Case 21D 121D 221D Wheel Loaders Operator's Manual 6-27772 - PDF DOWNLOAD

Ber 6-27772 GB

OPERATOR’S MANUAL 21D / 121D / 221D

The operator’s manual is in 5 sections; the sections are designed for different target groups: 2800415

Operator’s manual

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS

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

Part 2 OPERATION

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

Inspection and servicing personnel

Part 3 INSPECTION AND SERVICING

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

Repair personnel

Part 4 REPAIR WORK

Part 5 ANNEX

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 FUNDAMENTAL SAFETY INSTRUCTIONS ............................................................................................ 4 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 TECHNICAL DATA .................................................................................................................................. 17 Wheel loader 21D .................................................................................................................................... 17 TECHNICAL DATA .................................................................................................................................. 21 Wheel loader 121D .................................................................................................................................. 21 TECHNICAL DATA .................................................................................................................................. 25 Wheel loader 221D .................................................................................................................................. 25 Noise emissions Outside the machine ............................................................................................................................ 29 Inside the machine ................................................................................................................................ 29 Vibration levels Vertical vibration level at the operator’s seat ........................................................................................ 29 Vibration level at hands and arms ........................................................................................................ 29 CE Mark.................................................................................................................................................... 30 STABILITY Centre of gravity position during transport ............................................................................................ 31 Rated load at stability limit .................................................................................................................... 32 Warning and instruction signs Machine number.................................................................................................................................... 35 Engine number ...................................................................................................................................... 35 Axle number .......................................................................................................................................... 35 Travel pump number ............................................................................................................................ 35 Travel motor number ............................................................................................................................ 35 Attachments .......................................................................................................................................... 35

DRIVER’S CAB Entering and leaving the machine - Safety instructions ........................................................................ 36 Driver’s cab door Opening the door .................................................................................................................................. 37 Closing the door .................................................................................................................................... 37 Fold-down window.................................................................................................................................. 37 Emergency exit ...................................................................................................................................... 38 Documentation ........................................................................................................................................ 38 Cab interior lighting ................................................................................................................................ 39 Roller blind .............................................................................................................................................. 39 Adjusting the operator’s seat Adjusting the weight-oriented suspension ............................................................................................ 40 Weight adjustment ................................................................................................................................ 40 Height adjustment ................................................................................................................................ 40 Fore-and-aft adjustment ........................................................................................................................ 41 Backrest adjustment .............................................................................................................................. 41 Adjusting the right armrest .................................................................................................................... 42 Height adjustment ................................................................................................................................ 42 Fore-and-aft adjustment ........................................................................................................................ 42 WARNING, MONITORING AND CONTROL ELEMENTS ...................................................................... 43 Driver’s stand, overall layout ................................................................................................................ 44 Warning and control lamps .................................................................................................................... 45 Switches and pushbuttons .................................................................................................................... 49 PUTTING THE MACHINE INTO OPERATION ........................................................................................ 53 Refuelling Refuelling - Safety instructions .............................................................................................................. 53 Refuelling .............................................................................................................................................. 53 Electrical system ON / OFF Battery main switch .............................................................................................................................. 54 Immobilizer .............................................................................................................................................. 54 Electrical system key-switch Starting and stopping the engine .......................................................................................................... 55 Starting .................................................................................................................................................. 55 Engine does not start ............................................................................................................................ 56

Stopping the engine .............................................................................................................................. 56 Ventilation and heating Ventilation.............................................................................................................................................. 57 Heating .................................................................................................................................................. 58 Fan ........................................................................................................................................................ 58 Horn, travel direction indicator, main beam and windscreen wiper / -washer .................................. 59 Lighting .................................................................................................................................................... 61 Rear screen wiper / washer .................................................................................................................... 62 Cigarette lighter / Socket outlet ............................................................................................................ 62 DRIVING .................................................................................................................................................. 63 Driving - Safety instructions .................................................................................................................. 63 Adjustment of steering column Steering column - Safety instructions .................................................................................................... 63 Adjusting the steering column .............................................................................................................. 64 Seat belt Seat belt - Safety instructions ................................................................................................................ 64 Control lever - Travelling / Working ...................................................................................................... 65 Driving Warming up the machine ...................................................................................................................... 66 Engine .................................................................................................................................................. 66 Steering and working hydraulics .......................................................................................................... 66 Front and rear axle ................................................................................................................................ 66 Braking and stopping ............................................................................................................................ 66 Start ...................................................................................................................................................... 67 Travel direction and gears .................................................................................................................... 67 Fast-speed variant (optional equipment) Activating fast speed ............................................................................................................................ 68 Disengaging fast speed ........................................................................................................................ 68 Monitoring the indicators Hydraulic oil temperature ...................................................................................................................... 69 Engine oil pressure................................................................................................................................ 70 Alternator .............................................................................................................................................. 70 Air filter .................................................................................................................................................. 70 Coolant temperature.............................................................................................................................. 71 Braking pressure .................................................................................................................................. 71

Driving on public roads .......................................................................................................................... 72 Recovering / towing of the machine Recovery and towing, safety instructions .............................................................................................. 74 Towing lug ............................................................................................................................................ 74 Towing .................................................................................................................................................. 75 Transport Transport - Important information .......................................................................................................... 76 Loading by crane .................................................................................................................................. 76 Blocking the articulated joint .................................................................................................................. 77 WORKING OPERATION Working operation - Safety instructions ................................................................................................ 78 Driving on public road ............................................................................................................................ 84 Road transfer ........................................................................................................................................ 84 STANDARD EQUIPMENT ...................................................................................................................... 85 Control lever for bucket equipment Floating position of the bucket equipment ............................................................................................ 86 Combined functions .............................................................................................................................. 86 Control lever - 3rd/4th function .............................................................................................................. 87 Quick-change device ............................................................................................................................ 87 Control lever locking .............................................................................................................................. 87 Locking the control levers ...................................................................................................................... 87 Unlocking the control levers .................................................................................................................. 87 OPTIONAL EQUIPMENT Bottom-dum bucket .............................................................................................................................. 88 Sweeper ................................................................................................................................................ 88 After daily operation Securing the machine............................................................................................................................ 89 Cleaning and refuelling of machine ...................................................................................................... 89 Carry out visual inspection .................................................................................................................... 89 Chock .................................................................................................................................................... 89 WORKING EQUIPMENT .......................................................................................................................... 90 Assembling working equipment - safety instructions ........................................................................ 90 ATTACHMENTS ...................................................................................................................................... 92 Quick-change device .............................................................................................................................. 92 Bucket Attaching the bucket .............................................................................................................................. 92

Checking the bucket locking .................................................................................................................. 93 Detaching the bucket ............................................................................................................................ 93 Four-in-one bucket Attaching the four-in-one bucket............................................................................................................ 94 Detaching the four-in-one bucket (bottom-dump bucket) ...................................................................... 95 Equipment carrier with lifting forks Attaching the equipment carrier ............................................................................................................ 96 Removing the equipment carrier .......................................................................................................... 96 Lifting forks ............................................................................................................................................ 96 Working with lifting forks ........................................................................................................................ 97 Taking up loads .................................................................................................................................... 97 Transporting loads ................................................................................................................................ 97 Setting down loads ................................................................................................................................ 97 Floodlamps, front.................................................................................................................................... 98 Floodlamps, rear .................................................................................................................................... 98 Rotary beacon ........................................................................................................................................ 98 Acoustic reversing signal (Back-up alarm) .......................................................................................... 99 Pipe-break safety system Without shut-off possibility .................................................................................................................. 100

