock

It is possible to pass from the lifting position directly to the back-tipping position without going back to neutral first. The lifting function is then not active. After switching back to lifting, the function is reactivated. The above-described switching mode (priority switching) facilitates loading of material at the working face.

Fig. 5

66

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Control lever locking mechanism The control levers (40b and 41, Fig. 5) have a common mechanical locking device with which the working hydraulic functions can be locked, e.g. for road travel.

Fig. 6

Locking the control levers Turn knob (34, Fig. 6) counter-clockwise until the marking aligns with the "Locked" symbol.

Unlocking the control levers Turn knob (34) clockwise until the marking aligns with the "Unlocked" symbol.

67

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D OPTIONAL EQUIPMENT Bottom-dump bucket

30000182

Control lever (41, Fig. 7) initiates the following working movements:

Fig. 7

Control lever (41) forwards - bottom-dump bucket open Control lever (41) backwards - bottom-dump bukket closed Move the control in the same way for other equipment.

Connection of hydraulic lines, see Equipment "Attaching the bottom-dump bucket".

68

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D After daily operation

1946645

• Close windows.

Securing the machine To secure the machine carry out the following steps: • Secure the machine before carrying out any maintenance and repair work on the machine.

• Secure the machine before changing the attachments.

• Secure the machine before shutting it off after daily operation.

• Lock cab door and engine hood.

Cleaning and refuelling of machine • Remove gross dirt from machine.

• Fill up fuel tank.

Carry out visual inspection • for leaks in the hydraulic system • for leaks on axles and gearboxes

• Park machine on dry and level ground and stand the working equipment on a support or on the ground.

• If the machine is to be parked on sloping terrain, the machine must be positioned with the front facing downhill and with the teeth of the bucket pushed firmly into the ground.

• Secure the machine with the wheel chock (Fig. 1).

Escaping oil pollutes the environment.

Have leaks repaired immediately.

Report all oil accidents to the user of the machine.

• of the machine, tyres and the working equipment.

Chock

1946646

The chock is located below the cab door (Fig. 1).

Unsnap the spring clamp (2) and remove chock (1) from its support.

Fig. 1

• Apply the parking brake.

• The travel selector switches to neutral.

• Set control lever to position "0".

• Shut off engine.

Fig. 1

• Remove gross dirt from the machine.

Push chock (1) with the curved side against the tyre.

• Visual inspection: check hydraulic system for leaks.

• Visual inspection: check condition of machine, tyres and equipment.

When the chocks (1) are no longer needed, place back into the support and let spring clamp (2) engage.

• Protect the machine against unauthorized starting.

• Withdraw key from ignition switch.

69

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D WORKING EQUIPMENT

30000183

Assembling working equipment, safety instructions

Personnel

Tools and auxiliaries

Assembly work may be carried out only by operating or maintenance personnel who have the necessary know-how at their disposal.

Tools, hoists, slings, trestles and other devices must be in a safe and reliable state of operation.

If such know-how is lacking, meticulous instruction must be given by experienced personnel, e.g. from the manufacturer.

The operating manual and in particular the section headed "Fundamental saftey instructions" must have been read and understood.

Only such persons may start up the machine during assembly work in order to adjust the attachments.

Incorrect operation of the machine or the attachments may give rise to life-threatening situations.

Metal splinters may cause injury when attachment pins are being driven in or out.

A brass or copper mandrel should therefore be used for this purpose, and goggles must be worn.

Use the steps, platforms and handrails provided when climbing onto or off the machine.

Always keep steps and platforms as well as handles in a non-slip state. Remove any oil, grease, earth, clay, snow, ice and other foreign matter immediately.

Securing working equipment

Personal protective gear and working clothing

Stand working equipment on the ground in such a way that no movements can be made if mechanical or hydraulic connections become detached.

Wear closely fitting working clothing when working on the machine. Loose, wide garments may catch on machine parts and result in injury.

When working in jointed areas, block off the joints. Remove the blocks on finishing work.

Wear a safety helmet, safety footwear and gloves.

70

Secure any equipment or components which is to be mounted or dismantled, or whose position is to be changed, with hoists or appropriate slinging/supporting devices to prevent them from moving, slipping or falling inadvertently.

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D 2905636

Securing the machine Carry out work on the attachment only if the machine is secured as described in the section "Securing the machine".

Selecting the attachments The machine can be equipped with various attachments. The components of the attachments are assembled with hydraulic cylinders and connectors. Components can be combined in various ways for optimum adaptation of the attachments to the specific application.

Operate the machine only with the equipment and component combinations expressly approved by the manufacturer.

Cf. the "Technical Data" section".

Attachments from other manufacturers subject to the EC Machine Directive 89/392 EEC may be mounted and put into operation only if - the manufacturer’s declaration of conformity and - the declaration of compatibility from the manufacturer are at hand.

If the wheel-mounted loader is equipped with a bucket for light-weight material with a bulk density of less than to 1.4 t/m3, the driver’s field of vision can be obstructed.

In this case, work must either be carried out with the assistance of marshallers or the working range of the wheel-mounted loader be blocked off.

Other aids, e.g. monitor with camera, must have been checked for suitability for the specific deployment and approved.

If the machine is equipped with a quickchange device, ensure before beginning work that the quick-change device is safety locked with the working equipment.

30000190

The maximum operating pressure at the quick tool coupler i.e. at the hydraulic ports for the attachments is: 230 + _10 bars (23.000 kPa + _1.000 kPa).

71

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D TOOLS AND EQUIPMENT Quick tool coupler The wheel loader can be used with different working tools to be attached to the machine. For quick changing of the equipment, the wheel loader is equipped with an incorporated hydraulically operated quick tool coupler.

30000241

The quick tool coupler can only be activated if the foot-operated enable button (37,Fig. 2) is pressed at the same time.

Fig. 2 Fig. 1

Control lever (41, Fig. 1) is used for the following functions: control lever (41) forwards - quick tool coupler unlocked control lever (41) backwards - quick tool coupler locked

72

Do not raise the lifting frame in back-tilted condition without equipment. Risk of damage to the toggle lever and the connecting rod due to the absence of bucket stops.

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Bucket Attaching the bucket • Stand bucket on the ground.

• Drive forwards to align the lifting frame (10, Fig.3) and the bucket (11) ready for mounting (Fig. 3).

• When the pin has engaged (2), unlock the quick tool coupler, let the lower pins (3, Fig. 5) engage in the lifting frame and lock the coupler as shown in Fig. 5.

Fig. 5 Fig. 3

• Drive the loader towards the bucket so that the upper pin (2, Fig. 4) of the lifting frame engages the suspension hooks (4) of the bucket.

Fig. 4

73

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Checking the locked condition Raise the bucket slightly (transport position). In locked condition (3, Fig. 6) the pins (3) are visible on the outer edges (arrow).

If the pins (3) are not visible, stand bucket carefully on the ground and repeat the mounting procedure.

Fig. 6

74

Detaching the bucket Stand the bucket on the ground and unlock the quick tool coupler.

Tilt the lifting frame so that pin (2, Fig. 7) can be withdrawn from the suspension of the bucket by reversing the wheel loader.

Fig. 7

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Bottom-dump bucket (option)

30000192

Attaching the bottom-dump bucket Attach the bottom-dump bucket as described under "Attaching the bucket".

Shut off the engine and depressurize the hydraulic system by actuating control levers (40b and 41). Move the levers until the equipment stops performing working movements.

The eyelet welded onto the bottom-dump bucket (3, Fig.3) must only be used for transporting the bottom-dump bucket itself.

Do not transport loads with this eyelet.

Connect the hydraulic hoses (1 and 2, Fig. 1).

Fig. 3 Fig. 1

Detaching the bottom-dump bucket The hydraulic hoses must be connected in such a way that the following working movements are initiated when control lever (41, Fig. 2) is actuated.

Control lever (41) forwards - open bottom-dump bucket Control lever (41) backwards - close bottom-dump bucket

Stand the bottom-dump bucket on the ground.

Shut off the engine and depressurize the hydraulic system. To do so, actuate control lever (40b,41, Fig. 2) until the equipment stops peforming working movements. Detach the hydraulic lines (1,2, Fig. 1). Close the hydraulic lines and the openings with caps.

Continue as described under "Detaching the bukket".

Fig. 2

If this is not the case, exchange the hydraulic hoses (1,2, Fig. 1).

75

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Carrier with lifting forks

30000193

Attaching the carrier

Detaching the carrier

Stand carrier (1) with lifting forks (2) on the ground and attach as described under "Attaching the bucket" (Fig. 1 - 3) .

Detach the carrier as described under "Detaching the bucket".

Lifting forks

The loader’s overturning moment depends on its total weight.

The stability factor to be selected is influenced by the working conditions.

Center-of-gravity distances of more than 500 mm reduce the payload.

Fig. 1

The maximum admissible payloads for different overturning moments and stability factors are provided in the Technical Data.

The payload is the load to be lifted with the lifting forks including the packing. Pallets, cases or slings are part of the payload.

Fig. 2

Fig. 3

76

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Working with lifting forks

Depositing loads

Taking up loads

During unloading, the wheel loader must be in horizontal position. The place of unloading must have no transverse and no longitudinal inclination.

To take up loads, drive the loader slowly in front of the load. Hold the lifting forks in horizontal position and raise or lower to the respective height. Drive the lifting forks under the load or into the pallet. Then, lift the load, tilt the forks backwards and bring load up or down to transport height. The transport height ist the distance between the ground and the lower edge of the lifting forks and should not be greater than 30 cm.

Transporting loads During load transport, the lifting forks must always be tilted backwards. Pull lever (40b, Fig. 5) into position 3 (bac-tipping). When driving up and down a hill, the load must always be carried on the uphill side.

Raise the load to the necessary height only just before arriving at the point of unloading.

Do not leave the machine when the load is in raised position.

During interruptions of the work always stand the lifting forks on the ground.

During the work always make sure the forks are tilted back. With a load on the forks, approach the point of unloading slowly.

Bring the forks to horizontal position, lower and the load and deposit. After reversing, lower the forks again.

Fig. 4

77

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Front working floodlamps (option)

Rear working floodlamps (option)

30000194

The working floodlamps are installed on both sides of the cab roof.

30000195

The working floodlamps are installed on both sides of the cab roof.

Fig. 2 Fig. 1

• To switch on the working floodlamps.

- press symbol face of rocker switch (26, Fig. 1).

• To switch off the working floodlamps - press blank face of rocker switch (26).

78

• To switch on the working floodlamps - press symbol face of rocker switch (27, Fig. 2).

• To switch off the working floodlamps - press blank face of rocker switch (27).

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Rotary beacon (option)

Acoustic reversing signal (option) 30000197

30000242

The rotary beacon is placed with its magnetic base in a marked area in front of the cab roof.

A socket outlet is located in front at the left below the cab (Fig. 3).

During driving on the public highway, the acoustic reversing signal must be deactivated.

The wheel loader can be equipped on request with a disconnectable acoustic reversing singal.

Fig. 3

Fig. 5

• To switch on the acoustic reversing signal - press symbol face of rocker switch (29, Fig. 5).

• To switch off the acoustic reversing signal - press blank face of rocker switch (29).

Fig. 4

• Switching on the rotary beacon - Depress symbol face of rocker switch (30, Fig. 4).

• Switching off the rotary beacon - Depress blank face of rocker switch (30).

The rotary beacon can be removed and placed with its magnetic base on the console at the left of the driver’s seat.

79

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D

80

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D PART 3 - INSPECTION AND SERVICING

Operating manual

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS

2261178

Target group Operating personnel + Inspection and servicing personnel + Repair personnel

Operating personnel

Part 2 OPERATION

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

Inspection and servicing personnel

Part 3 INSPECTION AND SERVICING

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

Repair personnel

Part 4 REPAIR WORK

Part 5 ANNEX

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

Operating personnel + Inspection and servicing personnel + Repair personnel

81

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D

82

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Inspection and Servicing, Safety Instructions

30000256

Operating manual

Securing the working equipment

No inspection and servicing work may be carried out until the operating instructions have been read and understood.

Stand working equipment on the ground in such a way that no movements can be made if mechanical or hydraulic connections become detached.

Pay special attention to the: and all warning and safety instructions attached to the machine.

The operating instructions lists all jobs to be done. The descriptions of job sequences, however, provide only experienced personnel with the necessary instructions.

The operating instructions must be kept with the machine at all times.

Inspection and servicing personnel Inspection and servicing personnel must have the necessary know-how on the inspection and servicing of this or comparable machines.

The necessary know-how can be acquired in several days’ instruction, e.g. by a specialist fitter or by attending a training course.

"X" Jobs marked with this symbol should be carried out by our service department.

Personal protective equipment and working clothing Wear closely fitting working clothing when working on the machine. Loose, wide garments may catch on machine parts and result in injury.

Wear a safety helmet, safety footwear, gloves and, in the event of high noise levels, ear protectors.

When working in jointed areas, block off the joints. Remove the blocks on finishing work.

Secure any equipment or component which is to be mounted or dismantled, or whose position is to be changed, with hoists or appropriate slinging/supporting devices to prevent them from moving, slipping or falling inadvertently.

Securing the machine Carry out servicing work only if the machine is secured as described in the section "Securing the machine".

Climbing onto and off the machine Use only the steps, platforms and handrails provided when climbing onto or off the machine.

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

Always face the machine when climbing on and off.

Check state of tools Use only fully functional, reliable tools.

Select the right tool for the job.

Wrenches of the wrong size, for example, may slip and cause injury.

83

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D

Cleaning jobs

Fastening and securing elements

Clean the units within the working range before starting work.

Select the cleaning agent according to the material constituting the parts to be cleaned.

Check fastening and securing elements, e.g. bolts, nuts, washers, before using them again.

Replace any damaged parts.

Example: Never clean rubber or electrical parts with solvents or steam jets.

Use lint-free cleaning rags when working on the hydraulic system or the engine.

Cleaning agents and solvents may give off harmful, readily flammable vapours.

Never work with such agents except on well ventilated premises; never inhale the vapours and never smoke.

Prevent solvents and cleaning agents from coming into contact with the skin.

Wear solvent-proof gloves.

Observe the instructions on the packaging.

Handling flammable liquids When handling flammable liquids: -

never smoke, keep away from unshielded light sources and naked flames.

Fuel and other consumables often have low flash points and are readily ignited.

Never attempt to extinguish burning liquids with water. Use:

Handling oils and greases Hot lubricant or hydraulic oil emerging uncontrolled from the system may result in severe burns.

Never set foot within reach of the emerging oil jet.

Avoid contact with the skin. Wear gloves and firm protective clothing.

Used oil may be harmful to the skin.

Clean soiled skin thoroughly with warn soapy water and apply a barrier cream.

Never use fuels or solvents for cleaning the skin.

If you have swallowed any oil, avoid vomiting but consult a doctor immediately.

Visible loss of oil Have any visible leakage repaired immediately.

-

dry powder,

Escaping oil is an environmental hazard.

-

carbon dioxide or foam extinguishers

Soak up any oil that has escaped with a binding agent. Sweep up binding agent and dispose of it separately from other waste.

Water used for extinguishing purposes would vapourize instantaneously on contact with burning substances and spread burning oil, for example, over a wide area.

Water generates short circuits in the electrical system, possibly producing new hazards.

Notify the fire brigade.

84

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D

Only unpressurized hydraulic systems may be opened. Even when a machine is parked on a horizontal surface with its attachments supported on the ground and its driving motor switched off, there may still be substantial residual pressure in parts of the hydraulic system, e.g. primary pressure from the last hydraulic movements prior to stopping the machine.

Residual pressure is reduced only gradually. If an intervention into the hydraulic system is to be undertaken immediately after stopping, the system must be depressurized: -

Stand the working equipment on the ground Shut off the engine Move all control levers and pedals several times in all directions.

Screwed connections, piping, hydraulic hoses Repair any leakages in the piping and hose system immediately or have them repaired.

A fine, highly pressurized jet of hydraulic oil can penetrate the skin.

Never search for leakages with the fingers, but use a piece of cardboard and always wear goggles.

If oil has penetrated into the skin, consult a doctor immediately.

Tighten leaking screw plugs only when the system is depressurized.

Escaping oil is an environmental hazard.

Environmentally compatible disposal Oils, greases, brake fluids, cleaning agents, solvents and oily components, e.g. filters, cleaning rags, replaced wear parts and unserviceable machine parts, must be disposed of separately in the interest of environmental protection.

Never dispose of such substances with standard household refuse.

Empty substances into the containers provided for this purposes.

Even biodegradable "environmentally friendly" hydraulic oil has to be disposed of separately like any other oil.

Never allow oils and oily waste to get into the soil or into water: environmental hazard.

Sealing faces Clean sealing faces prior to assembly.

Exhaust gases Exhaust gases are a health hazard: never inhale them.

When working on enclosed premises, draw off exhaust gases with a suction plant and ventilate the premises well.

Never repair damaged piping; always replace it.

Replace hydraulic hoses immediately on detecting any damage or moist areas.

85

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D

Handling batteries

Selecting oils / greases

Batteries give off explosive gases.

Use the recommended qualitites only, matching viscosities with the temperature level.

Never handle batteries close to naked flames and unshielded light sources, never smoke.

Battery acid is toxic and corrosive.

Avoid any contact with the skin, mouth, eyes and clothing. Avoid spilling battery acid or inhaling the vapours.

Wear acid-proof gloves, firm protective clothing and goggles when handling batteries.

If the skin is splashed with acid, rinse thoroughly with water and consult a doctor.

If the eyes are splashed with acid, rinse thoroughly with running water and consult a doctor immediately.

Never set tools down on the battery. They may induce a short circuit, causing irreparable damage to the battery and injuring persons.

Never wear metal necklaces, bracelets or watch-straps when working on the battery. The metal parts may induce a short ciruit resulting in burns.

Dispose of used batteries separately from other waste in the interests of environmental protection.

Prior to work on the electrical system Prior to any work on the electrical system involving tools, spares, etc. coming into contact with electric cables or contacts, disconnect the battery.

Disconnect first the negative pole, then the positive pole.

After work: Connect first the positive pole, then the negative pole.

86

Filters Replace all filter elements or filter cartridges within the specified periods.

All filters are coordinated carefully with the equipment. Original spare-parts from O&K must be used to ensure smooth running and a long service life of the engine and the hydraulic units.

Sealing elements When dismantling parts, watch for sealing elements.

Check sealing elements prior to installation and replace any that are even slightly damaged.

When assembling, ensure a perfect fit.

Oil-level check and oil change Position the machine horizontally.

Change the oil when the machine is at operating temperature. Warm oil flows better and carries suspended particles (carbon or abraded matter) better.

Lubricating Clean the lubricating nipple, then lubricate as scheduled.

After servicing To prevent corrosion, coat all bright metal parts with a grease film.

On completing work, reinstall all protective devices.

Never start the drive motor while work is being done on the machine.

Carry out a performance test with the machine.

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D MAINTENANCE WORK

2905821

Securing the machine

Opening the engine compartment

Before carrying out any servicing or repair work the machine must be secured as follows:

Open the engine compartment before undertaking any servicing work.

• Park machine on level and firm ground.

Press the unlocking button in the handle (Fig. 1) and pull up the engine hood at the handle.

• Set the attachment down on the ground.

30000243

• Block articulated joint.

• Shut off engine.

• Apply the parking broke • Withdraw key from the key switch of the electrical system.

• Secure machine with wheel chocks.

• Disconnect battery before working on the electrical system or before carrying out any welding work (cf. section "Welding operations, safetyinstructions" and "Electrical system - safety instructions").

Fig. 1

The engine hood is held open by a spring.

To close the hood, press the unlocking device of the gas-filled spring. Pull the engine hood at the handle downwards until it engages.

87

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Draining hose for oil changes

30000244

Operating hours indicator

30000207

The operating hours of the machine are indicated by the hours-run meter (16, Fig. 1).

Collect escaping oil and discard without polluting the environment.

Carry out oil changes when the engine is at operating temperature; warm oil drains away more easily.

Engine, hydraulic oil reservoir and gearboxes may be equipped with special oil drain plugs (1, Fig. 1).

These plugs permit changing the oil in a clean and non-polluting manner.

Fig. 1

The hours-run meter sums up the operating hours of the machine.

Fig. 1

Carry out oil changes as follows: - Place a collecting recipient for used oil under the drain plug (recipient capacity see "Refilling quantities - oil"), - A suitable draining hose is part of the tool kit carried by the Technical Service or can be ordered from the spare-parts service.

- Unscrew the cap of the drain plug.

- Screw draining hose (2) onto the plug; the plug opens and the oil drains away.

- After the oil has drained away, unscrew the draining hose; the plug closes automatically.

- Screw the cap back onto the drain plug.

88

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Inspection and servicing plans, instructions

30000208

Intervals

Engine oil change

The inspection and servicing plans list all works to be performed on the machine at regular intervals.

The intervals specified for engine oil change are valid for fuels with a sulphur content of < _ 0.5% and a permanent ambient temperature down to -10oC.

The individual inspection and servicing plans are marked with letters.

These letters provide a link between the operating hours (OH) indicated by the hours-run meter and the inspection and servicing plans.

Explanations: Plan

For higher sulphur contents and/or permanent ambient temperatures below -10oC, shorter intervals must be observed (see engine operating instructions).

If the engine oil change intervals are not reached within one year, the oil must be changed at least once a year.

Carry out all work

Oils / greases V

.... once prior to initial commissioning

N

.... after initial commissioning

T

.... every 10 OH or per working shift1)

W

.... every 50 OH or weekly1)

B

.... after every 500 OH

C

.... after every 1000 OH

D

.... after every 3000 OH

For the specification of the oils and greases to be used refer to the "Lubricants" section.

The Roman numerals in the "Oil / grease" column of the inspection and servicing plans refer to: I

Oils for combustion engines and compressors

II

Oils for hydraulic systems

III

Oils for gearboxes and axles

V

Greases for bearings and slewing rings

1)

whichever occurs first OH = operating hours

Warranty One of the prerequisites for the manufacturer to fulfill his warranty obligations is the performance of the following compulsory servicing works by the Service or by a workshop authorized in writing by the manufacturer: 1.

compulsory service N at 30 - 50 operating hours after commissioning.

2.

compulsory service B at 500 operating hours after commissioning.

Cleaning Cleaning work, especially on cooling systems, must be done at shorter intervals if the machine is exposed to heavy dust build-up.

Servicing material The spare-parts list contains a central listing of the servicing material required for regular maintenance.

The due performance of the compulsory services has to be documented on the Service Checklists.

89

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Plan V - once prior to initial commissioning

30000248

Component designation

Servicing activity

Engine

Check oil level

Electrical system Battery

Check charge condition and fluid level1)

Lighting

Check functioning

1 1

Monitoring, warning and control elements

Check functioning

1

Hydraulic system Oil reservoir

Check functioning Check oil level

1 1

Brake

Check functioning

1

Wheel Tyres Wheel-nuts

Check pressure Check for tightness (torque wrench)

Axle Front axle Rear axle Distributor gearbox Rear axle suspension

Check oil level Check oil level Check oil level Grease

Equipment Dumping cylinder bearing Lifting cylinder bearing Bucket bearing Quick tool coupler Bottom-dump bucket

Grease Grease Grease Grease Grease

Lines, fittings and connections

Check visually for leaks

Machine frame Articulated joint

Grease

Lifting frame Lifting arm Toggle lever Connecting rod

Grease Grease Grease

Cardan shaft Cardan shaft intermediate bearing (only with high-speed option 321D )

Grease

1)

not applicable with maintenance-free battery

90

Oil/

Quantity/ grease number 1

4 4x8 3 3 1

1 4 2 2 4 resp. 6

2

1

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Plan N - after initial commissioning Component designation

Servicing activity

Oil/

Quantity/ grease number

After 5 OH once) Wheel-nuts

Retighten (torque wrench)

4x8

After 250 OH Axle Frontz axle Rear axle Distributor gearbox Planetary gearbox

Change oil Change oil Change oil Change oil

All lines, fittings and connections

Check for leaks and tightness

All screws

Check for tightness

91

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Plan T - every 10 OH or each working shift (whichever occurs first) Plan W - every 50 OH or weekly (whichever occurs first) Page 1 of 2 Component designation

Servicing activity

Oil/

Quantit- Plan y/ grease number T

Plan W

Machine

Visual checking of the machine and its units for defects, leaks and loss of consumables

•

•

Engine

•

V-belt

Check oil level in acc. with oil inspection plan Check

• •

Fuel system Water trap

Drain off water

Air intake system Ait filter dust discharge valve

•

Suction and clean-air line

Check for the presence of dust / clean the valve Checke visually for leaks

• •

• •

Electrical system Lighting system Battery and cable connections

Check functioning Check for condition and tightness

• • •

• • •

Monitoring, warning and control elements

Check functioning

Hydraulic system Oil reservoir Return-flow filter

Check visually for leaks Check oil level in acc. with oil inspection plan Check return pressure

Brake Disk brake

Check functioning Check visually for condition, clean

Wheel Tyres Wheel-nuts

Check visually for condition Check pressure Check for tighteness (torque wrench)

Axle Rear axle suspension Front axle suspension Equipment Dumping cylinder bearing Lifting cylinder bearing Bucket bearing Quick tool coupler Bottom-dump bucket

92

• • • •

• • • • • • • •

Grease in acc. with lubricating chart grease Check for tightness (torque wrench)

• •

Grease in acc. with lubricating chart grease Grease in acc. with lubricating chart grease Grease in acc. with lubricating chart grease Grease in acc. with lubricating chart grease Grease in acc. with lubricating chart grease

• • • • •

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Plan T - every 10 OH or each working shift (whichever occurs first) Plan W - every 50 OH or weekly (whichever occurs first) Page 2 of 2 Component designation

Machine frame Articulated joint Lifting frame Lifting arm Toggle lever Connecting rod

Servicing activity

Oil/

Quanti- Plan ty/ grease number T

Plan W

Grease in acc. with lubricating chart grease

•

Grease in acc. with lubricating chart grease Grease in acc. with lubricating chart grease Grease in acc. with lubricating chart grease

• • •

Cardan shaft Cardan shaft intermediate bearing (only with high-speed option) Grease

•

93

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Plan B - after every 500 OH

Plan D - after every 3000 OH

(at 500, 1500, 2500 ... OH)

(at 3000, 6000, 9000 ... OH)

Page 1 of 2

Plan C - after every 1000 Bh (at 1000, 2000, 4000 ... OH) Component designation

Servicing activity

Oil / Quantity / Plan Plan Plan grea- number B C D se

•

Servicing in acc. with W or T Engine 21D - 121D - 221D Oil filter Valve clearance Alternator and starter Crankcase breather Engine 321D Oil filter Valve clearance Alternator and starter Crankcase breather

Change oil in acc. with oil inspection plan 1) Replace Check Check visually for condition Check

•

•

•

•

•

• • • •

Check Check fluid level and charge condition3)

• •

• •

• •

Replace Replace Check / retighten hose clamps and screwed connections

•

•

•

•

• • •

• •

• •

Replace Remove impurities Check Clean

1) 2) 3)

Replace Replace Clean Change oil in acc. with oil inspection plan 2)

oil change after 1 year at the latest hydraulic oil change after 3 years at the latest not applicable with maintenance-free battery

94

• • • • • • • • • •

•

1

Check visually for condition Check

Fuel system Filter Tank Injection nozzles Water trap

Hydraulic system Return-flow filter Breather filter Oil cooler ribs Oil reservoir

• • • • • • • •

Check visually for leaks

Air intake system Filter element Safety filter element Suction hose

•

• • •

Change oil in acc. with oil inspection plan 1) Replace

Cooling system

Electrical system Cables and connections Battery

1

•

1

1 1 1

• • • •

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Plan B - after every 500 OH

Plan D - after every 3000 OH

(at 500, 1500, 2500 ... OH)

(at 3000, 6000, 9000 ... OH)

Page 2 of 2

Plan C - after every 1000 OH (bei 1000, 2000, 4000 ... OH) Component designation

Axle of standard version Planetary gearbox Front axle Rear axle Distributor gearbox Planetary gearbox Axle of high-speed version (option) Front axle

Servicing activity

Check oil level in acc. with oil inspection plan Change oil in acc. with oil inspection plan 1) Change oil in acc. with oil inspection plan 1) Change oil in acc. with oil inspection plan 1) Change oil in acc. with oil inspection plan 1)

Oil / Quantity / Plan Plan Plan grea- number B C D se 2

1

Travel motor

Check speed

Cardan shaft

Grease in acc. with lubricating chart grease

Heating Filter

Check for leaks Clean / replace

1

Air conditioner Filter Compressor V-belt Evaporator

Check for leaks Clean / replace Check Check soiling

1 1 1

1) 2) 3)

Check for tightness Clean / replace Grease in acc. with lubricating chart grease

• • • •

• • • •

• • • •

• • • •

• • • •

• • • • • •

• • • • • •

• • • • • •

• • •

• • •

• • •

2

Check Check

Driver’s cab Fastening screws Breather filter Hinges

• • • •

1

Brake Lining thickness Brake pressure

Planetary gearbox

• • • • •

1

1

Speed-change gearbox

• • • • •

1

Change oil in acc. with oil inspection plan 1) Change oil in acc. with oil inspection plan 1) Change oil in acc. with oil inspection plan 1) Change oil in acc. with oil inspection plan 1)

Rear axle

•

1 1 2

1 2

oil change after 1 year at the latest hydraulic oil change after 3 years at the latest not applicable with maintenance-free battery

95

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D LUBRICATING CHART - GREASE

Fig. 1

96

= operating hours

30000249

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Lubricating chart - Grease(key to chart) Pos.

Greasing location

2 3

Hydraulic system Dumping cylinder Lifting cylinder

4 5 6 7 8 9 10 11 12 13

14a 14b

15

Number

Lubricant properties 1)

Grease every .... operating hours

2 2x1

50 50

Rear axle Suspension

2

50

Machine frame Articulated joint

2

Lifting frame Lifting arms Connecting rod Toggle lever Quick tool coupler Reversing lever Equipment Bucket bearing Bottom-dump bucket Bottom-dump bucket cylinder Cardan shaft Standard Intermediate bearing (high-speed option 321D ) Driver’s cab Hinges

V 1)

50

2x2 2 1 4 2

50 50 50 50 50

2 2x2 2x2

50 50 50

2

500

1

50

2x2

500

1) See "Table of lubricants V"

Joints and hinges

2411970

Grease or oil all joints and hinges, e.g. on covers and flaps, in accordance with the inspection and servicing plan.

97

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D INSPECTION PLAN - OIL

Fig. 2

98

= operating hours

30000229_ok

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Inspection plan - oil (key to chart) Pos.

Number

Lubricant properties

Check oil level every ... operating hours

Change oil every ... operating hours

Engine 21D - 121D - 221D 321D

1 1

I I

10 10

500 1000

7

Hydraulic system

1

II

10

3000

10

Axles - Front axle - Rear axle - Distributor gearbox - Planetary gearbox

1 1 1 2x2

III III III III

------500

1000 1000 1000 1000

1

Component

Refilling quantities - oil Component Engine Hydraulic system

Filling quantity 1) liters approx. 12.0 approx. 65

Axles standard Front axle Rear axle and distributor gearbox Planetary gearbox

approx. 8.0 approx. 8.0 approx. 4 x 0.7

Axles high-speed (option) Front axle Rear axle Distributor gearbox Planetary gearbox

approx. 8.0 approx. 8.0 approx. 0.75 approx. 4 x 0.7

Refilling quantities - Other

1)

Component

Filling quantity1) liters

Fuel system

approx. 100

The consumable filling quantities indicated are approximate quantities intended as a help for planning.

Each unit has suitable checking facilities, eg. dipstick, inspection glasses or checking plug wich can be used for checking the exact filling level.

99

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D LUBRICANTS

I.

Oils for internal combustion engines ( 21D 121D 221D ) 30000272

Ambient temperature

Specification API ACEA AKCELA ENGINE OIL CH4

E5 SAE 15W - 40 / MS 1120 AKCELA NO.1 ENGINE OIL SAE 15W - 40 / MS 1121

API:

American Petroleum Institute

ACEA: Association des Constructeurs Européens d’Automobiles g.i.e.

Engine preheating necessary. Cold-starting may be sufficient in upper range. Perform warm-up, increasing engine speed and loading slowly.

For single-grade or other multigrade engine oils and at lower temperatures, the oil recommendations of the engine manufacturer must be observed. For details, cf. engine operating instructions.

100

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D

I.

Oils for internal combustion engines ( 321D )

Ambient temperature

Specification API ACEA AKCELA NO.1 ENGINE OIL CH4

E5 SAE 15W - 40 / MS 1121

API:

American Petroleum Institute

ACEA: Association des Constructeurs Européens d’Automobiles g.i.e.

Engine preheating necessary. Cold-starting may be sufficient in upper range. Perform warm-up, increasing engine speed and loading slowly.

For single-grade or other multigrade engine oils and at lower temperatures, the oil recommendations of the engine manufacturer must be observed. For details, cf. engine operating instructions.

101

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D

II.

Oils for hydraulic systems, mineral 30000274

Ambient temperature

Hydraulic oil, mineral ISO VG 46

Specification

ISO VG 68 NH 668

DIN 515424 T2 FZG Test >= 102

Warm-up phase required before commencement of work. Warm up hydraulic system for about 10 minutes at 50% engine speed and by repeated actuation of all control valves.