PART 3 - INSPECTION AND SERVICING INSPECTION AND SERVICING - SAFETY INSTRUCTIONS .............................................................. 103 MAINTENANCE WORK Securing the machine.......................................................................................................................... 107 Opening the engine hood .................................................................................................................... 107 SERVICING Draining hose for oil changes .............................................................................................................. 108 Operating-hours meter ........................................................................................................................ 108 Inspection and servicing plans - instructions Intervals .............................................................................................................................................. 109 Change of engine oil .......................................................................................................................... 109 Oil / Greases ...................................................................................................................................... 109 Cleaning jobs ...................................................................................................................................... 109 Servicing material ................................................................................................................................ 109 Plan V - once prior to initial commissioning ........................................................................................ 110 Plan N - After initial commissioning .................................................................................................... 111 Plan T - All 10 HOURS or each working shift ...................................................................................... 112 Plan W - All 50 HOURS or weekly ...................................................................................................... 112 Plan B - after every 500 HOURS ........................................................................................................ 114 Plan C - after every 1000 HOURS ...................................................................................................... 114 Plan D - after every 3000 HOURS ...................................................................................................... 114 LUBRICATING CHART - GREASE Lubricating chart - grease .................................................................................................................... 117 Joints and hinges ................................................................................................................................ 117 OIL INSPECTION PLAN Oil inspection plan .............................................................................................................................. 119 Refilling quantities - Oil ........................................................................................................................ 119 Refilling quantities - Other .................................................................................................................. 119 LUBRICANTS ........................................................................................................................................ 120 Oils for internal combustion engines.................................................................................................. 120 Oils for hydraulic system, mineral ...................................................................................................... 121 Oils for axles and gearboxes (selection) ............................................................................................ 122 Greases for bearing points and slewing rings .................................................................................. 123 ENGINE Safety instructions for inspection and servicing .................................................................................. 124

Checking the engine oil level / Topping up oil .................................................................................... 124 Changing the engine oil ...................................................................................................................... 125 Replacing the engine oil filter .............................................................................................................. 126 Crankcase ventilation .......................................................................................................................... 126 Valve clearance .................................................................................................................................. 127 COOLING SYSTEM Checking the cooling liquid level ........................................................................................................ 128 Changing the cooling liquid ................................................................................................................ 128 AIR-INTAKE SYSTEM Dust-discharge valve .......................................................................................................................... 129 Removing, checking and cleaning the main filter element .................................................................. 130 Cleaning the main filter element .......................................................................................................... 131 Checking / replacing safety filter.......................................................................................................... 131 Checking air-intake lines .................................................................................................................... 132 FUEL SYSTEM Fuel filter.............................................................................................................................................. 133 Water pre-separator ............................................................................................................................ 134 Draining off water ................................................................................................................................ 134 Cleaning the water pre-separator ........................................................................................................ 134 Cleaning the fuel tank .......................................................................................................................... 134 Injection nozzles .................................................................................................................................. 135 ELECTRICAL SYSTEM Safety instructions .............................................................................................................................. 136 Alternator, instructions ........................................................................................................................ 136 Battery main switch .............................................................................................................................. 137 Battery Battery - checking the fluid level .......................................................................................................... 138 Battery - checking the charge .............................................................................................................. 138 Removing and installing the battery .................................................................................................... 139 HYDRAULIC SYSTEM Checking the hydraulic oil level .......................................................................................................... 140 Return flow filter .................................................................................................................................. 140 Replacing the filter .............................................................................................................................. 140 Breather filter ...................................................................................................................................... 141 Hydraulic reservoir Changing the hydraulic oil .................................................................................................................. 142 Filling the hydraulic reservoir with oil .................................................................................................. 142 Bleeding the hydraulic working and steering systems

Working hydraulic system .................................................................................................................. 142 Steering hydraulic system .................................................................................................................. 142 OPTIONAL EQUIPMENT ...................................................................................................................... 143 Environmentally compatible hydraulic fluid (biodegradability) Environmentally compatible hydraulic fluid, operating instructions...................................................... 143 Environmentally compatible hydraulic fluid, conversion ...................................................................... 143 Environmentally compatible hydraulic fluid, sampling ........................................................................ 144 Oils for hydraulic system, synthetic (biodegradability) .................................................................... 145 AXLES .................................................................................................................................................... 146 Safety instructions................................................................................................................................ 146 Front axle .............................................................................................................................................. 146 Rear axle ................................................................................................................................................ 147 Transfer gearbox .................................................................................................................................. 147 Planetary gears .................................................................................................................................... 148 BRAKES Working on brakes, safety instructions ................................................................................................ 149 Parking brake ........................................................................................................................................ 149 Reducing braking pressure ................................................................................................................ 149 Checking the brake disks .................................................................................................................... 149 Bleeding the braking system Bleeding .............................................................................................................................................. 151 TYRES AND WHEELS Tyres and wheels - Safety instructions ................................................................................................ 152 Tyre pressure - Safety instructions ...................................................................................................... 153 Checking the tyre pressure - Reinflating the tyre ................................................................................ 154 Tyre pressure ...................................................................................................................................... 155 Changing a wheel................................................................................................................................ 156 Fastening of wheels ............................................................................................................................ 156 Tyre tread position .............................................................................................................................. 156 LUBRICATING THE GREASING POINTS ............................................................................................ 157 DRIVER’S CAB VENTILATION Filter .................................................................................................................................................... 157

PUTTING THE LOADER OUT OF OPERATION Preserving the engine ........................................................................................................................ 158 Battery storage .................................................................................................................................... 158 RECOMMISSIONING Removal of engine preserving agents ................................................................................................ 159

PART 4 - REPAIR WORK REPAIR WORK - SAFETY INSTRUCTIONS ........................................................................................ 163 ENGINE .................................................................................................................................................. 164 Engine - repair instructions Replacing V-belts ................................................................................................................................ 164 Replacing alternator / coolant pump V-belts........................................................................................ 164 Assisted starting (jump-starting) - Safety instructions Assisted starting (jump-starting) .......................................................................................................... 166 Prior to assisted starting ...................................................................................................................... 166 Connecting the jumper cables ............................................................................................................ 166 Starting the engines ............................................................................................................................ 166 ELECTRICAL SYSTEM Fuses .................................................................................................................................................. 167 Replacing fuses .................................................................................................................................. 168 Replacing bulbs .................................................................................................................................. 168 Lighting Headlamp ............................................................................................................................................ 169 Turn signal lamp .................................................................................................................................. 170 Tail/brake signal lamp ........................................................................................................................ 170 Cab interior lamp ................................................................................................................................ 171 Floodlamp............................................................................................................................................ 171 Rotary beacon .................................................................................................................................... 172 Replacing the lamp.............................................................................................................................. 172 WELDING OPERATIONS Welding operations - safety instructions .............................................................................................. 173 HYDRAULIC SYSTEM Replacing hydraulic hoses - Safety instructions .................................................................................. 174 Lifting cylinder - installation ................................................................................................................ 174 BRAKES Safety instructions .............................................................................................................................. 175 Checking the braking pressure ............................................................................................................ 176 Replacing the brake disks .................................................................................................................. 176 Checking the accumulator pressure .................................................................................................... 177 Checking the preloading pressure ...................................................................................................... 177 ACCUMULATORS ................................................................................................................................ 178 Safety instructions................................................................................................................................ 178

WORKING EQUIPMENT Bucket ................................................................................................................................................ 179 Replacing of teeth .............................................................................................................................. 179 Bucket limit stops ................................................................................................................................ 180 Upper dumping position ...................................................................................................................... 180 Rearward tilt position .......................................................................................................................... 180 Lifting forks Checking of fork prongs ...................................................................................................................... 181

PART 5 - ANNEX TROUBLESHOOTING .......................................................................................................................... 185 Instructions on troubleshooting .......................................................................................................... 185 Layout of fault table Fault .................................................................................................................................................... 185 Possible causes .................................................................................................................................. 185 Measure .............................................................................................................................................. 185 Section ................................................................................................................................................ 185 Engine .................................................................................................................................................... 186 Combustion engine start / stop .......................................................................................................... 187 Steering system .................................................................................................................................... 188 Working equipment .............................................................................................................................. 189 Transmission ........................................................................................................................................ 190 Brake system ........................................................................................................................................ 192 ABBREVIATIONS .................................................................................................................................. 193

OPERATOR’S MANUAL 21D / 121D / 221D PART 1 - INTRODUCTION

Operator’s manual

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS

2261176

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

Part 2 OPERATION

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

Inspection and servicing personnel

Part 3 INSPECTION AND SERVICING

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

Repair personnel

Part 4 REPAIR WORK

Part 5 ANNEX

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

Operating personnel + Inspection and servicing personnel + Repair personnel

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OPERATOR’S MANUAL 21D / 121D / 221D

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OPERATOR’S MANUAL 21D / 121D / 221D PREFACE

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These operator’s manual are designed to familiarize the operator with the machine and its designated use.

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

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

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

After-Sales-Service Our after-sales service will be pleased to deal with any queries you may have after reading through the operating instructions.

The operator’s manual are not work instructions for carrying out major repairs. Such work is willingly done for you by our after-sales service.

For maintenance work which cannot be easily carried out by the Owner, please contact your Dealer where you will find trained personnel, suitable correct tools and equipment and genuine spare parts. Service personnel and technicians will be glad to provide you with all explanations and suggestions you many need ant to carry out all required specialised repair work in case of loader unsatisfactory operation.

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

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

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

The operator’s manual are directed to the construction-machine specialist. They cannot provide basic know-how. This can be acquired, for example, in several days’ instruction by one of our qualified mechanics or by attending our training course for operators or maintenance personnel.

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OPERATOR’S MANUAL 21D / 121D / 221D FUNDAMENTAL SAFETY INSTRUCTIONS

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Warnings and symbols The following signs are used in the manual to designate instructions of particular importance: Precautionary rules and measures designed to protect the machine operator and other persons from life-threatening danger or injuries and to prevent extensive damage.

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

Designated use

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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 operator’s manual, and only by safety-conscious persons who are fully aware of the risks involved in operating the machine. Important information is provided at the beginning 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.

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.

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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.

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

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

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

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

OPERATOR’S MANUAL 21D / 121D / 221D Organizational measures The operator’s manual 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 operator’s manual, 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 operator’s manual 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 operator’s manual 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 whether the personnel is carrying out the work in compliance with the operator’s manual 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.

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

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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 operator’s manual 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.

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OPERATOR’S MANUAL 21D / 121D / 221D 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 operator’s manual.

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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OPERATOR’S MANUAL 21D / 121D / 221D 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 safety-oriented devices or any work related to maintenance, inspection and repair, always observe the start-up and shut-down procedures set out in the operator’s manual 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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OPERATOR’S MANUAL 21D / 121D / 221D 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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OPERATOR’S MANUAL 21D / 121D / 221D 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 operator’s manual.

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 operator’s manual.

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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OPERATOR’S MANUAL 21D / 121D / 221D

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OPERATOR’S MANUAL 21D / 121D / 221D PART 2 - OPERATION

Operator’s manual

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS

2261177

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

Part 2 OPERATION

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

Inspection and servicing personnel

Part 3 INSPECTION AND SERVICING

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

Repair personnel

Part 4 REPAIR WORK

Part 5 ANNEX

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

Operating personnel + Inspection and servicing personnel + Repair personnel

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OPERATOR’S MANUAL 21D / 121D / 221D

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OPERATOR’S MANUAL 21D / 121D / 221D OPERATION - SAFETY INSTRUCTIONS

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Operator’s manual

Safety belt

Never operate the machine before having read and understood the operator’s manual.

For machines with a safety belt for operating personnel:

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

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

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

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

Apply safety belt before starting work.

State of the machine

Keep the operator’s manual with the machine at all times.

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

Operating personnel

Always have inspection and maintenance work carried out on schedule.

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

The necessary know-how can be acquired in several days’ instruction.

Personal protective wear 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 clothing when operating the machine.

Loose, wide garments may result in the control lever being inadvertently activated.

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

Never install and commission other equipment and component combinations without we 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 dents. Always and the glass before starting

may result in acciclean the windows covers of all lights up the machine.

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

13

OPERATOR’S MANUAL 21D / 121D / 221D Entering and leaving the machine Use only the steps, platforms and handrails provided when entering and leaving 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 entering and leaving.

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.

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

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

14

Marshallers The marshaller must keep outside the hazard zone.

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

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

Keep in constant contact with the marshaller.

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

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

OPERATOR’S MANUAL 21D / 121D / 221D DESCRIPTION OF THE MACHINE

2913045

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

OPERATOR’S MANUAL 21D / 121D / 221D 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 and rear 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 front axle is equipped with a limited-slip differential and the rear axle with a conventional differential. The rear axle can also be equipped 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 The service brake is operated by means of the brake/inching pedal. Depressing this pedal lightly cuts out the transmission. Depressing the brake/inching pedal further applies full braking pressure to the multiple disk-brakes of the rear axle.

Reducing the speed of the engine causes the transmission to act as an additional service brake.

The parking brake, too, acts on the multiple diskbrake of the rear axle.

16

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, sweeper or hydraulic hammer, can also be attached to the loader.

OPERATOR’S MANUAL 21D / 121D / 221D TECHNICAL DATA

1946692

Wheel loader 21D

Operating weight 4.2 t Engine output 41.5 kW Standard-bucket 0.7 m3 Comfortable cab (ROPS/FOPS) Governed, hydrostatic all-wheel drive Planetary axles with self-locking differential in front axle Wet-disk brakes on rear axle Z-bar linkage with sealed bearing points Integrated hydraulic quick-hitch Wide range of attachments

17

OPERATOR’S MANUAL 21D / 121D / 221D Wheel loader 21D

Hydraulics

Engine Perkins Diesel Output ISO 9294 Cylinders Exhaust emission Cooling system Dry-type air filter with optional warning

Model 70430 41.5 kW / 2300 min-1 4 Euro 1 water

Pump flow for working and steering hydraulic 50 l/min Pressure, working hydraulic 230 bar Pressure, steering hydraulic 175 bar Cylinders: double-acting lift and tip cylinders Control unit: single-lever shift with lock for road travel Automatic neutral position • Float position • 3rd function.