102

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D

II.

Oils for hydraulic systems, synthetic (bio-degradable)

Ambient temperature Hydraulic oil, synthetic (bio-degradable)

Specification

ISO VG 46

DIN 515424 T2 FZG Test >= 102

Warm-up phase required before commencement of work. Warm up hydraulic system for about 10 minutes at 50% engine speed and by repeated actuation of all control valves.

103

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D

III.

Oils for axles and gearboxes 30000275

Ambient temperature Specification API: GL - 5 with LS additives API:

American Petroleum Institute

LS:

Limited slip

104

SAE 80W - 90

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D

V.

Greases for bearing points and slewing rings 30000276

Ambient temperature Specification NLGI 2 AKCELA Moly Grease

for central lubricating systems and tensioning systems Minimum requirements: Grease base

:

Lithium

Solid lubricant content (MoS2 or graphite)

:

max. 3%

NLGI - class

:

see above

Corrosion protection in acc. with ASTMD 17 43 (CRC)

:

Code no. 1

105

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D

106

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D ENGINE 2411971 Engine, safety instructions for inspection and servicing

Risk of injury from rotating fan blades and running V-belts.

Switch off the engine before opening the engine compartment.

Risk of burning due to hot parts on engine, exhaust and radiator.

Never begin servicing and repair work until engine, exhaust and radiator have cooled down.

Checking the engine oil level / topping 30000250_01 up oil Run the engine until the oil has reached operating temperature.

• Park the machine on level ground and protect against inadvertent movements.

• Shut off the engine.

• Wait one minute and pull out the dipstick (1, Fig. 1).

Wipe dipstick (1) clean with a lint-free cloth and reinsert.

Wear working gloves.

Secure the machine as described in the section "Securing the machine".

Read and observe: "Inspection and Servicing, Safety Instructions" and the operating instructions for the engine.

Fig. 1

• Pull out dipstick again: the oil level should lie between the marks. If the oil level is at the "min" mark or below, top up engine oil through the filler neck

Fig. 2

107

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Changing the engine oil

Risk of scalding by hot engine oil Collect escaping oil and discard without polluting the environment.

Read and observe: "Inspection and servicing, safety instructions".

• Bring engine to operating temperature.

• Park the machine on a horizontal surface and protect against inadvertent movements.

• Shut off the engine.

Fig. 4

To reach the oil drain valve, remove the grid under the machine at the rear.

• Remove hex screw (13, Fig. 3), push grid (14) towards the rear and swing downwards before removing.

Fig. 5

When the engine oil has drained away: • replace the engine oil filter,

Fig. 3

Place a collecting recipient below the drain valve.

The recipient capacity can be determined by means of the "Refilling quantities" table in this manual.

Unscrew plug (5, Fig. 4), attach the hose supplied with the machine (19, Fig. 5) and drain off the engine oil.

The use of the oil draining hose is described in the section "Draining hose for oil changes".

108

• unscrew draining hose (19) and screw the plug back onto the valve, • fill in engine oil into filler neck (3, Fig. 2) until the oil level reaches the max. mark, • start the engine and let it run for about 2 minutes at idling speed, • Check the oil level and, if necessary, top up with oil to the max. mark.

• After the work, reattach grid (14, Fig. 3) with screw (13) to the frame.

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Changing the engine oil filter

Risk of scalding by hot engine oil.

Collect escaping oil and discard without polluting the environment.

The oil filter is equipped with a valve and a special tube preventing the reflow of oil.

Deshalb nur Original Filterpatronen verwenden.

• Loosen the filter cartridge (6, Fig. 6) with a strap wrench or similar tool and screw off.

Fig. 6

• Clean filter head (7).

• Fill new filter cartridge (6) completely with new, clean engine oil (this may take some time).

• Smear the seal of filter cartridge (6) with clean engine oil.

• Attach new cartridge (6) and tighten only by hand. Do not use tools.

During the test run, pay attention to perfect tightness of the oil filter cartridge (6). Thereafter, check the oil level and top up, if necessary.

109

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D AIR INTAKE SYSTEM

Read and observe: "Inspection and servicing, safety instructions."

30000211

Replace or clean the main filter element, warning lamp (8, Fig. 2) lights up. In this the main filter element must be cleaned or ced even if the change interval has not reached.

when case, replabeen

Risk of injury caused by hot parts of the engine.

Carry out servicing and repair work only if the machine has been secured as described in the "Securing the machine" section of the present operating instructions.

Never start the engine when parts of the air-intake system have been removed.

Engine damage may occur if the engine is allowed to draw in unfiltered air.

Fig. 2

The wheel-loader is equipped with a dry-air filter (Fig. 1) comprising a main filter and a safety filter element. The dry-air filter is located under the engine hood.

Dust discharge valve Check that the discharge opening of the valve (8, Fig. 3) is not clogged up with dust. Remove any accumulated dust by pressing the lips of the valve together.

Fig. 1 Fig. 3

110

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Removing, cleaning and checking the main filter element Unsnap the clamps (5, Fig. 4) and withdraw the dust collector (6).

Checks before installation of the main filter element:

Remove the main filter element (1, Fig. 5) carefully.

• Check the filter paper with the help of a lamp bulb (Fig. 6). Filter damage is indicated where the light shines brightly through the paper. If damaged, replace the main filter element immediately.

Fig. 4

Fig. 6

• Check the seal (13, Fig. 7) visually. If the seal is damaged, replace the main filter element immediately.

• Check the intake line between filter and engine visually for leaks and tightness. The intake line must be free from apparent damage.

• Check the connecting hose between filter and intake line for tightness and perfect condition.

Use only hose clamps with screws.

Fig. 5

The safety filter element remains in place. Clean or replace the filter element. Before installing a new main filter element, apply a thin layer of oil, vaseline or similar lubricant on the sealing face of the element. The cleaned or the new filter element is installed in reverse order.

When installing the dust collector, pay attention to the "TOP" marking.

Turn the dust collector (6) slightly to the right or left so that the dowel pin can engage in the filter housing before closing the clamps (5, Fig. 4).

Fig. 7

After the re-installation of a new or cleaned main filter element, the warning lamp (8, Fig. 2) must go out .

111

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Cleaning the main filter element

Checking / replacing the safety filter

Dry-cleaning

Never clean filter elements by beating them against hard objects.

After 3 cleaning cycles or after one year of operation at the latest, the main filter element must be replaced.

Cleaning with compressed air is suitable if the filter element is to be re-used immediately.

The air pressure at the nozzle must not exceed 5 bars.

Do not start the engine when the safety filter element has been removed.

The engine may be damaged if it is allowed to suck in unfiltered air.

The safety filter must be replaced if it becomes apparent during servicing of the dry-air filter that the main filter element is damaged or that it has been improperly serviced.

If the warning lamp (8, Fig. 2) lights up again immediately after servicing, the safety filter has to be replaced.

Start cleaning the cartridge surface by blowing dry compressed air diagonally from outside into the filter element (Fig. 8).

After 5 cleaning cycles of the main filter element, but after 2 years at the latest, the safety filter has to be replaced by a new one.

Fig. 8

Continue cleaning by blowing compressed air from inside against the element.

Cleaning is finished when all visible dust has been removed from the element.

Do not beat the filter element against hard objects.

Never clean filters with petrol and flammable or hot liquids.

112

Fig. 9

Unsnap the clamps (5) and remove the dust collector (6, Fig. 9) carefully.

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Withdraw the main filter element (1, Fig. 10) carefully.

Check the air intake lines The engine must not be allowed to draw in unfiltered air. For this reason: • Check all hosepipes and pipelines for leaks.

• Check that all clamps are in place and tight.

Fig. 10

The safety filter element (2, Fig. 11) can be withdrawn thereafter. Before installing a new safety filter element, apply a thin layer of oil, vaseline or similar lubricant on the sealing face of the element.

Fig. 11

Before installing a new safety filter element, check the discharge nozzle at the filter housing and the accessible part of the intake line with your fingers for the presence of dust. If dust is detected in the intake line, contact the Service dept. immediately.

113

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D FUEL SYSTEM

30000212_01

Fuel filter • Clean the outside of the fuel filter (Fig. 1) carefully.

Risk of explosion During work on the fuel system: -

• Loosen the fuel filter cartridge with the corresponding tool and screw off .

Shut off the engine Keep away open flames Do not smoke

Collect escaping fuel and discard without polluting the environment.

Discard used filter cartridges without polluting the environment.

Diesel fuel may cause skin injuries. Wear protective gloves or use a barrier cream.

Read and observe: Safety instructions.

Secure the machine as described in the "Securing the machine" section.

Fig. 1

• Collect escaping fuel.

• Clean the sealing surface of the filter head (Fig. 2) carefully.

• Oil the gasket of the new fuel filter cartridege lightly or apply a small amount of diesel fuel on the gasket.

Fig. 2

• Screw the cartridge by hand onto the filter head until the seal is in contact with the head.

• Tighten the fuel filter cartridge by another half turn.

• Bleed the fuel system.

• Check system for leaks.

114

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Fuel pre-filter

Cleaning the fuel tank

• Detach the hose clamps at the filter end.

• Remove the filter (Fig. 3) from the fuel line.

• Collect escaping fuel.

Risk of explosion Do not use white spirit, paraffin oil or other solvents.

Use diesel fuel for cleaning and flushing instead.

• Empty the tank beforehand by using up as much fuel as possible.

• Unscrew the drain plug (8, Fig. 4) below the fuel tank.

• Drain off fuel and collect in a suitable recipient.

• Filter the remaining fuel for re-use or discard without polluting the environment.

Fig. 3

• Install a new filter. Py attention to the direction of flow.

• Bleed the fuel system.

• Flush the tank with diesel fuel.

• Screw drain plug (8) back in place and fill in fuel through the filler neck.

• Check filter for leaks.

Fig. 4

• Bleed the fuel system.

• Check for leaks

115

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Injection nozzles

Consult a doctor immediately, if your skin has come into contact with fuel under high pressure.

Keep away from moving parts when the engine is running. Some of the moving parts are not directly visible when the engine is on.

The injection nozzles do not require regular servicing. The nozzles should be replaced and not cleaned. Replacement is, however, not necessary unless an injection nozzle is defective. The main signs indicating that it may be necessary to replace a nozzle are: The engine does start at all or starts only with difficulty.

Insufficient engine performance.

The engine has ignition failure or runs irregularly.

High fuel consumption.

Emission of black smoke.

Engine knocking or vibrating.

Engine overheating.

To find out which of the injection nozzles is defective, let the engine run at high idling speed.

Loosen the cap nut on the injection line of each injection pump one after another and retighten.

Do not loosen the cap nut by more than a half turn. Loosening of the cap nut on the defective nozzle has only little or no influence on the speed of the engine.

116

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Air conditioner - Inspection and servicing work

30000006

Work to be performed every month Read and observe: Inspection and servicing work, safety instructions.

Location of components inside the machine.

Fig. 1

The visual checks should be performed even in case the air conditioner is not used.

The air conditioner should moreover be switched on once a month for 10 to 15 minutes to prevent drying out and embrittlement of the shaft seal in the compressor with the risk of refrigerent leaking out of the unit. This measure also ensures regular lubrication of the compressor components.

Fig. 2

The heater / air conditioner is installed in the driver’s cab on the right side of the driver’s seat.

In the cab

• Blower (1, Fig.1)

Evaporator (3, Fig.1) soiled or ribs deformed?

• Heat exchanger (2)

• Blow out dirt and remove by suction .

Straighten the ribs.

• Evaporator (3) • Heating filter (4) • Heating valve (5) These components are accessible after removal of the cover (1). The heat exchanger, the evaporator and the blower require no servicing.

Antifreeze protection sensor on evaporator kinked or leaking?

• Have sensor repaired.

Filter mat (4) soiled?

• Depending on the conditions of use, the filter mat must also be checked more often and cleaned by blowing out or by beating.

Temperature control knob (38, Fig.2) easy to move?

• If sluggish, check Bowden cable for kinking or corrosion and replace if necessary.

117

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D In the engine compartment

30000013

• V-belt of compressor (1, Fig.1) in good condition?

Replace defective V-belt.

• V-belt properly tensioned?

Readjust, if necessary.

• Compressor (4, Fig.2) safely fastened?

Tighten loosened screws.

• Chafing marks on hoses and lines?

Have damaged hoses and lines replaced, lay and fasten new ones in a safer place (5, Fig.2).

(This work must be performed by a specialized workshop).

Fig. 1

Fig. 2

118

• Condenser (1, Fig.3) contaminated?

Contaminated condensers have a bad condensing performance. Clean by blowing out or wash with water (do not use high-pressure jet cleaners). Deformed ribs can be repaired by straightening.

• Amount of refrigerant (2, Fig.3) in the system suffficient?

With the engine running and the unit switched on, the refrigerant visible in the inspection glass on top of the refrigerant container (arrow, Fig. 3) must be free of bubbles. Bubbles in the inspection glass are a sign that the amount of refrigerant in the system is insufficient. The system must be checked for leaks and refilled by a specialized workshop for air conditioners.

Fig. 3

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Work to be performed every 6 months (by approved special workshop) Check refrigerant circuit and refrigerant level. (Replace contaminated refrigerant).

Check hoses and screwed connections for fastening, tightness and proper laying.

Check compressor and magnetic clutch for proper operation (noise-free running, oil level, safe fastening of compressor).

Check electrical lines and connectors for perfect conditions and tight fit.

Check the complete system.

After each intervention in the refrigerant circuit, the refrigerant container should be replaced together with the drier.

Work to be performed every 2 years (by approved special workshop) Perform all works described under "Work to be performed every 6 months".

Check the complete system.

Replace the refrigerant container with the drier.

119

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D AIR CONDITIONER Safety instructions for inspection and servicing The following section describes inspection and servicing work that can be performed by the machine operator.

Any other work on the air conditioner requires special knowledge and tools and must therefore be carried out only by specially trained personnel. Have any such work be carried out by special workshops for air conditioners.

For the sake of your personal safety, always observe the following instructions: Do not stick your hand or any other objects into the unit.

Shut off the engine and let it cool down before carrying out any servicing work.

Disconnect the blower from the power supply to avoid injury when the blower starts up inadvertently.

Some parts of the air conditioning unit (e.g. the heat exchanger and the resistor on the blower) may still be hot after shutdown so that there is always a risk of burning yourself. Let these parts cool down before working on them in the opened unit.

30000007

Work on the refrigerant circuit (specially trained personnel): R134a, the refrigerating agent used, is known as a safety refrigerant. This means that this refrigerant is non-combustible, non-explosive, non-toxic, non-irritating, odourless and tasteless. Nevertheless, the following points must be observed: Avoid any contact with liquid refrigerating agent. Treat parts of the skin that have come in contact with this agent as,for instance, chillblains, and seek medical advice.

Wear goggles to protect your eyes. In case refrigerant gets into contact with the eyes, seek medical advice immediately.

Before carrying out repairs on the air conditioners, the system must be emptied.

Don’t let refrigerating agent escape into the air. For sucking agent out of the system, use only approved evacuation equipment.

It is strictly forbidden to carry out welding work on parts of the closed system or in the vicinity thereof. Whether the system is filled with refrigerating agent or not, heating always produces high overpressure which may cause damage to the unit or even explosions.

Full refrigerant bottles must not be thrown and exposed for prolonged periods to sunlight or other sources of heat. The maximum admissible temperature of a full refrigerant bottle must not exceed 45˚C. It is essential to keep the refrigerating system free from chlorine or chlorine-containing substances and from oils and greases. Evacuating and filling equipment should be used exclusively for R 134a.

120

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D ELECTRICAL SYSTEM

2904905

Safety instructions Alternator, instructions 30000257

Risk of injury from battery acid and gases.

Wear goggles, protective gloves and sturdy working clothing.

Prior to working on the electrical system Prior to working on the electrical system, where tools, spare parts etc. may come into contact with electric cables or contacts, disconnect the battery.

Disconnect first the negative, then the positive pole.

After work: Connect first the positive, then the negative pole.

Read and observe "Inspection and Servicing - Safety instructions".

Never disconnect cables from the alternator, regulator and battery when the engine is running.

This would damage the alternator and regulator.

Take care not to interchange the cables when connecting the batteries (observe polarity).

Carry out voltage and continuity checks with a measuring instrument only.

Do not use a check lamp.

Do not check by "touching ground" with a bare wire The resulting short-circuit would damage the alternator or the electronic control units.

To start up the engine, the alternator is controlled (pre-excited) by an electronic circuit. This ensures that the alternator can deliver power.

Use only measuring instrument for voltage and continuity testing, never use a test lamp.

The circuit is an integral part of the central electronic system in the control console.