Front-End Equipment

Transmission Governed hydrostatic transmission with care-type controls • Automatic matching of rimpull and travel speed • "Inch pedal" reduces travel speed at full engine rpm with more engine output being diverted to working hydraulics • Powershift for all gears.

Integrated quick hitch Tip bucket capacity* acc. SAE J 742b/CECE 0.7 m3 Dump bucket capacity* acc. SAE J 742b/CECE 0.65 m3 Tipload (articulated) 2800 kg Effective lift force at ground level 40.0 kN Effective break-out force acc. SAE J 732C-ISO 8313 47.0 kN Tip angle at max. lift height 42˚ Tip-back angle at ground level/carry position 45˚/54˚ Lift / lower / tip 6.0 / 3.0 / 1.0 sec. * Stability acc. DIN 24094 / ISO 5998 / SAE J818b

Speed (with tyres 335 / 80R18) Travel range 2 (max. rimpull / max. speed) Travel range 1 (max. rimpull / red. speed)

0 - 20 km/h 0 - 6 km/h

Axles All-wheel drive with Planetary axles • Rear axles oscillating mounted oscillation + _12˚= 24˚ Multi-disk self-locking differential in front axle, optional for rear axle.

Tyres Diagonal type tyres Radial type tyres

12.5-20 335/80 R18 365/70 R18

Other tyres on request

Brakes Service brake, pump and accumulator brake: Inboard wetdisk brake in rear axle, hydraulic actuated via inch-brake pedal. Brake protected against dirt and water.

Additional brake: wear-free all-wheel brake through retardation in hydrostatic transmission, actuated via inch-brake pedal.

Auxiliary and parking brake: mechanically actuated inboard wet-disk brake in rear axle.

Steering Hydrostatic, central artic-frame steering with one steering cylinders • Steering lock 41˚ to each side • Turning radius over outside edge of bucket 3990 mm • Emergency steering system when engine is stopped • Articulated frame with playfree tensioners and adjustment-free artic bearings.

18

Refill Quantities Fuel tank Hydraulic system Cooling system

90 l 60 l 15.5 l

Cab Spacious, elastically mounted, removable cab "ROPS" acc. DIN/ISO 3471/SAE 1040 C "FOPS" acc. DIN/ISO 3449 Walk-through cab • Windscreen wipers at front and rear with windscreen washer • Panorama tinted safety glazing • Folddown window on right • Seat with hyd. suspension, weight adjustment, safety belt • Water heating • heater/ventilator with de-icer setting and air filter • Any-setting steering column with dashboard.

Electrics Alternator 3-phase 12 V / 65 A Starter 2,5 kW / 12 V Battery 12 V / 92 Ah Battery voltage 12 V Lighting acc. German regulations: H4 halogen headlights • Glow plug for cold start.

Noise Emission Levels acc. to EC Directive Noise power level LwA Noise pressure level LpA

100 dB(A) 76 dB(A)

General CE design approval acc. to EC Directive on construction machinery. Document certifying compliances with ISO 9001/EN 29001.

OPERATOR’S MANUAL 21D / 121D / 221D Dimensions 21D

Bottom Dump Bucket 0.65 m3 bucket 1900 mm wide, = 1.8 t/m3* (with 335/80 - R18 tyres) mm mm A= 5080 G= 745 B= 4920 G1 = 560 D= 3760 G2 = 760 D= 4255 H= 800 E= 3025 C= 100 F= 2405 Weight approx. 4260 kg with ROPS/FOPS cab * counterweight (200 kg) required

Lifting forks with Quick-Hitch Dimensions: with tyres 335/80R18 mm F 100 F1 1715 F2 2765 G 835 G1 1205 G2 515 1450 100

Lift height

Width of fork carriage Tine width

Payload with lifting forks and load at 500 mm CoG Configuration Fork carriage Fork tine Quick-hitch Tyres Additional counterweight Total weight Tip load (articulated) Safety factor 1.25 1.67

FEM II, 1450 mm wide 100 x 45 x 1200 2B standard 335/80 R18 -4100 kg 1750 kg Payload 1400 kg * 1050 kg

Configuration FEM II, 1450 mm wide 100 x 45 x 1200 2B standard 335/80 R18 200 kg 4260 kg 1875 kg Payload 1500 kg 1125 kg

* not applicable to full lifting height. Max payload over full lifting height: 1550 kg.

Stability factor 1.25 for tip load with loader on level ground.

Stability factor 1.67 for tip load with loader on uneven ground. Tip loads calculated acc. to DIN 24094.

19

OPERATOR’S MANUAL 21D / 121D / 221D Loading bucket 21D 0.65 m3 bucket, 1800 mm wide, 0.70 m3 bucket, 1900 mm wide, 0.8 m3 bucket, 1900 mm wide, * with counterweight

= 2.0* t/m3 = 1.8 t/m3 = 1.6 t/m3

Dimensions: (for tyres 335/80R18) bucket 0,65 m3 mm mm mm A = 5035 G = 740 T = 415 B = 4920 H = 2655 C = 70 I = 1880 D = 3765 J = 1440 E = 3025 K = 330 F = 2450 N = 2120 Dimensions: (for tyres 335/80R18) bucket 0,7 m3 mm mm A = 5035 G = 740 B = 4920 H = 2655 C = 70 I = 1880 D = 3765 J = 1440 E = 3025 K = 330 F = 2450 N = 2120

20

mm T = 415

Dimensions: (for tyres 335/80R18) bucket 0,8 m3 mm mm A = 5110 G = 835 B = 5040 H = 2655 C = 70 I = 1880 D = 3760 J = 1440 E = 3025 K = 330 F = 2365 N = 2120

mm T = 415

OPERATOR’S MANUAL 21D / 121D / 221D TECHNICAL DATA

1946693

Wheel loader 121D

Operating weight 4.7 t Engine output 45 kW Standard-bucket 0.8 m3 Comfortable cab (ROPS/FOPS) Governed, hydrostatic all-wheel drive Planetary axles with self-locking differential in front axle Wet-disk brakes on rear axle Z-bar linkage with sealed bearing points Integrated hydraulic quick-hitch Wide range of attachments

21

OPERATOR’S MANUAL 21D / 121D / 221D Wheel loader 121D

Hydraulics

Engine Perkins Diesel Output ISO 9294 Cylinders Exhaust emission Cooling system Dry-type air filter with optional warning

Model 70430 45 kW / 2300 min-1 4 Euro 1 water

Pump flow for working and steering hydraulic 60 l/min Pressure, working hydraulic 210 bar Pressure, steering hydraulic 175 bar Cylinders: double-acting lift and tip cylinders Control unit: single-lever shift with lock for road travel Automatic neutral position • Float position • 3rd function.

Front-End Equipment

Transmission Governed hydrostatic transmission with care-type controls • Automatic matching of rimpull and travel speed • "Inch pedal" reduces travel speed at full engine rpm with more engine output being diverted to working hydraulics • Powershift for all gears.

Integrated quick hitch Tip bucket capacity* acc. SAE J 742b/CECE 0.8 m3 Dump bucket capacity* acc. SAE J 742b/CECE 0.7 m3 Tipload (articulated) 3350 kg Effective lift force at ground level 45.0 kN Effective break-out force acc. SAE J 732C-ISO 8313 55.0 kN Tip angle at max. lift height 42˚ Tip-back angle at ground level/carry position 45˚/56˚ Lift / lower / tip 5.7 / 3.2 / 1.2 sec. * Stability acc. DIN 24094 / ISO 5998 / SAE J818b

Speed (with tyres 365 / 80R20) Travel range 2 (max. rimpull / max. speed) Travel range 1 (max. rimpull / red. speed)

0 - 20 km/h 0 - 6 km/h

Axles All-wheel drive with Planetary axles • Rear axles oscillating mounted oscillation + _12˚= 24˚ Multi-disk self-locking differential in front axle, optional for rear axle.

Tyres Diagonal type tyres Radial type tyres

12.5-20 14.5-20 365/80 R20 405/70 R20

Other tyres on request

Brakes Service brake, pump and accumulator brake: Inboard wetdisk brake in rear axle, hydraulic actuated via inch-brake pedal. Brake protected against dirt and water.

Additional brake: wear-free all-wheel brake through retardation in hydrostatic transmission, actuated via inch-brake pedal.

Auxiliary and parking brake: mechanically actuated inboard wet-disk brake in rear axle.

Steering Hydrostatic, central artic-frame steering with one steering cylinders • Steering lock 41˚ to each side • Turning radius over outside edge of bucket 4250 mm • Emergency steering system when engine is stopped • Articulated frame with playfree tensioners and adjustment-free artic bearings.

22

Refill Quantities Fuel tank Hydraulic system Cooling system

100 l 65 l 15.5 l

Cab Spacious, elastically mounted, removable cab "ROPS" acc. DIN/ISO 3471/SAE 1040 C "FOPS" acc. DIN/ISO 3449 Walk-through cab • Windscreen wipers at front and rear with windscreen washer • Panorama tinted safety glazing • Folddown window on right • Seat with hyd. suspension, weight adjustment, safety belt • Water heating • heater/ventilator with de-icer setting and air filter • Any-setting steering column with dashboard.

Electrics Alternator 3-phase 12 V / 65 A Starter 2.5 kW / 12 V Battery 12 V / 92 Ah Battery voltage 12 V Lighting acc. German regulations: H4 halogen headlights • Glow plug for cold start.

Noise Emission Levels acc. to EC Directive Noise power level LwA Noise pressure level LpA

101 dB(A) 76 dB(A)

General CE design approval acc. to EC Directive on construction machinery. Document certifying compliances with ISO 9001/EN 29001.

OPERATOR’S MANUAL 21D / 121D / 221D Dimensions 121D

Bottom Dump Bucket 0.7 m3 bucket 2050 mm wide, = 1.8 t/m (with 365/80-R20 tyres) mm mm A= 5335 F= 2525 B= 5205 G= 715 C= 110 G1 = 540 D= 3955 G2 = 810 D1 = 4405 H= 2765 E= 3155 Weight approx. 5300 kg with ROPS/FOPS cab

Lifting forks with Quick-Hitch Dimensions: with tyres 365/80R20 mm

Lift height

Width of fork carriage Tine width

F 100 F1 1715 F2 2765 G 835 G1 1205 G2 515 1450 100

Payload with lifting forks and load at 500 mm CoG Configuration Fork carriage Fork tine Quick-hitch Tyres Total weight Tip load (articulated) Safety factor 1.25 1.67

FEM II, 1450 mm wide 100 x 45 x 1200 2B standard 365/80 R 20 4700 kg 2250 kg Payload 1800 kg * 1350 kg

* not applicable to full lifting height. Max payload over full lifting height: 2000 kg.

Stability factor 1.25 for tip load with loader on level ground.

Stability factor 1.67 for tip load with loader on uneven ground.

Tip loads calculated acc. to DIN 24094.

23

OPERATOR’S MANUAL 21D / 121D / 221D Loading bucket 121D 0.7 0.8 0.8 0.9

m3 m3 m3 m3

bucket, 1950 bucket, 1950 bucket, 2050 bucket, 2050

mm wide, mm wide, mm wide, mm wide,

= = = =

2.0 1.8 1.8 1.6

t/m3 t/m3 t/m3 t/m3

Dimensions: (for tyres 365/80R20) bucket 0.7 m3, 1950 mm wide mm mm mm A = 5280 G = 700 T = 460 B = 5150 H = 2765 C = 80 I = 1945 D = 3883 J = 1526 E = 3155 K = 380 F = 2580 N = 2250

Dimensions: (for tyres 365/80R20) bucket 0.8 m3, 2050 mm wide mm mm mm A = 5305 G = 720 T = 460 B = 5185 H = 2765 C = 85 I = 1945 D = 3920 J = 1526 E = 3155 K = 380 F = 2555 N = 2250

Dimensions: (for tyres 365/80R20) bucket 0.8 m3, 1950 mm wide mm mm mm A = 5035 G = 720 T = 460 B = 5185 H = 2765 C = 85 I = 1945 D = 3920 J = 1526 E = 3155 K = 380 F = 2555 N = 2250

Dimensions: (for tyres 365/80R20) bucket 0.9 m3, 2050 mm wide mm mm mm A = 5340 G = 770 T = 460 B = 5250 H = 2765 C = 85 I = 1945 D = 3985 J = 1526 E = 3155 K = 380 F = 2510 N = 2250

24

OPERATOR’S MANUAL 21D / 121D / 221D TECHNICAL DATA

1946694

Wheel loader 221D

Operating weight 5.2 t Engine output 46.5 kW Standard-bucket 0.9 m3 Comfortable cab (ROPS/FOPS) Governed, hydrostatic all-wheel drive Planetary axles with self-locking differential in front axle Wet-disk brakes on rear axle Z-bar linkage with sealed bearing points Integrated hydraulic quick-hitch Wide range of attachments

25

OPERATOR’S MANUAL 21D / 121D / 221D Wheel loader 221D

Hydraulics

Engine Perkins Diesel Output ISO 9294 Cylinders Exhaust emission Cooling system Dry-type air filter with optional warning

Model 70430 46.5 kW / 2500 min-1 4 Euro 1 water

Pump flow for working and steering hydraulic 64 l/min Pressure, working hydraulic 230 bar Pressure, steering hydraulic 175 bar Cylinders: double-acting lift and tip cylinders Control unit: single-lever shift with lock for road travel Automatic neutral position • Float position • 3rd function.

Front-End Equipment

Transmission Governed hydrostatic transmission with care-type controls • Automatic matching of rimpull and travel speed • "Inch pedal" reduces travel speed at full engine rpm with more engine output being diverted to working hydraulics • Powershift for all gears.