Never "tap against ground".

A warning lamp in the control console (alternator) indicates that the alternator is functioning correctly. This warning lamp must light up when the key switch is switched on; it is extinguished when the engine is running.

If this is not the case, there is a fault in the alternator circuit or in the control console.

This causes a short circuit with consequent damage to the generator or to the electronics.

To prevent further damage, the cause of the fault must be traced and eliminated as quickly as possible.

Contact the Service Dept.

121

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D WORKING EQUIPMENT

30000183

Assembling working equipment, safety instructions

Personnel

Tools and auxiliaries

Assembly work may be carried out only by operating or maintenance personnel who have the necessary know-how at their disposal.

Tools, hoists, slings, trestles and other devices must be in a safe and reliable state of operation.

If such know-how is lacking, meticulous instruction must be given by experienced personnel, e.g. from the manufacturer.

The operating manual and in particular the section headed "Fundamental saftey instructions" must have been read and understood.

Only such persons may start up the machine during assembly work in order to adjust the attachments.

Incorrect operation of the machine or the attachments may give rise to life-threatening situations.

Metal splinters may cause injury when attachment pins are being driven in or out.

A brass or copper mandrel should therefore be used for this purpose, and goggles must be worn.

Use the steps, platforms and handrails provided when climbing onto or off the machine.

Always keep steps and platforms as well as handles in a non-slip state. Remove any oil, grease, earth, clay, snow, ice and other foreign matter immediately.

Securing working equipment

Personal protective gear and working clothing

Stand working equipment on the ground in such a way that no movements can be made if mechanical or hydraulic connections become detached.

Wear closely fitting working clothing when working on the machine. Loose, wide garments may catch on machine parts and result in injury.

When working in jointed areas, block off the joints. Remove the blocks on finishing work.

Wear a safety helmet, safety footwear and gloves.

122

Secure any equipment or components which is to be mounted or dismantled, or whose position is to be changed, with hoists or appropriate slinging/supporting devices to prevent them from moving, slipping or falling inadvertently.

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Battery Securing the machine Carry out work on the attachment only if the machine is secured as described in the section "Securing the machine".

2905174

The battery is located on the righthand side of the wheeled loader in the rear frame (Fig. 2).

Opening the engine cover gives access to the battery.

Selecting the attachments The machine can be equipped with various attachments. The components of the attachments are assembled with hydraulic cylinders and connectors. Components can be combined in various ways for optimum adaptation of the attachments to the specific application.

Operate the machine only with the equipment and component combinations expressly approved by the manufacturer.

Cf. the "Technical Data" section".

Attachments from other manufacturers subject to the EC Machine Directive 89/392 EEC may be mounted and put into operation only if - the manufacturer’s declaration of conformity and - the declaration of compatibility from the manufacturer are at hand.

Fig. 1

Battery - checking the fluid level

2411957

(Not applicable to maintenance-free batteries) • Unscrew the caps.

• If checking inserts are installed, the battery fluid must reach the bottom of the inserts.

• If no checking inserts are installed, insert a clean piece of wood into the battery down to the top of the plate. The wood must be wet over at least 10 mm.

• If the fluid level is too low, top up with distilled water only.

123

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Battery - checking the charge The acid temperature should be 20˚C. • Unscrew the battery caps (Fig. 1).

• Measure the acid density of the battery with a standard test instrument (Fig. 1).

The acid density is in direct correlation with the battery charge.

Fig. 1

Acid density in kg / dm3

Charge

Normal

Tropics

1.28

1.23

charged

1.20

1.12

half-charged, recharge

1.12

1.08

discharged, recharge at once

124

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Removing and installing the battery

Shut off the engine before removing batteries to prevent damage to the alternator and regulator or to electronic modules.

Turn key-switch for electrical system to "0" and withdraw key.

Detach and attach the pole terminals in the given sequence.

Failure to observe this sequence may result in short-circuits.

• Detach pole terminal at negative pole of battery.

• Detach pole terminal at positive pole of battery.

• Insulate pole terminals.

2905177

Before installing the new battery, polish the contact surfaces of the battery terminals and of the pole terminals.

• Install new battery.

• Screw battery holder (1) in place.

• Connect pole terminal to positive pole of battery.

Tighten clamping screws of pole terminals without using force, as this would cause damage.

• Connect pole terminal to negative pole of battery.

• Grease battery poles and pole terminals with pole grease of non-corrosive Vaseline.

Loose or corroded terminals overload the alternator and regulator.

• Unscrew battery holder (1, Fig. 1).

• Lift battery out of battery box.

Fig. 1

125

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D HYDRAULIC SYSTEM

30000269

Hydraulic oil level Park the wheel loader on a horizontal surface and stand the working equipment on the ground.

Apply the parking brake.

The oil level should reach the middle of the inspection glass (1, Fig. 1). If it is below the lower edge of the inspection glass, top up oil. To do so, unscrew the cap (6) of the breather filter and top up hydraulic oil.

Shut off the engine beforehand.

Depressurize the hydraulic system. To do so, move the control levers of the working equipment with the engine off until the working equipment stops making movements.

Secure the machine as described in the section "Securing the machine".

Read and observe "Inspection and servicing, safety instructions".

Avoid skin contact with hydraulic oils.

Wear gloves and firm working clothing.

Skin contact with hydraulic oils is a health hazard.

126

Fig. 1

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Return-flow filter

Replacing the filter

The hydraulic system is equipped with a returnflow filter (3, Fig. 2).

Unscrew cover (2, Fig. 2) without losing gasket (11, Fig. 4) and spring (10). Withdraw filter pot (12, Fig. 3) with filter cartridge (16). Remove filter cartridge (16) by turning and pulling at the same time from filter pot (12) and discard without polluting the environment.

Fig. 2

A built-in bypass valve protects the return-flow filter against overpressure.

When the bypass is open, the filter is no longer in the circuit. The filter cartridge should therfore be replaced in time.

To check the return-flow pressure with pressure gauge (4), the engine must be run at full speed by setting the travel direction selector to "0", by applying the parking brake and by bringing the engine with the accelerator to maximum speed. A second person can now read the pressure gauge.

Fig. 3

Pour the oil remaining in filter pot (12) into a recipient for used oils. Clean filter pot (12) with white spirit or diesel fuel. Check gasket (5) and replace, if damaged.

Should the return pressure lie in the red range of the pressure gauge, the filter cartridge must be replaced even if the schedule change interval has not yet elapsed.

Do not stick your hands into moving machine parts. Risk of injury Read and observe "Inspection and servicing, safety instructions".

Fig. 4

Re-assemble the filter in reverse order.

Secure the machine against unauthorized starting.

127

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Breather filter The breather filter (Fig. 5) ensures aeration and deaeration of the hydraulic reservoir when the hydraulic oil level varies.

Hydraulic reservoir Hydraulic oil change • Lower the equipment to the ground.

• Shut off the engine, apply the parking brake.

Risk of scalding from hot engine oil.

Collect escaping hydraulic oil and discard without polluting the environment.

Read and observe "Inspection and servicing, safety instructions".

Never start the engine while the hydraulic oil reservoir is empty.

Secure the machine against unauthorized starting.

Fig. 5

The breather filter is equipped with a filter element which prevents dust and dirt from getting into and oil splashes from getting out of the reservoir. Replacing or cleaning is not possible.

The breather filter must therefore be replaced completely in acc. with servicing plan D .

For draining, unscrew the plug at the combined radiator.

Place a collecting recipient under the hydraulic reservoir. Capacity: see table of refilling quantities.

Unscrew the cover (2, Fig. 2) of the return-flow filter and withdraw the filter pot (12). Clean the bottom and the inside of the reservoir through the opening with hydraulic or flushing oil and screw the plug back in place.

Filling oil into the hydraulic reservoir Unscrew the breather filter. Fill in new hydraulic oil through a strainer-equipped funnel using a hand pump or an oil can until the oil level reaches the upper area of the inspection glass.

Screw cover (2) back in place and bleed the whole system.

128

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Bleeding the working and steering hydraulics After each hydraulic oil change, in the event of hydraulic system malfunctions or after prolonged downtimes, the system must be bled.

Steering hydraulics

Working hydraulics

Repeat until there are no more bubbles in the reservoir and until the steering is smooth and noise-free.

Check the oil level in the hydraulic reservoir. If necessary, top up oil. Start the engine and let it run at idling for a few minutes. Extend and retract the piston rods of all hydraulic cylinders.

Turn the steering wheel fully to both sides.

After filling, check the hydraulic oil level once again and top up any missing oil.

129

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Environmentally compatible hydraulic fluid (biodegradable) (option) 30000214.01

Environmentally compatible hydraulic fluid, operating instructions The hydraulic system of this machine can be filled at the factory with environmentally compatible, synthetic hydraulic fluid (option). Stickers with corresponding instructions are then attached to the machine.

Environmentally compatible hydraulic fluid, conversion

Read and observe: "Inspection and Servicing, Safety Instructions".

For the initial filling, the manufacturer uses only: BIO FLUID HYDRAULIC EXCAVATORS .

This synthetic hydraulic fluid has been tested by the manufacturer and approved for application in the machines.

A change from mineral hydraulic oil to this synthetic hydraulic fluid can, however, be made also at a later date.

- Bring the hydraulic system to operating temperature.

Environmentally compatible hydraulic fluid, too, must not be simply poured away but disposed of in the same way as used oil.

- Activate all hydraulic functions including travelling for about 30 minutes. The hydraulic system is being flushed.

If hydraulic fluid seeps into the ground, the machine owner and the competent authorities must be informed.

- Drain off the hydraulic fluid thereafter.

The hydraulic fluid can be used repeatedly for flushing. Otherwise it must be properly disposed of. A disposal expert must be consulted in this case, the oil being a mixture of synthetic hydraulic fluid and mineral hydraulic oil.

BIO FLUID HYDRAULIC EXCAVATORS can only be used for hydraulic systems.

- Retract all hydraulic .

- Drain off hydraulic oil (see operating instructions Part 3 "Inspection and Servicing").

- Fill hydraulic reservoir with BIO FLUID HYDRAULIC EXCAVATORS .

BIO FLUID HYDRAULIC EXCAVATORS is not soluble in water. Condensed water may therefore settle in the hydraulic reservoir.

For this reason, condensed water must therefore be drained off regularly and after prolonged downtimes and disposed of in the same way as used oil.

- Replace all filters in the hydraulic system.

Use only BIO FLUID HYDRAULIC EXCAVATORS for changing or topping up hydraulic fluid.

The hydraulic fluid must not be mixed with hydraulic oils or hydraulic fluids from other manufacturers, as this affects its biodegradability.

- Start up the machine. Check the level in the hydraulic reservoir as indicated in the servicing plan.

Working equipment and attachments driven with mineral hydraulic oil must not be fitted unless they have been thoroughly emptied, cleaned and flushed.

An analysis can show whether the hydraulic fluid can be used beyond the standard changing intervals.

See section: "Environmentally compatible hydraulic fluid, sampling".

130

- Fill the hydraulic reservoir with new BIO FLUID HYDRAULIC EXCAVATORS .

- Fix an instruction sticker: - in the cab, - on the hydraulic reservoir and - on the working attachment.

- The hydraulic fluid can dissolve deposits in the hydraulic system.

Therefore, all filters must be replaced 30-50 operating hours after the conversion to the new oil.

Make subsequent filter replacements in acc. with the servicing plan.

- Sample the hydraulic fluid after 30 - 50 operating hours and send in for analysis. (See section: "Environmentally compatible hydraulic fluid, sampling").

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Environmentally compatible hydraulic fluid, sampling For taking the required samples, a special analysis kit containing all necessary parts is available.

- The kits are available from the Spare-parts service.

- The addresses of companies where hydraulic fluids can be analysed can be obtained from the Technical Service.

- The first sample is to be taken after 30 - 50 operating hours with the environmentally compatible hydraulic fluid.

Send this sample to the above address for analysis. The company will then notify you of the result of the analysis.

- Thereafter, it is recommended sending in a sample for analysis every 1000 operating hours or once a year.

It is essential that the hydraulic fluid should be analysed not later than after 3000 operating hours.

The results of the analysis show whether the hydraulic fluid is still serviceable and the changing interval can be extended.

In case of queries, contact the Technical Service.

131

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D AXLES, GEARBOXES

30000262

Axles and gearboxes, safety instructions

• Clean the checking and filling plug (1, Fig. 2) and screw back in place.

• Repeat the check after ca. 10 minutes and top up again, if necessary.

Park the machine on a horizontal surface and lower the equipment to the ground.

Shut off the engine and apply the parking brake.

Secure the machine by placing chocks under the wheels to prevent inadvertent movements.

Secure the machine against unauthorized starting.

Before working on axles or gearboxes, bleed axles and gearboxes.

Risk of scalding from hot oil.

Collect escaping oil and discard without polluting the environment.

Read and observe "Inspection and servicing, safety instructions".

Secure the machine as described under "Securing the machine".

Front axle Checking the oil level • Activate the breather valve (3, Fig.1).

Fig. 1

• Unscrew the checking and filling plug (1, Fig. 2). The oil level must reach up to the opening.

If this is not the case, fill in oil through the opening until it emerges from the opening.

132

Fig. 2

Changing the oil • Activate the breather valve (3, Fig.1).

• Place a collecting recipient under the front axle.

Capacity: see table of refilling quantities.

• Unscrew the drain plug (2). After complete draining, clean drain plug (2) and screw back in place.

• Now fill in oil as described under "Checking the oil level".

Replace damaged sealing rings.

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Rear axle

Distributor gearbox

Checking the oil level

Checking the oil level

• Activate the breather valve (4, Fig.3).

• Unscrew the checking and filling plug (5, Fig. 4). The oil level must reach up to the opening.

If this is not the case, fill in oil through the opening until it emerges from the opening.

• Unscrew the checking and filling plug (1, Fig. 2). The oil level must reach up to the opening.

If this is not the case, fill in oil through the opening until it emerges from the opening.

• Clean the checking and filling plug (1) and screw back in place.

• Repeat the check after ca. 10 minutes and top up again, if necessary.

• Clean the checking and filling plug (5) and screw back in place.

• Repeat the check after ca. 10 minutes and top up again, if necessary.

Fig. 3

Fig. 4

Changing the oil

Changing the oil

• Place a collecting recipient under the rear axle.

Capacity: see table of refilling quantities.

• Place a collecting recipient under the distributor gearbox. Capacity: see table of refilling quantities.

• Unscrew the drain plug (2, Fig. 4), collect the used oil and discard without polluting the environment. After complete draining, clean drain plug (2) and screw back in place.

• Unscrew the drain plug (6). After complete draining, clean drain plug (6) and screw back in place.

• Now fill in oil as described under "Checking the oil level".

• Now fill in oil as described under "Checking the oil level".

Replace damaged sealing rings.

Replace damaged sealing rings.

133

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Planetary gearbox Checking the oil level

Changing the oil

• Park the machine on a horizontal surface. Wait 10 minutes until the oil level in the axles is balanced before beginning the check.

• Place a collecting recipient under the planetary gearbox. Capacity: see table of refilling quantities.

• Turn the wheels until plug (3, Fig. 5) is in position A .

To remove air from the planetary gearbox, unscrew the checking and filling plug (3) and screw back in place.

• Turn the wheels until plug (3, Fig. 5) is in position A .

To remove air from the planetary gearbox, unscrew the checking and filling plug (3) and screw back in place.

Fig. 5

Fig. 6

• Turn the wheels until plug (3, Fig.6 ) is in horizontal position.

Unscrew the checking and filling plug (3).The oil level must reach up to the opening. If this is not the case, fill in oil until it emerges from the opening. Clean plug (3) and screw back in place.

•

• Repeat the check after ca. 10 minutes and add oil, if necessary.

134

• Turn the wheels until plug (3, Fig. 5) is in position B .

Unscrew plug (3).

• After complete draining, clean drain plug (3) and screw back in place. Now fill in oil as described under "Checking the oil level".

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D

135

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D BRAKES

30000217

Working on brakes, safety instructions

Personnel Never do repair work on brakes unless you are qualified to work on brake systems.

Never let hydraulic oils come into contact with the skin. Wear rubber gloves and firm protective clothing. Skin contact with hydraulic oils is a severe health hazard.

If in doubt, have the work done by the servcice department.

If contact with the skin cannot be avoided, protect the skin with a barrier cream.

Read and observe the section: "Repair, important information"

Contact with the skin should be as brief as possible. Afterwards, wash your hands thoroughly with soap and water.

Securing the machine Never do repair work on brakes unless the machine is secured as described in the section "Securing the machine".

When working on brakes, block the articulated joint.

Health protection Always store hydraulic oil only in the original containers.

Do not inhale the dust from brake linings.

Use a respiratory mask for protection.

Swallowing hydraulic oil is a severe health hazard.

When hydraulic oil has been swallowed, avoid vomiting, but consult a doctor or go to a hospital.

Do not let hydraulic oil get into the eyes.

If oil has splashed into the eyes, rinse immediately with plenty of clear water and consult an ophthalmologist.

136

Disposal Never let hydraulic oil penetrate into the ground; it contaminates the ground water.

Collect escaping hydraulic oil and dispose of it separately from other wastes and without polluting the environment. Never mix with used oil.

Cloths saturated with hydraulic oil and old brake linings must also be disposed of separately from other wastes and without polluting the environment.

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Parking brake

30000218

The parking brake requires virtually no maintenance. The brake is applied when the hand brake lever reaches the 4th notch. When the braking efficiency diminishes, check the lining thickness of the brake disks and contact the Technical Service.

Bleeding the brake system

30000267

The system must be bled when air has penetrated into the line system. This happens when brake lines are being losened or when parts of the brake system are being replaced or detached.

Bleeding requires two persons.

Observe the following sequence when bleeding the system:

Reducing braking pressure

• Right bleeding valve (2, Fig. 1) on the front axle (only with high-speed option) 2731581

The braking pressure must be reduced prior to any work on the braking system.

• Set working equipment down on ground.

• Switch off engine.

• Apply parking brake.

• Depress brake pedal 10-15 times.

The braking system is depressurized when the pedal can be depressed without marked resistance.

Fig. 1

• Left bleeding valve (2, Fig. 1) on the front axle. (only with high-speed option) • Bleeding valve (1, Fig. 1) on the disk brake.

137

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Bleeding For bleeding, connect a hose (2, Fig. 2) to the respective bleeding valve and hold the other end into a recipient filled with some hydraulic oil (e.g.

Fig. 2).

Fig. 2

While the first person depresses the brake pedal and holds it depressed with the engine running, the second person opens the bleeding valve by approx. 1/2 turn and closes it only after the hydraulic oil flowing into the recipient is free from bubbles. Only then can the first person release the brake pedal.

To make sure all the air has been removed from the system, perform this procedure at least twice.

138

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D WHEELS AND TYRES

2904113

Tyre pressure - Safety instructions

Bursting tyres and parts splintering away from the rims or from the tyre itself may cause severe injury.

The following instructions must therefore be strictly observed: - Before inflating the tyre, check the tyres, rims and rim parts for damage, penetrated foreign objects and proper fitting.

- Have all damage detected repaired by a qualified workshop.

- Check the tyre inflation pressure only when the tyres are cold. After warming up, the pressures indicated are higher than usual.

- Use filling equipment with long filling hose, self-fixing nozzle and pressure gauge.

-

-

Always inflate tyres to the prescribed pressure: - Excessive pressure means poor handling properties off the road and a risk of bursting tyres.

- Insufficient pressure means increased wear on the tyres and inadequate stability of the machine.

Inflate the tyres only with compressed ambient air. Never use inflammable gases: risk of explosion.

During tyre inflation, do not stand near the tyre and always in the plane of the tyre tread.

-

Watch the tyre and the pressure gauge of the filling equipment permanently during the inflation and never exceed the prescribed tyre pressures.

-

If available, place a safety cage around the wheel.

-

Make sure that nobody is standing near the tyre when it is being inflated.

139

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Checking the tyre inflation pressure Refilling the tyre

Read and observe the: "Tyre inflation pressure - Safety instructions".

• Park the machine on level and firm ground.

• Stand the working equipment on the ground.

• Apply the parking brake.

• Shut off the engine.

• Attach the self-locking nozzle of the filling equipment to the tyre filling valve (Fig. 1).

• Inflate all tyres with the prescribed pressure (cf.

"Table of tyre inflation pressures").

Fig. 1

140

Tyre pressure

30000251

The machine can be equipped with different types of tyres.

For better driving comfort, reduce the air pressure of the front wheels to that of the rear wheels before undertaking long transport drives.

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Tyre pressures and approved tyres for 30000252 21D Tyre size

Front axle Working operations Carrier fork Dumping and other and loading equipment bucket

Rear axle

Tyre pressures and approved tyres for 30000253 121D Tyre size

in bars

Front axle Working operations Carrier fork Dumping and other and loading equipment bucket

Rear axle

in bars in bars

in bars

in bars

in bars

10.5/80-18 EM TG 42 DU

X

3,25

2,5

12.5-R20 MPT SP PG 8 DU

X

3,5

2,5

12.5-18 MPT E 91 -2 DU

X

2,5

1,75

14.5-20 MPT E 91 DU

3,5

2,5

1,5

14.5-R20 SP PG 8 DU

3,5

3,0

2,0

12.5-20 MPT TG 32 DU

3,5

3,0

1,5 335/80 R20 EM SP T 9 DU

X

3,0

1,5

12,5-R20 MPT SP PG 8 DU

3,5

335/80 R20 MPT XM27 MI

X

3,0

1,5

5.5/55 R18 MPT SP PG 7 DU

4,0

365/80 R20 EM SP T 9 DU

3,5

2,75

2,0

335/80 R18 MPT XM27 MI

3,5

365/80 R20 EM VUT L2 BS

3,5

3,3

3,3

335/80 R18 EM SP 9 DU

3,5

375/75 R20 MPT XM27 MI

3,5

2,5

1,5

335/80 R20 MPT SP T 9 DU

3,0

405/70 R20 MPT XM27 MI

3,5

2,5

1,5

335/80 R20 EM SP T 9 DU

3,25

16/17-20 EM E 91-2 DU

2,75

2,25

1,50

335/80 R20 EM VUT L2 BS

3,5

405/70 R20 EM PG 75 R DU

3,25

2,75

1,75

335/80 R20 MPT XM27 MI

3,0

405/70 R20 EM SP T 9 DU

3,0

2,5

1,5

366/70 R18 EM SP T 9 DU

3,25

3,0

3,0

2,5

3,0

2,5

2,75

3,3

2,0

2,75

2,0

2,0

1,5

2,0

1,5

1,75

2,9

1,5

1,75

X not suitable for carrier fork operation

X not suitable for carrier fork operation

141

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Tyre pressures and approved tyres for 30000254 221D Tyre size

Front axle Working operations Carrier fork Dumping and other and loading equipment bucket

Rear axle

Tyre pressures and approved tyres for 30000255 321D Tyre size

in bars

Front axle Working operations Carrier fork Dumping and other and loading equipment bucket

Rear axle

in bars in bars

in bars

in bars

in bars

12.5-R20 MPT SP PG 8 DU

X

4,0

2,5

12.5-R20 MPT SP PG 8 DU

X

4,0

2,5

14.5-20 MPT E 91 DU

3,5

2,75

1,75

14.5-20 MPT E 91 DU

3,5

3,0

2,0

14.5-R20 MPT SP PG 8 DU

4,0

3,5

2,0

14.5-R20 MPT SP PG 8 DU

4,0

3,5

2,0

335/80 R20 EM SP T 9 DU

X

3,25

1,75

335/80 R20 EM SP T 9 DU

X

3,75

2,0

335/80 R20 MPT XM27 MI

X

3,0

1,5

335/80 R20 MPT XM27 MI

X

3,8

2,0

365/80 R20 EM SP T 9 DU

3,5

3,0

2,0

365/80 R20 EM SP T 9 DU

3,5

3,0

2,0

365/80 R20 EM VUT L2 BS

4,0

3,5

3,5

375/75 R20 MPT XM27 MI

3,5

2,5

1,5

375/75 R20 MPT XM27 MI

3,5

2,5

1,5

405/70 R20 MPT XM27 MI

3,5

3,5

1,5

405/70 R20 MPT XM27 MI

3,5

2,5

1,5

16/17-20 EM E 91-2 DU

3,25

2,75

1,75

16/17-20 EM E 91-2 DU

3,0

2,5

1,5

405/70 R20 EM PG 75 R DU

3,75

3,25

2,25

405/70 R20 EM PG 75 R DU

3,5

3,0

2,0

405/70 R20 EM SP T 9 DU

3,5

3,0

2,0

405/70 R20 EM SP T 9 DU

3,25

2,75

1,75

405/70 R20 EM VUT L2 BS

40

3,5

3,5

X not suitable for carrier fork operation

142

X not suitable for carrier fork operation

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Tyres and wheels - Safety instructions 2904114

Bursting tyres and parts splintering away from the rims or from the tyre itself may cause severe injury.

Do not carry out works on tyres and wheels unless you have received a special training for such work.

When driving on public roads observe the maximum tread wear values and the correct tyre pressure.

Mount only tyres of the same size and degree of wear on both axles.

Replace tyres with broken or worn-off treads or damaged flanks in time (or have them replaced).

Different tyre diameters may cause damage to the differential gears.

Have damaged rims or rim parts repaired immediately.

-

To avoid excessive wear of tyres: do not set off or brake abruptly, do not take corners too fast.

Never carry out mechanical, welding or flame-cutting work on rims or rim parts of inflated tyres.

If in doubt about the safe condition of tyres, rims and rim parts, have the complete wheel checked in a qualified workshop.

Changing of tyres, rims or rim parts requires special tools and procedures. Have these works performed in a qualified workshop that is specially equipped for such work.

Tighten wheel nuts with a torque wrench.

After several operating hours, check with a torque wrench for tightness.

143

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Changing a wheel

2904493.01

• Fitting the new wheel: Read and observe: "Tyres and wheels, safety instructions".

"Tyre pressures, safety instructions".

• Park the machine on firm and level ground.

- Inflate the tyre to approx. 1 bar.

- Observe the instructions in the section "Wheels, position of tyre tread".

- Do not damage the threads of the wheel studs.

• Tighten the wheel nuts by hand.

Block the articulated joint.

Apply the parking brake.

• Slacken the wheel nuts of the wheel to be changed by approx. 1 full turn.

• Raise the axle with the defective wheel slightly until the wheels come clear of the ground.

Front axle: Jack up the wheel loader with the bucket (Fig. 1).

Rear axle: Raise the wheel loader with a jack or a winch.

• Place supports on both sides under the raised axle (e.g. timber squares) to prevent it from lowering (Fig. 1).

• Remove the supports under the raised axle and lower the axle.

• Tighten the wheel nuts crosswise with the prescribed torque. Tightening torque: see "Fastening of the wheels".

• Inflate the tyre with the correct pressure, see "Tyre pressure".

• Check the wheel nuts after 5 hours of operation for tightness using a torque wrench.

Fastening of the wheels Check the wheel nuts after 5 HOURS OF OPERATION for tightness and retighten with a torque wrench.

Check all wheels in accordance with serving plan W for tightness and retighten the wheel nuts, if necessary.

Tightening torque: 450 Nm.

Position of tyre tread When fitting the wheels (Fig. 2) pay attention to the direction of the tyre tread. Fig. 2shows the tread position offering the best traction during forward travel under normal conditions.

Fig. 1

• Secure the machine as described under "Securing the machine".

• Deflate the tyres.

• Unscrew the wheel nuts and remove the wheel making sure not to damage the wheel studs.

Do not lose the centering rings, spring washers and wheel nuts. Re-use them for refitting the wheel.

Fig. 2

In special cases, another tread position may be of advantage. In such cases, contact the O&K Service.

144

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Lubricating the greasing points 2716686.01

Read and observe "Inspection and servicing, safety instructions".

CAB VENTILATION

30000219

Filter Replace the filter in acc. with servicing plan "B".

In extremely dusty conditions, replace at shorter intervals.

Before beginning greasing work: -

Stand working equipment on the the ground in dumping position (Fig. 1).

Secure the machine as described under "Securing the machine".

Do not throw away grease-stained cleaning rags, but discard separately from other waste.

Fig. 1

• The filter is accessible after opening of the service door (Fig. 1).

• Remove the wing nuts of the filter frame and detach the frame.

• Withdraw the filter element and discard without polluting the environment.

• Install a new filter element.

Fig. 1

• Refit the filter frame

Lubricate the greasing points on the working equipment and on the machine using a manual grease gun.

• Lock up the service door

• Withdraw the protective cap from the greasing nipple concerned.

• Clean the greasing nipple.

• Press the nozzle of the grease gun on the greasing nipple.

• Inject grease until the fresh grease squeezes the used grease out of the bearing joints.

• Wipe off used grease with cleaning rags.

• After greasing, put protective cap back onto the greasing nipple.

145

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D PUTTING THE LOADER OUT OF 2905158 OPERATION

Battery storage

If the loader is to be put out of operation for longer periods, the following measures are recommended:

For extended outage periods, remove battery / batteries and store on dry, well ventilated premises at ca. 20˚C. Observe the following maintenance points:

• Block articulated joint.

• Clean battery/batteries.

• Place the machine on supports to lift the tyres clear of the ground.

• Check acid density and battery fluid level once a fortnight.

• Release parking brake.

• Charge batteries when acid density has fallen to 1.23 kg/dm3 or earlier.

• Stand working equipment on the ground.

• Set control lever to position "0".

• Apply grease on bright-metal parts of the machine.

• Perform engine preservation.

• Carry out preservation of the engine in acc. with the engine operating instructions.

• Set battery main switch to OFF.

Preserving the engine (see engine operating instructions) • Clean engine with high-pressure equipment.

• Run engine up to operating temperature, then switch off.

• Drain off engine oil and fill in anti-corrosion oil (see engine operating instructions).

• Drain fuel from tank.

• Prepare fuel mixture from 90 % diesel and 10 % anti-corrosion oil and fill up tank.

• Run engine for ca. 10 minutes.

• Switch off engine.

• Race engine repeatedly by hand for cylinder and combustion chamber preservation.

• Dismantle V-belts and store in packaged form.

• Spray V-belt pulley grooves with anti-corrosion agent.

• Close intake opening and exhaust opening.

146

2411346

• Keep battery / batteries clean and dry externally.

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D RECOMMISSIONING

2905159

Before recommissioning the machine after a longer downtime observe the following points:

Removal of engine preserving agents

• Remove engine preservation. Fill in new engine oil.

• Remove anti-corrosion agent from the grooves of the V-belt pulley.

• Check battery charge condition.

• Mount V-belts and adjust tension after a brief operating period.

• Install battery and reconnect to the electrical system.

• Set battery main switch to ON. • Check tyre pressure.

(see engine operating instructions)

• Remove closures from intake and exhaust openings.

• Start up engine.

• Degrease piston rods of hydraulic cylinders.

• Put loader back on its wheels.

• Check operation of the electrical system.

• Remove articulated joint blocking mechanism.

• Check operation of braking and steering systems.

• Bring machine into driving position and apply parking brake.

• Bleed hydraulic system.

147

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D

148

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D PART 4 - REPAIR WORK

Operating manual

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS

2261179

Target group Operating personnel + Inspection and servicing personnel + Repair personnel

Operating personnel

Part 2 OPERATION

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

Inspection and servicing personnel

Part 3 INSPECTION AND SERVICING

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

Repair personnel

Part 4 REPAIR WORK

Part 5 ANNEX

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

Operating personnel + Inspection and servicing personnel + Repair personnel

149

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D

150

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Repair, safety instructions

30000220

Operating instructions

Blocking the articulated joint

Carry out repairs only after the operating instructions have been read and understood.

Block the articulated joint when performing work in the pivoting range. Remove the blocking on completion of the work.

Observe in particular: "Fundamental safety instructions", "Inspection and servicing, safety instructions" and all warning and instruction signs attached to the machine.

The descriptions of working sequences are intended only for experienced personnel.

The operating instructions must always be at hand in the machine.

Prestressed units Never open defective prestressed units, but replace them altogether.

In exceptional cases, open only when the system and the operating sequence are precisely known and when the special tools required are available.

The operating manual contains no information on this point.

Repair personnel The repair personnel must have knowhow and experience concerning the repair of this or of comparable machines.

If this know-how is lacking, meticulous training must be given by experienced repair personnel, e.g. by the Technical Service.

Have work marked "X" done by the Technical Service.

Dismantling components Never dismantle while the machine is at operating temperature.

Oils, greases, brake fluid or coolants may have a high temperature and thus cause burns and scalding.

Leave time for the machine to cool down.

Before starting work, depressurize piping and hoses, cylinders, coolers, hydraulic reservoir, compressed-air reservoir and other systems or units.

Replace defective components in time to avoid major damage.

Clean the defective component carefully before dismantling it.

Mark dismantled parts in the right order to facilitate re-assembly.

When dismantling the component, close off open hose and pipe connections, bores and casings carefully to prevent any dust from penetrating.

151

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D

Never remove lead seals Never change the rated pressure of pressure relief valves without the express approval of the manufacturer.

Do not remove lead seals on pressure relief valves and accumulators.

After the repair To prevent corrosion, coat all bright-metal machine parts with a grease film.

On completion of the work, refit all protective devices, covers and all insulating materials protecting against sound and vibration.