Integrated quick hitch Tip bucket capacity* acc. SAE J 742b/CECE 0.9 m3 Dump bucket capacity* acc. SAE J 742b/CECE 0.85 m3 Tipload (articulated) 3850 kg Effective lift force at ground level 49.0 kN Effective break-out force acc. SAE J 732C-ISO 8313 60.0 kN Tip angle at max. lift height 42˚ Tip-back angle at ground level/carry position 45˚/56˚ Lift / lower / tip 5.7 / 3.2 / 1.2 sec. * Stability acc. DIN 24094 / ISO 5998 / SAE J818b

Speed (with tyres 365 / 80R20) Travel range 2 (max. rimpull / max. speed) Travel range 1 (max. rimpull / red. speed)

0 - 20 km/h 0 - 6 km/h

Axles All-wheel drive with Planetary axles • Rear axles oscillating mounted oscillation + _12˚= 24˚ Multi-disk self-locking differential in front axle, optional for rear axle.

Tyres Diagonal type tyres Radial type tyres

14.5 - 20 365/80 R20 405/70 R20

Other tyres on request

Brakes Service brake, pump and accumulator brake: Inboard wetdisk brake in rear axle, hydraulic actuated via inch-brake pedal. Brake protected against dirt and water.

Additional brake: wear-free all-wheel brake through retardation in hydrostatic transmission, actuated via inch-brake pedal.

Auxiliary and parking brake: mechanically actuated inboard wet-disk brake in rear axle.

Steering Hydrostatic, central artic-frame steering with one steering cylinders • Steering lock 41˚ to each side • Turning radius over outside edge of bucket 4300 mm • Emergency steering system when engine is stopped • Articulated frame with playfree tensioners and adjustment-free artic bearings.

26

Refill Quantities Fuel tank Hydraulic system Cooling system

100 l 65 l 15.5 l

Cab Spacious, elastically mounted, removable cab "ROPS" acc. DIN/ISO 3471/SAE 1040 C "FOPS" acc. DIN/ISO 3449 Walk-through cab • Windscreen wipers at front and rear with windscreen washer • Panorama tinted safety glazing • Folddown window on right • Seat with hyd. suspension, weight adjustment, safety belt • Water heating • heater/ventilator with de-icer setting and air filter • Any-setting steering column with dashboard.

Electrics Alternator 3-phase 12 V / 65 A Starter 2.5 kW / 12 V Battery 12 V / 92 Ah Battery voltage 12 V Lighting acc. German regulations: H4 halogen headlights • Glow plug for cold start.

Noise Emission Levels acc. to EC Directive Noise power level LwA Noise pressure level LpA

101 dB(A) 76 dB(A)

General CE design approval acc. to EC Directive on construction machinery. Document certifying compliances with ISO 9001/EN 29001.

OPERATOR’S MANUAL 21D / 121D / 221D Dimensions 221D

Bottom Dump Bucket 0.85 m3 bucket 2050 mm wide, = 1.8 t/m (with 365 / 80R20 tyres) mm mm A= 5340 F= B= 5280 G= 775 C= 85 G1 = 550 D= 4045 G2 = 820 D1 = 4505 H= 2765 E= Weight approx. 5300 kg with ROPS/FOPS cab

Lifting forks with Quick-Hitch Dimensions: with tyres 365/80R20 mm F 100 F1 1340 F2 2930 G 810 G1 1215 G2 485 1450 100

Lift height

Width of fork carriage Tine width

Payload with lifting forks and load at 500 mm CoG Configuration Fork carriage Fork tine Quick-hitch Tyres Additional counterweight Total weight Tip load (articulated) Safety factor 1.25 1.67

FEM II, 1450 mm wide 100 x 45 x 1200 2B standard 365/80 R20 --5100 kg 2250 kg Payload 1800 kg * 1350 kg

Configuration FEM II, 1450 mm wide 100 x 45 x 1200 2B standard 365/80 R20 150 kg 5300 kg 2750 kg Payload 2200 kg 1650 kg

* not applicable to full lifting height. Max payload over full lifting height: 2200 kg.

Stability factor 1.25 for tip load with loader on level ground.

Stability factor 1.67 for tip load with loader on uneven ground.

Tip loads calculated acc. to DIN 24094.

27

OPERATOR’S MANUAL 21D / 121D / 221D Loading bucket 221D 0.9 m3 bucket, 2050 mm wide, 1.0 m3 bucket, 2100 mm wide,

= 1.8 / 2.0* t/m3 = 1.8 t/m3

* with counterweight

Dimensions: (for tyres 365 / 80R20) bucket 0.9 m3, 2050 mm wide mm mm mm A = 5340 G = 770 T = 460 B = 5250 H = 2765 C = 85 I = 1945 D = 3985 J = 1526 E = 3155 K = 380 F = 2510 N = 2250

28

Dimensions: (for tyres 365 / 80R20) bucket 1.0 m3, 2100 mm wide mm mm mm A = 5345 G = 770 T = 460 B = 5250 H = 2765 C = 90 I = 1945 D = 4040 J = 1526 E = 3155 K = 380 F = 2510 N = 2250

OPERATOR’S MANUAL 21D / 121D / 221D

BLANK PAGE Noise emissions

1946695

Outside the machine The sound power level LWA during working is: 21D - 100 dB(A) 121D / 221D - 101 dB(A). identical machines in compliance with standard 2000/14/EC.

Inside the machine The sound pressure level LpA inside the driver’s cab is: 21D / 121D / 221D - 76 dB(A).

Vibration levels

1946679

Vertical vibration level at the operator’s seat Upon investigations carried out on identical machines in travel and digging conditions over cycles of different lenghts, the averaged vibration level is estimated to be EQUAL TO or LOWER THAN 2,0 m/s2.

(RMS valve weighed using the "wide band" method in accordance with the ISO 2631-1 Standards).

Vibration level at hands and arms Upon investigations carried out on identical machines in travel and digging conditions over cycles of different lenghts, the estimated vibration level is LOWER THAN 1,4 m/s2.

(RMS valve weighed using the "wide band" method in accordance with the ISO 2631-1 Standards).

29

OPERATOR’S MANUAL 21D / 121D / 221D CE Mark

1946704

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

CE is short for "Communauté Européenne".

Fig. 1

30

OPERATOR’S MANUAL 21D / 121D / 221D STABILITY

2913051

Fig. 1

Centre of gravity position during transport With operator and std. bucket 21D

121D

221D

x = 1270 mm

x = 1250 mm

x = 1410 mm

The center of gravity position depends upon the attachment position.

31

OPERATOR’S MANUAL 21D / 121D / 221D Rated load at stability limit 21D Tyres

121D

221D

Steering angle max. payload Steering angle max. payload Steering angle max. payload (kg) (kg) (kg)

STANDARD

0˚

1500

0˚

1800

0˚

2170

Bucket

41˚

1325

41˚

1575

41˚

1900

OPTIONAL

0˚

1600 *

0˚

1950 *

0˚

2300 *

Lifting forks without additional counterweight

41˚

1400 *

41˚

1800 *

41˚

2200 *

OPTIONAL

0˚

1700 *

-

-

-

-

Lifting forks with additional counterweight

41˚

1500 *

-

-

-

-

* on level ground This machine, as approved, is not intended for any other applications, namely is should not be used as means to hook, lift or move suspended loads.

Therefore, all uses other than applications with the bucket MUST BE ABSOLUTELY AVOIDED, unless the machine is factory-fitted with special equipment and instructions for the specific application.

32

OPERATOR’S MANUAL 21D / 121D / 221D Warning and instruction signs

1946696

Fig. 1

33

OPERATOR’S MANUAL 21D / 121D / 221D Always observe the warning and instruction signs attached to the machine.

Legend to Fig. 1 1

- The reservoir for fluid for the windscreen washing system is located here.

Keep signs clean and legible.

2

- Fuel filter

Replace signs immediately if they have become illegible.

3

- Fuel tank, fill in diesel fuel here.

4

- Risk of injury from hot cooling fluid. Never open the radiator filler cap until the radiator has cooled down.

6

- Risk of injury to persons standing between the machine and an obstruction.

Never reverse until the hazard zone behind the machine is free.

7

- Check wheel nuts at regular intervals, see operator’s manual.

8

- Keep clear of this surface. It is not designed for this load and may break.

9

- Risk of injury from crushing. Never start up the machine while there are persons within the hazard range of the pivot.

New warning and instructions signs can be ordered from our Spare-Parts Service. The part nos. required for orders can be found in the spare-parts list of your machine.

10 - Locking mechanism for quick-change device; see operator’s manual.

11 - Risk of injury from working equipment being lowered. All persons must keep well clear of the area below lifted working equipment.

12 - Risk of injury from unauthorized startingup of the machine. Before starting work on the machine, stop the engine and withdraw the key.

13 - The CE sign indicates the this machine has been built in conformity with the European prescriptions for the safety of machines.

LWA is the level of noise emissions specified in dB A (in acc. with standard 2000/14/EC).

34

OPERATOR’S MANUAL 21D / 121D / 221D Machine number

2905024

The MACHINE NUMBER is engraved on the nameplate (Fig. 2). You will also find this number stamped into the chassis frame above the nameplate.

Travel pump number The nameplate with the travel pump number is located on the travel pump’s control unit (Fig. 5).

Fig. 5 Fig. 2

Engine number The NAMEPLATE with the engine number is attached to the engine (Fig. 3).

Travel motor number The travel motor number can be found on the nameplate of the travel motor (Fig. 6).

Fig. 6 Fig. 3

Axle number

Attachments

The axle number can be found on the nameplate at the axle tube (Fig. 4).

The loader attachments are equipped with an identification plate. Fig. 7 shows the identification plate of the bucket.

Fig. 4

Fig. 7

35

OPERATOR’S MANUAL 21D / 121D / 221D DRIVER’S CAB Entering and leaving the machine Safety instructions

2905324

2747580

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

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

The wheel mounted loader is equipped with a ROPS/FOPS drivers cab.

The plate (Fig. 1) contains detailed specifications of the driver’s cab.

Risk of injury due to slipping.

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

Always face the machine when entering or leaving it.

Fig. 1

The detailed specifications are (Fig. 2):

Fig. 1

Fig. 2

A = Serial number B = Part number ROPS/FOPS structure C = Driver’s cab - manufacturer D = Machine type E = max. weight of machine F = Inspection code ROPS/FOPS G = Machine manufacturer

36

OPERATOR’S MANUAL 21D / 121D / 221D Driver’s cab door

2905026

Opening the door

Fig. 1

Fig. 3

• Unlock door with key (Fig. 1).

• Depress lock button and swing door sideways.

Closing the door

• The cab door engages in its limit position.

Always close the cab door before driving on the highway.

Fold-down window For improved ventilation, the cab is equipped with a fold-down window on the right-hand side.

Press the arrested (Fig. 4) together and slide the window up or down as required.

Release arrester in the desired position.

Fig. 2

To release, press lever (Fig. 2) towards door. The door can then be closed.

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

Fig. 4

Slide the window until the arrecters lock safely.

37

OPERATOR’S MANUAL 21D / 121D / 221D Emergency exit

Documentation

Leave the cab through the rear window if the door cannot be opened.

The documentation can be stowed in a compartment below the driver’s seat (Fig. 6).

The wheeled loader is equipped with an emergency hammer (Fig. 5).

Fig. 6

Fig. 5

Risk of injury from splintering glass and sharp edges.

Break the rear window and knock out the glass with the emergency hammer so that the cab can be left without risk of injury.

38

OPERATOR’S MANUAL 21D / 121D / 221D Cab interior lighting

Roller blind 2904978

2905271

The roller blinds (1, Fig. 8) are mounted above the windscreen and the rear window.

Fig. 7 Fig. 8

The interior lighting is switched on and off with the switch (1, Fig. 7).

The power supply to the lamp is not interrupted even after the key-switch cutting off the electrical system has been set to the OFF position.

So always switch off the lamp when leaving the machine. The batteries may otherwise be discharged if the interior lighting is left on for a long time.

Letting down the roller blind The roller blind can be let down as far as required by pulling on the strap (2).

Retracting the roller blind Press back red lever (3) at righthand end of roller-blind casing. The roller blind is retracted.

Switch (1) in central position: both lamps OFF. Switch up: reading lamp (2) ON. Switch down: interior lighting (3) ON.

39

OPERATOR’S MANUAL 21D / 121D / 221D 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.

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.

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).

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

40

OPERATOR’S MANUAL 21D / 121D / 221D 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 locking 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

41

OPERATOR’S MANUAL 21D / 121D / 221D Adjusting the right armrest The armrest (1, Fig. 1) can be adjusted in height and position by means of 2 levers.

The levers are located outside below the cushioning.

2905354

Height adjustment Release left lever (2) and bring armrest (1) to required position. Then engage lever again.

Fore-and-aft adjustment Releae right lever (3) and slide armrest (1) into required position.

Then engage lever again.

Fig. 1

42

OPERATOR’S MANUAL 21D / 121D / 221D WARNING, MONITORING AND CONTROL ELEMENTS

1946862

Fig. 1

43

OPERATOR’S MANUAL 21D / 121D / 221D Driver’s stand, overall layout (Fig. 1) No. Element

Function

1

Instrument panel

Accommodates the warning and monitoring lamps, indicator instruments and switches

2

Steering column

Accommodates the travel direction switch and steering wheel

3

Right console

Accommodates control levers, key-switches, knobs for the heating system, and switches

4

Left console

Accommodates the parking brake

5

Operating hourmeter

Adds up the machine operating hours.

Maintenance and inspection work should be scheduled according to the meter reading

6

Immobilizer (option)

Prevents unauthorized starting of the machine

7

Parking brake

Pull upwards - parking brake applied Press knob, release lever - parking brake released

8

Knob

9

Radio

10

12V socket outlet

44

Lock the parking brake

Press in knob, push lever down to limit stop, parking brake is released.

Compartment for radio

Symbol

OPERATOR’S MANUAL 21D / 121D / 221D Warning and control lamps

Fig. 2

45

OPERATOR’S MANUAL 21D / 121D / 221D Warning and control lamps (Fig. 2) No. Element

Page 1 of 2

Function

1

Control lamp

Travel direction indicator, left

Lights up when the left travel direction indicator is switched on.

2

Warning lamp

Alternator

Lights up when the battery is not being charged.

3

Warning lamp

Engine oil pressure

Lights up when the engine oil pressure is too low.

Shut off engine and rectify fault.

4

Warning lamp

Air filter

Lights up when the filter cartridge is contaminated.