Never start up the drive engine while work is being done on the machine.

Check the repaired components and all machine functions in a trial run.

Release the machine for recommissioning only after it is fully operational in all its functions.

152

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D ENGINE

30000221

Engine, repair information

Assisted starting (jump-starting) 2905170 Safety instructions

Read and observe: "Repair, safety instructions" and the engine operating manual before undertaking any work on the engine.

Risk of injury from hot or rotating parts of the engine.

Shut off the engine and leave to cool down.

Risk of explosion Battery gases contain hydrogen and are readily flammable. Keep any potential ignition sources, such as unshielded lights or burning cigarettes, away from the batteries.

Carry out repair work only if the machine is secured as described in the "Securing the machine" section of the present operating instructions.

Risk of injury from splashing acid and battery gases.

Never lean over the batteries when jumpstarting a vehicle.

Wear goggles.

Check and change V-belts only when the engine is stationary.

Never use assisted starting when the batteries are defective or frozen.

Repair work on the engine demands extensive know-how and special tools.

Never connect batteries (battery assemblies) unless they have the same voltage.

In cases of doubt, have repair work carried out by the Technical Service.

Use only tested jumper cables with insulated terminal clips and an adequate lead diameter.

Replacing V-belts

2905160

Replacing alternator / coolant pump V-belts This repair work is detailed in the engine operating instructions.

Ensure that the bodies of the supplying and receiving machines are not in contact. Otherwise a current flow might result from connecting the positive poles. Risk of short-circuiting.

Never use jumper cables with overvoltage, e.g. two or three batteries or booster units connected in series and generating voltages in excess of 12V. Never use welding generators or welding transformers as a source of current.

Position jumper cables in such a way that they cannot be caught by rotating engine components.

Read and observe: "Inspection and servicing - Safety instructions", paying special attention to the section "Handling batteries".

153

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Assisted starting (jump-starting)

2905162

Prior to assisted starting

Read and observe: "Assisted starting, Safety instructions".

• Check whether the battery of the receiving machine (discharged battery) is in working order: - Switch off electrical consumers (headlamps, fan).

- Turn key-switch to "ON". The engine monitoring lamps must light up.

- If the monitoring lamps do not light up, the battery is defective (exhaustive discharge or internal short-circuit).

In this case the machine must not be started, as the alternator would then be damaged.

Install a functional battery before jump-starting.

• Switch off all electrical consumers in receiving machine and turn key-switch to 0 .

• Switch off all consumers in supplying machine (booster battery) and shut off engine.

Connecting the jumper cables

Risk of explosion A high current flows on connection of the earthing cable. Sparks occurring at the contact point may ignite gases at the discharged battery.

The earthing terminal should therefore be connected as far as possible from the discharged battery.

• Connect the red jumper cable to the positive terminal of the discharged battery (1, Fig. 1) and then to the positive terminal of the booster batters (2).

• Connect the black jumper cable first to the negative terminal of the booster battery (3) and then to a bright-metal point on the receiving machine (4).

154

Fig. 1

Starting the engines • Start the engine of the supplying machine and run it with stepped-up revolutions.

• Start the engine of the receiving machine. If the engine does not start up after 15 seconds, wait one minute before re-starting.

• When the engine has started up, continue running both machines in no-load operation for about two or three minutes with the jumper cables still connected.

• Once the engine has started up, proceed as follows: - Switch on some high-consumption units, e.g. complete lighting system, fan on stage 3 and air-conditioning system if present. This prevents voltage peaks, which might damage electronic modules, from occurring when the jumper cables are disconnected.

- Disconnect the jumper cables in the following sequence: - Negative terminal on receiving machine (4) - Negative terminal on supplying machine (3) - Positive terminal on supplying machine (2) - Positive terminal on receiving machine (1) - Switch off high-consumption units again.

- Run the engine at moderate speed for about half an hour to start recharging the batteries.

Have the electrical system of the machine chekked to determine why the batteries were discharged.

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D ELECTRICAL SYSTEM Fuses

Shut off the engine and set the key-switch to ’0’ before removing the fuses.

30000199.01

Upper row of fuses (Fig. 2) F1:

A 7,5A Emergency steering system B 7,5A Load stabilisation system C 7,5A Switch 2nd gear

F2:

A 5A

F3:

B 15A Socket outlet, switch illumination C 7,5A Multifunction lever, creep speed solenoid A 7,5A Instrument panel, hand brake

Replace defective fuses only by fuses with the same load rating.

Replacing a fuse Withdraw the defective fuse and insert a new one with the same load rating.

Fuses in the cab The fuses are accessible after opening the service door on the right-hand side of the cab.

Parking light right, tail light left, license plate illumination

B 7,5A Solenoid valve forward and reverse C 7,5A Main beam left F4:

A 7,5A Reversing lamp, reversing alarm B 7,5A Engine stop solenoid C 15A Reserve

F5:

A 10A B 10A

Turn signal, hazard warning signal Socket outlet, rotary beacon

C 10A

Cab light, radio +30

Lower row of fuses (Fig. 2) F6:

F7:

A 7,5A Wiper, washer rear B 5A Floating position C 10A A 5A B 10A C 15A

Fig. 1

F8:

F9:

Reserve Parking light left, tail light right, panel backlighting Stop light, hazard warning signal Wiper, washer front, radio +15

A 15A Working floodlamp, rear B 7,5A Dipped beam left C 7,5A Dipped beam right

A B C F10: A B

7,5A 7,5A 15A 15A 15A

C 10A

Main beam right Preheating control input Working floodlamp, front Signal horn Reserve Immobilizer

Fuse on the right (Fig. 2) F31:

30A

Blower

Fig. 2

155

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Fuse in the engine compartment

Replacing bulbs

2905444

The fuse of the preheating control is located under the engine hood in front at the right.

Shut off engine and set key-switch to "0" before replacing any bulbs.

Replace defective bulbs only with bulbs with the same ratings.

Never touch new bulbs with bare fingers.

Finger marks and dirt will burn in when the bulb is hot and may reduce the service life of the bulb.

Before installing a new bulb: Remove all traces of corrosion from the holder and the electrical contacts.

This helps avoid contact problems and high contact resistances.

Fig. 3

F1.1 Flame glow system 50 A

156

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Lighting

30000200

Fig. 1

Headlamp

Fig. 2

1 - Headlamp

• Loosen the 4 screws at the rear (3, Fig. 2).

2 - Turn signal

• Withdraw connector (6) and rubber cap (5).

3 - Tail light, stop light, turn signal and reversing light

• Remove lamp bulb (1) from socket (7) and insert a new one.

4 - Working floodlamp, front

• Re-assemble in reverse order.

5 - Working floodlamp, rear (option) 6 - Rotary beacon (option)

Turn signal

Fig. 3

• Loosen the 2 screws at the rear (4, Fig. 3).

• Remove the front cap.

• Replace the defective lamp bulb.

• Re-assemble in reverse order.

157

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Tail light / stop light / turn signal (variant

Tail light / stop light / turn signal (variant

1)

2)

• Unscrew the caps (Fig. 4) of the lamp. The lamp bulbs are accessible.

• Unscrew the cap (Fig. 6) of the lamps. The lamp bulbs are accessible.

Fig. 4

Fig. 6

11 - Tail light

1 - Tail light

12 - Stop light

2 - Stop light

13 - Turn signal lamp

3 - Turn signal lamp

14 - Reversing lamp

4 - Reversing lamp • Replace the defective lamp bulb.

• Re-assemble in reverse order.

Fig. 5

• Replace the defective lamp bulb.

• Re-assemble in reverse order.

158

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Interior lamp • Withdraw the cap (Fig. 7)

Working floodlamp

• Replace the defective lamp bulb.

• Loosen the screws (13, Fig. 8) and withdraw the lamp glass (14) carefully.

Fig. 7

Fig. 8

• Re-assemble in reverse order.

• Unsnap the safety clamp (15, Fig. 9).

Fig. 9

• Remove the defective lamp bulb (16, Fig. 10) from the socket (17) and insert a new lamp bulb.

Fig. 10

• Re-assemble in reverse order.

159

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D OPTIONAL EQUIPMENT

2413656

Rotary beacon

Rotary beacon - replacing the reflector

Depress catch (21, Fig. 1) and take off cover (22).

Detach cover (22) as described above.

Withdraw clip (24, Fig. 3) using small pincers.

The reflector can then be completely withdrawn together with motor (25).

Fig. 1

Take out bulb (23, Fig. 2) and replace by a new one.

Fig. 3

Install new reflector with motor (25). Insert clip (24) and put on cover (22).

Fig. 2

Put on cover (22), depress catch (21) and allow cover (22) to engage.

160

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D WELDING OPERATIONS Welding operations - safety instructions

Never perform welding operations unless you are qualified to do so.

Observe the accident prevention regulations.

Any work on receptacles that contain or have contained substances which are - combustible or which encourage combustion, which - are susceptible to explosion, or which

2281253

Prior to any welding operations on the machine: - Set battery main switch to position II OFF. - Disconnect the battery, first the negative terminal and then at the positive terminal.

- Disconnect the positive terminal at the alternator.

may develop health-hazardous gases, vapours, mist or dust during welding operations

Protect the disconnected terminals and plugs from short-circuiting and soiling by covering them with foil or adhesive tape.

must be carried out only under expert supervision and only by experienced persons authorized to do such work.

Apply the welding current terminals very close to the welding point.

-

Detailed information on the correct execution of welding operations is given in the technical manual "Welding for maintenance and repair".

Should you have any problems or queries, apply to the O&K after-sales service department.

The welding current must not flow through gearboxes, bolted or articulated joints or hydraulic cylinders.

On completion of the welding operation, restore all electrical connections.

When connecting the battery, first connect the positive terminal and then the negative terminal.

If parts of the machine have to be dismantled, read and take note of the following sections: "Assembling attachments - safety instructions", "Inspection and servicing - safety instructions", "Repair - safety instructions".

161

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D HYDRAULIC SYSTEM Repair

30000263

Replacing hydraulic hoses, safety instructions

Lifting cylinder - installation

• During the installation of a new lifting cylinder (2, Fig. 1) take care that the retaining screws (1) of lifting cylinder (2) face inside.

Before detaching hydraulic hoses: Depressurize the hydraulic system.

Replace damaged and leaking hydraulic hoses by new ones.

Use original spare parts. They are coordinated with the respective function.

Do not re-use used hoses.

Dispose of leaked oil and oily wastes without polluting the environment. Oil and oily wastes must be prevented from seeping into the ground or from reaching water.

Hydraulic hoses should be replaced after a six-year period of use to prevent an increased risk of failure.

Read and observe also the section "Inspection and servicing, safety instructions".

162

2904150

Fig. 1

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D BRAKES

2905778

Working on brakes - safety instructions

Personnel Never do repair work on brakes unless you are qualified to work on brake systems.

Contact with the skin must be as brief as possible. Afterwards, wash your hands thoroughly with soap and water.

If in doubt, have the work done by the O&K Service Dept.

Hydraulic oils are harmful to the skin.

Wear gloves and heavy-duty working clothing.

Read and take note of the section: "Repair work - Safety instructions".

Disposal

Securing the machine

Never let hydraulic oil penetrate into the soil; it contaminates the ground water.

Never do repair work on brakes unless the machine is secured as described in the section "Securing the machine".

Block the articulated joint when carrying out work on the brake system.

Health protection

Catch any emerging hydraulic oil and dispose of it separately from other waste in the interests of environmental protection.

Never mix with used oil.

Dispose of cloths saturated with hydraulic oil and removed parts separately from other waste in the interests of environmental protection.

Always store hydraulic oil in the original containers.

Do not inhale particles from damaged brake linings, wear a protective mask.

Swallowing hydraulic oil is a severe health hazard.

If hydraulic oil is swallowed, induce vomiting immediately and go straight to a hospital.

Always keep hydraulic oil away from the eyes. If the eyes are splashed, rinse immediately with plenty of clear water and consult an ophthalmologist.

Never let hydraulic oil come into contact with the skin; wear rubber gloves.

If contact with the skin cannot be avoided, protect the skin with a barrier cream.

163

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Checking the braking pressure • Secure the machine as described in the section "Securing the machine".

• Removing the braking pressure.

To remove the braking pressure, depress the brake pedal 10-15 times. The brake system is depressurized when the pedal can be depressed without resistance.

30000264

• Check the braking pressure. The pressure gauge (4, Fig. 1) must indicate a pressure of 50 +5 bars.

• Connect a pressure gauge (measuring range up to 200 bars). Unscrew the cap (1, Fig. 1) from measuring port (2) on brake valve (3) and connect gauge (4) to the port.

Thread size: M 16 x 2

Fig. 2

If -

the warning lamp does not go out, the acoustic warning signal continues to sound,

-

the braking pressure is below 50 bars or above 55 bars,

Fig. 1

the brake system is defective.

• Check that the parking brake is applied and that the travel selector lever is set to "0".

Contact the Service Dept.

• Start the engine and wait until the required minimum braking pressure is reached. This is the case, when warning lamp (3) goes out and when the acoustic warning signal stops sounding.

164

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Checking the accumulator pressure 30000265

Secure the machine as described in the section "Securing the machine".

On completion of the work • Remove the braking pressure.

• Detach the pressure gauge.

• Screw cap back onto the measuring port.

• Remove the braking pressure.

• Unscrew the cap (8, Fig. 1) at measuring port (9) (M 16 x 2) on valve (10).

Fig. 1

• Attach pressure gauge (measuring range up to 200 bars) to the port.

• Start the engine and wait until the braking pressure has built up. The acoustic warning stops sounding and warning lamp (3, Fig.2) is off.

Fig. 2

• The gauge must indicate a pressure of 150 bars.

• If the accumualtor pressure is lower, check the accumulator precharging pressure.

165

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Checking the precharging pressure of the accumulator

On completion of the work • Remove the braking pressure.

30000266

• Detach the pressure gauge.

Secure the machine as described in the section "Securing the machine".

• Unscrew the cap (8, Fig. 1) at measuring port (9) (M 16 x 2) on valve (10).

Fig. 1

• Attach pressure gauge (measuring range up to 200 bars) to the port.

• Start the engine and wait until the braking pressure has built up. The acoustic warning stops sounding and warning lamp (3, Fig.2) is off.

Fig. 2

• When the braking pressure has built up, the engine must be shut OFF. • Depress the brake pedal and observe the pressure gauge.

• After each press on the pedal, the accumulator pressure drops slightly. The value at which the pressure drops sharply is the accumulator precharging pressure of 50 bars.

• If this pressure is less than 16 bars, the accumualtor must be replaced.

166

• Screw cap back onto the measuring port.

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Pressure accumulator Pressure accumulator, safety instructions

30000222

Replacing the accumulator The accumulator must be replaced in acc. with maintenance plan "D" .

Contact the Technical Service for this work.

Accumulators are installed in the hydraulic system. These accumulators contain nitrogen under high initial pressure.

Even if the hydraulic pressure in the system is eliminated, the nitrogen in the accumulator remains under pressure.

The accumulators are completely safe in operation. If incorrectly handled, however, there is a risk of explosion.

Therefore: -

-

Never perform mechanical work on accumulators, never weld or solder them.

Testing and servicing work must be carried out by experts only.

Prior to any testing and servicing work, depressurize the hydraulic part of the system.

To dismantle the accumulator, always wear goggles and working gloves.

Fill accumulators with nitrogen only, never with compressed air or oxygen.

Report any defects or damage to the machine owner without delay.

Prior to recommissioning, an inspection by a specialist or expert is essential if the accumulator was damaged or if the admissible operating temperature or operating pressure was exceeded.

Never remove or paint over warning and information plates, rating plates or type identification markings. Replace illegible or damaged plates immediately.

167

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D EQUIPMENT

2801554

Working equipment - replacing a tooth

Read and observe the section on "Fitting of working equipment - Safety instructions".

Secure the machine (cf. "Securing the machine").

Nobody must stand in the direction of the ejected safety latch and tooth.

The safety latch or the tooth can suddenly be ejected when driven out and hit persons.

Metal splinters may cause injury.

Fig. 2

Wear your personal protective equipment and goggles.

• Clean inside of housing and remove dirt and corrosion.

• Drive out tooth safety latch (1, Fig. 1) using a piece of smooth metal or of hard wood.

Fig. 1

• Drive tooth (3, Fig. 2) out of housing (4) using a piece of smooth metal or of hard wood.

• Insert new tooth (3, Fig. 3) into housing (4).

The tooth must be in contact with the housing (arrow, Fig. 4).

Fig. 3

• Drive in new safety latch (1, Fig. 4).

The latch can be driven into the housing from either side.

Fig. 4

168

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Bucket limit stops

2905805

Make sure nobody is standing under the lifting frame.

The space between the toggle link and lifting frame limit stop can be compensated by plates (see spare-parts illustration 60.500).

Raise the lifting frame and bring into dumping position so that toggle link (2, Fig. 3) rests on the limit stop (7) at traverse (8) of the lifting frame.

There must be no play in between.

The bucket limit stops between bucket and lifting frame must be in perfect alignment to avoid severe damage to the lifting frame.

Upper dumping position Raise the empty bucket (1) and bring into dumping position (Fig. 1).

Fig. 3

Any existing play can be compensated by plates (see spare-parts illustration 60.500).

Rearward tilt position Set bucket (1) on the ground and tilt rearwards.

The bucket (1) must contact the lifting frame (3, Fig. 4).

Fig. 1

The bucket (1) should contact the lifting frame (3) at the same time as toggle link (2). The toggle link (2) may also be the first to contact the frame.

The tolerance of the bucket limit stops (4) on the lifting frame am (3) must be 0+1,5 mm (Fig. 2).

Fig. 4

The tolerance of the bucket limit stops (5) on the lifting frame (3) with respect to one another must not be greater than 3 mm.

Fig. 2

Any greater deviation can otherwise be compensated by plates. (see spare-parts illustration 64.200).

169

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Lifting forks (option)

30000273

Lifting forks, instructions

Fork prongs Types Standard fork prong (Fig. 1)

Operating personnel The operating personnel must have a license for operating industrial trucks with lifting forks.

The legal regulations in the country of use must be observed.

General Always take up the load with both fork prongs.

Check the prongs by permanent visual inspections and put them out of operation immediately if damge is detected.

Fork prongs are not designed to withstand lateral forces. Avoid driving the prongs diagonally under the load or pushing the load with the side.

Fig. 1

Collapsible fork pronk (Fig. 2) Driving without load and raised prongs reduces the risk of accidents. If a carpet or a boom eperon is attached, the prongs must not be removed.

Do not let loads fall on fork prongs.

The transport of molten or fused material is forbidden.

The transport of persons on fork prongs is forbidden.

Do not lift loads with the tip of the prongs. Risk of overloading.

Checks Have legally prescribed checks performed regularly by qualified personnel or by the Service Dept.

The rules and regulations in force in the country of use must be observed.

Perform regular measurements of prong wear.

Repair Have the prongs repaired only by specialized workshops.

If one of the prongs is damaged, never replace only the damaged one, but always both.

170

Fig. 2

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Marking Fork prongs are durably marked (Fig. 3). Fork prongs without marking must be must be withdrawn from circulation.

Cracking test

Cracking tests must be performed by specially qualified experts.

In the event of positive cracking test results, both prongs must be replaced immediately.

Critical zones are the fork bending point and the welds at the suspensions.

The usual methods of testing applied are the magnetic powder test or the dye penetration test.

Fig. 3

Principle of destruction-free testing for cracks by means of the dye penetration method (Fig. 4):

1 = Carrying capacity kg/piece 2 = Load center of gravity (LPS)/mm 3 = Material 4 = Week of manufacture 5 = Year of manufacture 6 = Material code 7 = Article number

Inspection interval Inspections have to be performed regularly. ISO 5057 prescribes an inspection at least every 12 months. Depending on the conditions of use, e.g. multi-shift work or severe operating conditions, the inspections are to be performed more frequently. Moreover, the user is obliged to perform regular visual checks.

The following points must be checked:

Fig. 4

1. Clean the zone to be tested thoroughly.

2. Spray red penetrant on the test zone.

3. Remove red penetrant.

4. Spray developer on the test zone. Cracks are now visible.

• wear • cracking in the bent area • cracking in welding seams • deformations and warping • functioning of the arresters • damage of fork hook and fork tip • general condition

171

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Deformation check

Wear check

If the bending angle of the prongs is greater than 91˚ or less than 88˚, both fork prongs must be replaced immediately.

If the wear is greater than 10%, both fork prongs must be replaced immediately.

Fork prongs are delivered with a bending angle of 90˚ (Fig. 5).

They are designed in such a way that they can withstand even twice the nominal load without any remaining deformation.

Fork prong wear occurs most often in the outer bending area (Fig. 7).

Fig. 7

Fig. 5

In practice, permanent deformation may, however, occur by overloading, misuse or unilateral loading.

Measurement (Fig. 6):

Starting point of the wear measurement is the original nominal thickness n (Fig. 7) of the fork prong.

At a nominal thickness of, for instance, 40mm, the wear limit is 36 mm.

When a wear of 10% is exceeded, both fork prongs must be replaced immediately.

Fig. 6

• Make a mark at the vertical and horizontal distance of 500 mm.

• Measure diagonal distance d (Fig. 6).

• The diagonal distance may be 695 to 713 mm.

• If the measured distance is less than 695 mm or greater than 713 mm, both fork prongs must be replaced immediately.

172

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D PART 5 - ANNEX

Operating manual

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS

2261969

Target group Operating personnel + Inspection and servicing personnel + Repair personnel

Operating personnel

Part 2 OPERATION

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

Inspection and servicing personnel

Part 3 INSPECTION AND SERVICING

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

Repair personnel

Part 4 REPAIR WORK

Part 5 ANNEX

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

Operating personnel + Inspection and servicing personnel + Repair personnel

173

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D

174

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D TROUBLESHOOTING

30000268

Instructions for troubleshooting

Fault table layout

Faults are often due to the machine not having been operated or serviced properly.

Fault

When dealing with faults, it is therefore necessary to read the corresponding chapter of the operating instructions once again.

The fault is described as a result of an observation or of a preceding activity.

Observe the machine carefully.

If you cannot find the cause of a fault or rectify it, contact our Service Dept.

Examine the problem thoroughly. First think, then act.

Describe the fault and the accompanying circumstances as precisely as possible when contacting our Service Dept. Exact information helps to locate and to rectifiy faults as fast as possible.

Ask yourself the following questions:

Never do work for which you are not qualified.

The present fault table lists the faults reported to date, their possible causes and the remedial action. In exceptional cases, a described fault may also have another cause.

- Which warning signs preceded the fault?

- Which repair and servicing work had been performed beforehand?

- Has this defect already been noticed in the past?

- Are we faced with one or with several defects occurring at the same time?

Possible causes This column describes the possible causes of the fault observed. The causes are listed in the order of their probability of occurrence, i.e. the possible cause applying in most of the cases is mentioned in first place.

Remedial action This column informs about how to detect the causes of faults and how to remedy them.

Chapter reference The chapter reference informs the reader where to find the pertaining troubleshooting instructions in these operating instructions. In the event of missing reference, please contact our Service Dept.

175

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Steering system

30000225

Fault

Steering wheel hard to turn, working equipment not functional Steering wheel hard to turn when driving on level ground Steering wobbly, permanent correction necessary Steering wheel easy to turn at limit stop During fast steering action, wheel turns fast for a short time (steering catching up) Steering wheel continues to turn on its own when released

Cause

• • • • • • • • • • •

176

Remedial action Check Adjust Replace Top up Lubricate

P E W A S

Clean

R

X Contact Service

Chapter

Hydraulic oil level too low

A

Air in hydraulic system

X

Internal leaks in steering valve / cylinder

X

Pressure setting too low

X

Oil supply rate insufficient

X

Limited-slip differential or steering mechanics sluggish

X

Steering valve jamming

X

Pump drive coupling defective

X

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Working equipment

30000226

Fault Lifting, dumping and steering not functional Lifting and dumping not functional; combustion engine load audibly higher Lifting and dumping not functional, combustion engine not loaded Control lever for loading bucket equipment does not remain locked in floating position

Remedial action Check Adjust Replace

P E W

Top up Lubricate Clean

A S R

Dumping and lifting times too long Dumping or lifting time too long

X Contact Service

Lowering time too long, floating position not lockable Strong dumping movement with engine stationary and control valve not actuated Significant lowering movement with engine stationary and control valve not actuated Lifting and dumping movements with control valve not actuated and engine running Lifting force insufficient Back-tipping force insufficient Strong engine throttling with lifting/dumping function against block

• • •• ••••• •• •• • • • • •• •• • ••• • • • •

Cause

Chapter

Hydraulic oil level too low

Hydraulic system

A

Kinematics fault (working equipment components deformed), limit stops incorrect

X

Operating kinematics at control valve defective

X

Primary pressure setting too low

X

Secondary pressure setting too low

X

Max. engine speed too low

X

Internal leaks in control valve or in cylinders

X

Control travel of control valve piston insufficient

X

Zero-position centering of control valve(s) defective

X

Pump delivery rate too low

X

Control piston locking in control valve defective

X

Pump drive coupling defective

X

Primary pressure setting too high

X

177

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Travel drive

30000227

Page 1 of 2

Fault No forward travel, no reversing, working and steering hydraulics not functional No forward travel, no reversing; signal horn and screen washer not functional No forward travel, no reversing; combustion engine not loaded No forward travel, no reversing, central warning lamp on No forward travel, no reversing, stop light on No forward travel, no reversing, combustion engine loaded

Remedial action Check Adjust Replace Top up Lubricate Clean

P E W A S R

X Contact Service

No forward travel or no reversing Machine sets in motion on level ground only when engine speed relatively high, unnatural noise Insufficient acceleration resp. push in both travelling directions Heavy throttling of combustion engine speed during acceleration and push Max. travelling speed not reached Max. travelling speed not reached, jerky deceleration at fast reduction of engine speed Jerky deceleration at fast reduction of combustion engine speed Machine does not respond to working gear shift Strong oil heating, oil emerging from tank breather, cooling fan working continuously Strong oil heating, oil emerging from tank breather

• •

•••• • ••• • • •

• • •

178

•

•

Cause

Chapter

Hydraulic oil level too low

Hydraulic system

A

Parking still applied

Driving

P

Feed circuit filter contaminated

Hydraulic system

P, W

Incorrect tyre pressure

Tyres and wheels

P, A

Oil of wrong viscosity used

Oils

Radiator soiled

Cooling system

W R

Oil temperature too high Tyre diameters significantly different

Tyres and wheels

Fuse defective

Electrical system

W

Pressure in pump accumulator brake too low

X

Parking brake switch jamming in open position

X X X

Travel direction switch defective

•

P P

Travel direction solenoid valve defective

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Travel drive

Page 2 of 2

Fault No forward travel, no reversing, working and steering hydraulics not functional No forward travel, no reversing; signal horn and screen washer not functional No forward travel, no reversing; combustion engine not loaded No forward travel, no reversing, central warning lamp on No forward travel, no reversing, stop light on No forward travel, no reversing, combustion engine loaded

Remedial action Check

P

Adjust

E

Replace

W

Top up

A

Lubricate

S

Clean

R

X Contact Service

No forward travel or no reversing Machine sets in motion on level ground only when engine speed relatively high, unnatural noise Insufficient acceleration resp. push in both travelling directions Heavy throttling of combustion engine speed during acceleration and push Max. travelling speed not reached Max. travelling speed not reached, jerky deceleration at fast reduction of engine speed Jerky deceleration at fast reduction of combustion engine speed Machine does not respond to working gear shift Strong oil heating, oil emerging from tank breather, cooling fan working continuously Starke Ölerwärmung, Ölaustritt aus der Tankbelüftung

Cause

• • • • • • •• • •• ••• •••• ••• • •••

• • • • •

Chapter

Working gear solenoid defectivve

X

Brake actuation caught up

X

Fuse defective

Electrical system

W X

Temperature switch or cooling fan motor defective Engine speed too low

Engine OM

E

Engine performance insufficient

Engine OM

P

Friction losses in axle drive or brake too high

X

Malfunction in control-pressure circuit of the travel pump

X

Malfunction in high-pressure circuit of the travel drive

X

Malfunction in feed-pressure circuit of the travel pump

X

Malfunction in travel motor regulator

X

Front axle, rear axle or brake blocking

X

Travel motor without positive connection to reat axle

X

Pump drive coupling defective

X

179

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Brake system

30000228.01

Fault Insufficient braking action or no braking action at all Braking action too strong Precision inch-braking not possible Max. accumulator pressure not reached Brakes noisy Cause

• • • • • • • • • • • • • •

180

Remedial action Check Adjust Replace Top up Lubricate Clean

P E W A S R

X Contact Service Chapter

Leaks in brake system

X

Inching valve setting incorrect

X

Brake plates worn, brake disk or brake linings worn

X

Malfunction of brake pedal valve

X

Brake pressure setting incorrect

X

Malfunction of inching valve

X

Malfunction of accumulator charging valve

X

Pump defective

X

Wrong oil sort used Malfunction of pilot-pressure valve

Oils

W X

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Air conditioner, troubleshooting

30000012_01

Blower:

Page 1 of 4

Malfunction

Cause

Remedial action

Blower not working

Fuse defective or loose

Check fuse contact, if necessary plug in correctly.

Replace defective fuse. Reappearance of the defect after a short time indicates a short-circuit.

Check blower for blocking or other faults and eliminate the cause.

Connector loose

Check that connectors at the bottom of the unit are firmly in place and correct, if necessary.

Check connections at blower switch.

Open the unit and check the electrical connections inside.

Connecting cable damaged or ripped off

Replace cable, observing correct cable run and connection.

Electrical connections interchanged

Check connecting cables and reconnect properly, if necessary.

Blower switch defective

Replace by new OEM part.

Blower assembly blocked

Eliminate the cause of the blockage, e.g. by removing foreign object from rotor. If necessary, install a new blower.

Blower motor defective

Replace the blower.

Blower cannot be switched off

Blower switch internal short-circuit

Replace blower switch.

Reduced blower performance

Rated supply voltage incorrect

Rated voltage of conditioner and of vehicle system must be identical. Replace blower.

Contacts dirty

Clean connector contacts. Proceed with care to avoid short-circuits.

Insufficient cross-section of electrical cables

Lay cables with the recommended cross-sections.

Heat exchanger heavily contaminated

Clean carefully to avoid causing damage to the exchanger which might result in consequential leaks.

Blower ducts obstructed

Check air ducts and outlets for obstructions and remove any foreign objects.

181

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Cooling performance:

Page 2 of 4

Malfunction

Cause

Remedial action

Compressor not working

Open circuit in compressor solenoid

Check power supply to the clutch.

Thermostat defective

Replace thermostat.

V-belt loose or broken

Adjust V-belt tension, replace V-belt.

Belt pulley not turning although magnetic clutch is engaged

Check compressor and replace, if necessary.

Compressor clutch slipping

Repair clutch or replace compressor.

Evaporator flooded

Expansion valve jammed or stuck in open position

Replace expansion valve.

Evaporator frozen up

Thermostat sensor in wrong position

Install sensor in another place.

Evaporator clogged up

Cooling ribs dirty

Clean evaporator.

Loss of refrigerant

Refrigerant line defective

Check all lines for defects caused by external influences or chafing.

Leaks in the system

Evacuate the system, refill, check for leaks and repair.

Air filter clogged up

Clean air filter or replace.

Air filter

182

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Heating performance:

Page 3 of 4

Malfunction

Cause

Remedial action

Heating not working

Coolant still cold

Wait until the engine has reached operating temperature.

Heating valve closed

Open the valve (see operating instructions: "Heating").

Heat exchanger or filter heavily contaminated

Clean carefully, to avoid causing damage which might result in consequential leaks.

Bowden cable of heating valve incorrectly adjusted

Readjust Bowden cable.

Air in heat exchanger

The radiator is self-venting. Wait until the radiator has finished self-venting.

Unit under-dimensioned

Consider installing an additional heating or more powerful unit.

Adjustment of Bowden cable controlling the heating valve inappropriate

Readjust the Bowden cable.

Control element or Bowden cable defective

Check control element or Bowden cable and replace, if necessary.

Flap hinges sluggish

Check flap and lubricate, if necessary.

Flap deformed

Check flap.

Flap blocked by foreign object

Check flap and remove foreign object, if any.

Heating working with reduced performance

Heating cannot be switched off

Air distribution flaps cannot be adjusted

183

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D Conditioner very noisy:

Page 4 of 4

Malfunction

Cause

Remedial action

Conditioner very noisy

V-belt loose or excessively worn

Retension V-belt or replace.

Compressor clutch noisy

Repair clutch.

Compressor supporting bracket loose or internal compressor parts worn out

Repair bracket, replace compressor.

Blower motor excessively worn

Replace blower.

System overfilled

Evacuate refrigerant until the high pressure reading is normal again.

Not enough refrigerant in the system

Check for leaks, refill the system.

184

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D

185

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D ABBREVIATIONS A A2 A4 abt. acc.

Ad. 1 Ah

Ampere (SI base unit of electric current) 2-point bracing (claws) 4-point bracing (claws) about according to with reference to 1 Ampere hours (SI base unit of quantity of electricity) API American Petroleum Institute approx. approximately BA bar Bh

= OI = Operating instructions unit of pressure measurement (1 bar = 14.5 psi) = OH = Operating hour

CE

Communaute Européenne = European Community CECE Committee for European Construction Equipment (Defines a measure for bucket, grab, or scoop filling) CEN European Standardization Committee cf. refer to cm centimeter (= 1/100 m) cm3/rev Cubic centimeters per revolution dB(A) dia.

DIN

Decibel (Sound intensity according to measuring method A) Diameter German Standardisation Organization

EDS eff. e.g. etc.

Electronic diagnostic system effective for example etcetera

fig.

FOPS GLR

Figure, serial number of illustration Falling objects protective structures Load limit regulator (electronic module for PMS)

HD HDS hp Hydr.

Heavy duty Heavy duty small Horsepower /1 hp = 0.7457 kW) Hydraulic, Hydraulics

186

2261966

i i.e.

IFN incl.

ISO kg kg/dm3 km/h kNm kW

Transmission ratio id est = that is ISO service rating, blocked including, inclusive of International Standardisation Organisation Kilogram (unit of weight) Kilograms per cubic decimeter ( = unit of specific density) Kilometers per hour KiloNewtons per meter (1 kNm = 1000 Nm) = unit of torque Kilowatt (1 kW = 1.36 hp)

l LC Lb/in2 LED l/min LpA LS LS LwA

Liter Long crawler Pounds per square inch (= psi) Light-emitting diode Liters per minute Sound pressure at workplace Limited slip Load sensing Sound power level of the machine in stationary operation

m MA mA max.

MH MHS

Meters Tightening torque Milliampere (= 1/1000 A) maximal, maximum Mobile hydraulics (excavator) Mobile hydraulic excavator for road and rail operation minimal, minimum Revolutions per minute Millimeter (= 1/1000 m)

min. min-1 mm N N, kN NLGI

Normal, standard version Newton, kiloNewton (unit of force) National Lubricating Grease Institute (USA) NLGI- Consistency - lubricant classification Klasse acc. to DIN 51 818 Nm Newtonmeter (unit of torque) No./Nos. number/numbers

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D ABBREVIATIONS OH OLS op. inst.

OW

Operating hour load stabilization Operating Instructions Superstructure

PLA PMS P/N. PS

Bulldozer blade Pump Managing System Part number Metric horsepower (1 PS = 0.74 kW)

Qty.

Quantity

R, r resp.

RH ROPS rpm

Radius Respectively Crawler hydraulics (excavator) Roll-over protective structures Revolutions per minute (= min-1)

SAE sec.

SN SW

Society of Automotive Engineers (USA) Second Item number Width across flats

t THB TL tm

Metric ton (= 1000 kg) Technical Manual Backhoe dipper (attachment) Tons by meters (obsolescent unit of slewing torque) Typical

typ.

U/min

Revolutions per minute

V VDMA

Volt (unit of electric voltage) Association of German Machinery and Systems Manufacturers

W ˚C ˚kW > <

Watt (unit of electric power) Degrees Celsius (temperature) Degrees crank angle greater than less than

187

OPERATING INSTRUCTIONS 21D - 121D - 221D - 321D KHD engine operating instructions

188

motor_2011

B A

Backrest adjustment .......................................... 29

ABBREVIATIONS .................................... 186, 187

Basic unit ............................................................ 16

Acoustic reversing signal .................................... 79

Battery .............................................................. 123

Activating the high-speed function ...................... 52

Battery - checking the charge .......................... 124

Activation / deactivation ...................................... 43

Battery - checking the fluid level ...................... 123

Adjusting the conditioner air temperature .......... 43

Battery main switch ............................................ 39

Adjusting the operator’s seat .............................. 28

Battery storage ................................................ 146

Adjusting the steering column ............................ 48

Before starting work ............................................ 63

Adjusting the weight-oriented suspension .......... 28

Bleeding............................................................ 138

Adjustment of steering column .......................... 48

Bleeding the brake system .............................. 137

After daily operation............................................ 69

Bleeding the working and steering hydraulics .. 129

After-sales service ................................................ 3

Blocking the articulated joint .............................. 62

Air conditioner .................................................... 43

Blower ................................................................ 43

AIR CONDITIONER ........................................ 120

Bottom-dump bucket .................................... 68, 75

Air conditioner - Inspection and servicing work 117

Brake pressure monitoring ................................ 56

Air conditioner, troubleshooting ........................ 181

Brake pressure monitoring in high-speed gear .. 56

Air filter .............................................................. 55

Brake system .................................................... 180

AIR INTAKE SYSTEM ...................................... 110

Brakes ................................................................ 16

Alternator ............................................................ 55

BRAKES .................................................. 136, 163

Alternator, instructions ...................................... 121

Braking and stopping .......................................... 50

Assembling working equipment, safety instructions ............................................................ 70, 122

Breather filter .................................................... 128

Assisted starting (jump-starting) ...................... 154 Assisted starting (jump-starting) - Safety instructions .......................................................... 153

Bucket ................................................................ 73 Bucket limit stops.............................................. 169

C

Attaching the bottom-dump bucket .................... 75 Cab interior lighting ............................................ 27 Attaching the bucket .......................................... 73 CAB VENTILATION.......................................... 145 Attaching the carrier .......................................... 76 Carrier with lifting forks ...................................... 76 Attachments........................................................ 23 Carry out visual inspection ................................ 69 Axle number ...................................................... 22 CE Mark.............................................................. 17 Axles .................................................................. 16 Changing a wheel ............................................ 144 Axles and gearboxes, safety instructions ........ 132 Changing the engine oil .................................... 108 AXLES, GEARBOXES .................................... 132 Changing the engine oil filter ............................ 109 Chapter reference ............................................ 175 Chassis .............................................................. 16

Check the air intake lines ................................ 113

Driving .......................................................... 50, 51

Checking / replacing the safety filter ................ 112

Driving on public roads ...................................... 57

Checking the accumulator pressure ................ 165

Driving the machine on the public highway ........ 64

Checking the braking pressure ........................ 164

Driving, safety instructions .................................. 47

Checking the engine oil level / topping up oil.... 107

Dust discharge valve ........................................ 110

Checking the locked condition ............................ 74 Checking the precharging pressure of the accumulator .......................................................... 166 Checking the tyre inflation pressure - Refilling the tyre.............................................................. 140

E Electric energy ...................................................... 8 Electrical system ................................................ 16 ELECTRICAL SYSTEM............................ 121, 155

Chock ................................................................ 69 Emergency exit .................................................. 26 Cleaning ............................................................ 89 Engine ................................................................ 50 Cleaning and refuelling of machine .................... 69 ENGINE .................................................... 107, 153 Cleaning the fuel tank ...................................... 115 Engine does not start.......................................... 41 Cleaning the main filter element ...................... 112 Engine number .................................................. 22 Closing the door ................................................ 25 Engine oil change .............................................. 89 Connecting the jumper cables .......................... 154 Engine oil pressure ............................................ 55 Control lever - Travelling / Working .................... 49 Engine oil temperature ...................................... 56 Control lever additional function ........................ 66 Engine, repair information ................................ 153 Control lever locking mechanism ........................ 67 Cracking test .................................................... 171

Engine, safety instructions for inspection and servicing .......................................................... 107

D

Entering and leaving the machine - Safety instructions ........................................................ 24

Deformation check............................................ 172 Depositing loads ................................................ 77 DESCRIPTION OF THE MACHINE .................. 15 Designated use .................................................... 4 Detaching the bottom-dump bucket .................... 75 Detaching the bucket .......................................... 74 Detaching the carrier .......................................... 76

Environmentally compatible hydraulic fluid (biodegradable) ................................................ 130 Environmentally compatible hydraulic fluid, conversion ........................................................ 130 Environmentally compatible hydraulic fluid, operating instructions ...................................... 130 Environmentally compatible hydraulic fluid, sampling .......................................................... 131 EQUIPMENT .................................................... 168

Distributor gearbox .......................................... 133 Documentation .................................................. 27

F

Draining hose for oil changes ............................ 88

Fastening of the wheels.................................... 144

Drive unit ............................................................ 16

Fault.................................................................. 175

DRIVER’S CAB .................................................. 24

Fault table layout .............................................. 175

Driver’s cab door ................................................ 25

Filling in fuel........................................................ 38

DRIVING ............................................................ 47

Filling oil into the hydraulic reservoir ................ 128

Filter.................................................................. 145

Inspection and servicing plans, instructions ...... 89

Floating position of loading bucket .................... 65

Inspection and Servicing, Safety Instructions .... 83

Fore-and-aft adjustment .................................... 29

Inspection interval ............................................ 171

Fork prongs ...................................................... 170

INSPECTION PLAN - OIL .................................. 98

Front and rear axle ............................................ 50

Inspection plan - oil ............................................ 99

Front axle.......................................................... 132

Instructions for troubleshooting ........................ 175

Front working floodlamps .................................. 78

Interior lamp...................................................... 159

Fuel .................................................................... 38

Intervals .............................................................. 89

Fuel filter .......................................................... 114 Fuel pre-filter .................................................... 115 FUEL SYSTEM ................................................ 114 Fuse in the engine compartment ...................... 156 Fuses ................................................................ 155

J Joints and hinges................................................ 97

K KHD engine operating instructions .................. 188

Fuses in the cab .............................................. 155

L G Gas, dust, steam and smoke ................................ 8 Greases for bearing points and slewing rings .. 105

H Headlamp ........................................................ 157 Heating .............................................................. 43 Height adjustment .............................................. 28 High-speed model .............................................. 52 Hydraulic and pneumatic equipment .................... 9 Hydraulic oil change ........................................ 128 Hydraulic oil level.............................................. 126 Hydraulic oil temperature.................................... 55 Hydraulic reservoir............................................ 128 Hydraulic system ................................................ 16 HYDRAULIC SYSTEM ............................ 126, 162

I In the cab .......................................................... 117 In the engine compartment .............................. 118 Injection nozzles .............................................. 116 Inside the cab .................................................... 17

Layout of the machine ........................................ 15 Lifting cylinder - installation .............................. 162 Lifting forks ................................................ 76, 170 Lifting forks, instructions .................................. 170 Lighting ...................................................... 46, 157 Load stabilization system .................................. 54 Loading bucket equipment control lever ............ 65 Loading by crane ................................................ 61 Location of components inside the machine..... 117 Locking the control levers .................................. 67 LUBRICANTS .................................................. 100 LUBRICATING CHART - GREASE .................... 96 Lubricating chart - Grease .................................. 97 Lubricating the greasing points ........................ 145

M Machine number ................................................ 22 MAINTENANCE SAFETY INSTRUCTIONS ........ 7 MAINTENANCE WORK .................................... 87 Marking ............................................................ 171 Monitoring the indicators and instruments .......... 55

N

Possible causes................................................ 175

Noise .................................................................... 9

Preface ................................................................ 3

Noise emissions ................................................ 17

Preserving the engine ...................................... 146 Pressure accumulator ...................................... 167

O

Pressure accumulator, safety instructions ........ 167

Oil, grease and other chemical substances .......... 9

Prior to assisted starting .................................. 154

Oils / greases...................................................... 89 Oils for axles and gearboxes ............................ 104

PUTTING THE LOADER OUT OF OPERATION ................................................................ 146

Oils for hydraulic systems, mineral .................. 102

PUTTING THE MACHINE INTO OPERATION .. 38

Oils for hydraulic systems, synthetic ................ 103

Q

Oils for internal combustion engines ........ 100, 101 Quick tool coupler ........................................ 66, 72 Opening the door ................................................ 25 Opening the engine compartment ...................... 87

R

Operating hours indicator .................................. 88

Rear axle .......................................................... 133

OPERATING SAFETY INSTRUCTIONS.............. 6

Rear screen wiper / washer ................................ 46

Operation, safety instructions ............................ 13

Rear working floodlamps .................................... 78

OPTIONAL EQUIPMENT .......................... 68, 160

Rearward tilt position ........................................ 169

Organizational measures...................................... 5

RECOMMISSIONING ...................................... 147

Outside the machine .......................................... 17

Recovering / towing of the machine.................... 58

P

Recovery and towing, safety instructions .......... 58 Reducing braking pressure .............................. 137

Parking brake .................................................. 137 Refilling quantities - oil ........................................ 99 PART 1 - INTRODUCTION .................................. 1 Refilling quantities - Other .................................. 99 PART 2 - OPERATION ...................................... 11 Refuelling............................................................ 38 PART 3 - INSPECTION AND SERVICING ........ 81 Refuelling, safety instructions ............................ 38 PART 4 - REPAIR WORK ................................ 149 Remedial action ................................................ 175 PART 5 - ANNEX ............................................ 173 Removal of engine preserving agents .............. 147 Plan B - after every 500 OH................................ 94 Removing and installing the battery.................. 125 Plan C - after every 1000 Bh .............................. 94 Plan D - after every 3000 OH ............................ 94

Removing, cleaning and checking the main filter element .................................................... 111

Plan N - after initial commissioning .................... 91

Repair, safety instructions ................................ 151

Plan T - every 10 OH or each working shift ........ 92

Replacing a fuse .............................................. 155

Plan V - once prior to initial commissioning ........ 90

Replacing alternator / coolant pump V-belts .... 153

Plan W - every 50 OH or weekly ........................ 92

Replacing bulbs ................................................ 156

Planetary gearbox ............................................ 134

Replacing hydraulic hoses, safety instructions 162

Position of tyre tread ........................................ 144

Replacing the accumulator .............................. 167

Replacing the filter ............................................ 127

T

Replacing V-belts ............................................ 153

Tail light / stop light / turn signal ...................... 158

Return-flow filter .............................................. 127

Taking up loads .................................................. 77

Road travel ........................................................ 64

TOOLS AND EQUIPMENT ................................ 72

Rotary beacon ............................................ 79, 160

Towing ................................................................ 60

Rotary beacon - replacing the reflector ............ 160

Towing lug .......................................................... 59 Transport ............................................................ 61

S Safety instructions ............................................ 121

Transport - Important information ...................... 61

Seat belt ............................................................ 48

TRANSPORTING AND TOWING - RECOMMISSIONING ........................................................ 9

Seat belt - Safety instructions ............................ 48

Transporting loads .............................................. 77

Securing the machine .................................. 69, 87

Travel direction and working mode .................... 51

Selection and qualification of personnel .............. 6

Travel drive .............................................. 178, 179

Servicing material .............................................. 89

Travel motor number .......................................... 23

Setting off .......................................................... 51

Travel pump number .......................................... 23

Side window ...................................................... 26

TROUBLESHOOTING .................................... 175

Signal horn, turn signal, main beam and screen wiper / washer ........................................ 44

Turn signal ........................................................ 157

Socket outlet ...................................................... 47 Standard operation .............................................. 6 Starting and stopping the engine ........................ 40 Starting the engine ............................................ 40

Types ................................................................ 170 Tyre pressure .................................................. 140 Tyre pressure - Safety instructions .................. 139 Tyre pressures and approved tyres for ............

141, 142 141 Tyres and wheels - Safety instructions ............ 143

Starting the engines.......................................... 154 Steering and working hydraulics ........................ 50

U

Steering column - Safety instructions ................ 48

Unlocking the control levers .............................. 67

Steering hydraulics .......................................... 129

Upper dumping position.................................... 169

Steering system ................................................ 176

Using combined functions .................................. 66

Stopping the engine............................................ 41 Sun visor ............................................................ 27

V

Switch off high-speed function ............................ 53

Ventilation .......................................................... 42

Switches and pushbuttons.................................. 34

Ventilation and heating ...................................... 42

Switching on the air conditioner .......................... 43

Vertical vibration at the operator’s seat .............. 17

Switching the electrical system on and off .......... 39

Vibration level .................................................... 17 Vibrations in the hands and arms ...................... 17

W Warming up the machine .................................... 50 Warning and instruction signs / Europe .............. 18 Warning and instruction signs / North America .. 20 WARNING OF SPECIAL DANGERS .................. 8 Warnings and symbols ........................................ 4 Warranty ........................................................ 3, 89 Wear check ...................................................... 172 Weight adjustment .............................................. 28 WELDING OPERATIONS ................................ 161 Welding operations - safety instructions .......... 161 WHEELS AND TYRES .................................... 139 Work to be performed every 2 years ................ 119 Work to be performed every 6 months ............ 119 Work to be performed every month .................. 117 Working equipment ............................................ 16 WORKING EQUIPMENT............................ 70, 122 Working equipment .......................................... 177 Working equipment - replacing a tooth ............ 168 Working floodlamp ............................................ 159 Working hydraulics .......................................... 129 Working on brakes - safety instructions ............ 163 Working on brakes, safety instructions ............ 136 WORKING OPERATION .................................... 63 Working operation, safety instructions ................ 63 Working with lifting forks .................................... 77