5

Warning lamp

Central warning

Lights up when: - hydraulic oil temperature is too high (with warning lamp 16) - engine oil pressure is too low (with warning lamp 3) - coolant temperature is too high (with warning lamp 17) - braking pressure is too low (with warning lamp 7)

6

Control lamp

Parking brake

Lights up when the parking brake is applied.

7

Warning lamp

Braking pressure

Lights up when the braking pressure is too low.

Stop loader immediately and rectify fault.

8

Control lamp

Main beam

Lights up when the headlamps are on main beam.

9

Control lamp

Travel direction indicator, right

Lights up when the right travel direction indicator is switched on.

10

Control lamp

Light

Lights up when dipped beam is switched on.

11

Control lamp

Floodlamps

Lights up when the floodlamps are switched on

12

Control lamp

Creep speed

Lights up when creep speed is engaged

13

Control lamp

Travel direction reverse

Lights up when reverse travel has been selected

46

Symbol

OPERATOR’S MANUAL 21D / 121D / 221D Warning and control lamps

Fig. 3

47

OPERATOR’S MANUAL 21D / 121D / 221D Warning and control lamps (Fig. 3) No. Element

Page 2 of 2

Function

14

Control lamp

Travel direction forward

Lights up when forward travel has been selected

15

Control lamp

Working speed

Lights up when working speed has been selected

16

Warning lamp

Hydraulic oil temperature

Lights up when hydraulic oil temperature is too high Shut off engine and rectify fault.

17

Warning lamp

Coolant temperature

Lights up when coolant temperature is too high.

Stop loader immediately and run engine at idling speed to cool down.

18

Fuel indicator

Indicates fuel level

19

Coolant temperature indicator

Shows the coolant temperature.

Coolant temperature indicator in green zone - temperature OK. Coolant temperature indicator in red zone (at the same time the warning lamp (17) and the "Central Warning" (5) light up and the acoustic warning sounds) - temperature too high.

Stop loader immediately and run engine at idling speed to cool down.

20

Lever

Horn, travel direction indicator, main beam, windscreen wiper / washer, front

Activates the functions for hooter, travel direction indicator, main beam, windscreen wiper / washer, front

21

Control lamp /switch

Flashing warning light

Flashes when flashing warning light system is selected in conjunction with control lamp (1 and 9).

45

Speedometer (option)

48

Shows the travelling speed of the machine.

Symbol

OPERATOR’S MANUAL 21D / 121D / 221D Switches and pushbuttons

Fig. 4

49

OPERATOR’S MANUAL 21D / 121D / 221D Switches and pushbuttons (Fig. 4) No. Element 22

Pedal

Function Service brake and inching

Depress pedal lightly - machine is gently braked.

Depress pedal completely - machine is braked with service brake.

23

Lever

Steering column engagement

Steering column adjustment

24

Pedal

Speed change

Regulates the driving speed

25

Control lever

Driving / working

Selects the functions for driving operation and working hydraulics

26

Lever

3rd/4th function

Actuates hydraulic rapid-change device or bottom-dump bucket, for example

27

Ashtray

28

Key-switch

Electrical system

Electrical system ON/OFF. Engine start/stop

29

Free for options

30

Free for options

31

Free for options

32

Toggle switch

Acoustic reversing signal (Back-up alarm) (option)

Selects the acoustic reversing signal Reversing signal ON - press switch surface with symbol Reversing signal OFF - press symbol-free switch surface

33

Toggle switch

Rotary beacon (option)

Rotary beacon ON press switch surface with Symbol Rotary beacon OFF press symbol-free switch surface

34

Toggle switch

Floodlamps, front

Floodlamps ON - press switch surface with symbol Floodlamps OFF - press symbol-free switch surface

35

Toggle switch

Floodlamps, rear (option)

Floodlamps ON - press switch surface with symbol Floodlamps OFF - press symbol-free switch surface

36

Toggle button / Windscreen wiper/ switch washer, rear

50

Wiper ON - press switch surface with symbol Washer ON - continue pressing switch surface with symbol Wiper OFF - press symbol-free switch surface

Symbol

OPERATOR’S MANUAL 21D / 121D / 221D Switches and pushbuttons

Fig. 5

51

OPERATOR’S MANUAL 21D / 121D / 221D Switches and pushbuttons (Fig. 4) No. Element

Function

37

Toggle switch

Lighting

Dipped beam ON - press switch surface with symbol as far as 1st engagement position Headlight ON - press switch surface with symbol as far as 2nd engagement position Dipped beam / Main beam OFF - press symbol-free switch surface

38

Rotary switch

Blower

1, 2, 3 = Blower speed 0 = OFF

39

Rotary switch

Heating

Controls the heating output

40

Rotary switch

Fresh air intake

Controls the fresh air intake and the circulating air system

41

Rotary switch

Air conditioning (option)

Switches the air conditioning system on and off

42

Cigarette lighter and socket outlet

43

Control lamp

44

Armrest

52

Preheating

Lights up during the preheating process Adjustable

Symbol

OPERATOR’S MANUAL 21D / 121D / 221D PUTTING THE MACHINE INTO OPERATION Before daily start-up and operation carry out works in acc. with maintenance plan T (cf. Part 3 "Inspection and servicing")

2913054

121D / 221D

Refuelling Refuelling - Safety instructions Explosion hazard!

Avoid open flames and stop smoking.

Diesel fuel may cause skin injury.

Therefore, wear protective gloves or use a barrier cream.

Stand working equipment on the ground.

Shut off engine.

Do not spill fuel and do not allow fuel to penetrate into the soil. Fuel pollutes the environment.

Absorb spilt fuel immediately with cleaning rags or binding agents.

Fuel and cleaning material must be disposed of without polluting the environment.

Fuel accidents must be reported immediately to the user or his representative.

Fig. 2

Refuelling • Unscrew cap of filler neck (1, Fig. 1 and Fig. 2).

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

If possible, use a microfilter in the filling line.

21D

Fig. 1

53

OPERATOR’S MANUAL 21D / 121D / 221D Electrical system ON / OFF

2905334

Battery main switch (option) The battery main switch (1, Fig. 1) is located under the engine hood on the right, close to the battery.

Never set battery main switch to OFF when the engine is running.

Electronic components may be irreparably damaged by voltage peaks.

The entire electrical system is disconnected from the battery with the battery main switch (1). The switch positions shown in Fig. 1 have the following meaning: I = ON II = OFF In OFF position, the battery main switch (1) prevents

Immobilizer (option)

This machine is equipped with an electronic immobilizer to prevent the machine from being started up by unauthorized persons.

When the immobilizer is activated, the LED (2, Fig. 2) above the socket (3, Fig. 1) flashes.

The electrical system can be operated with the key-switch. The engine cannot be started up.

The immobilizer must always be deactivated before starting up the engine.

Insert deactivating key (1, Fig. 2) briefly into socket (3). The immobilizer is deactivated for ca. 10 seconds. The LED (2, Fig. 2) above the socket (3) does not flash.

Keep the deactivating key in a place to which unauthorized persons have no access.

This ensures that your machine cannot be started up by unauthorized persons.

• unauthorized starting of the engine • inadvertent discharge of the battery.

Fig. 1

Fig. 1

Fig. 2

54

2904964

OPERATOR’S MANUAL 21D / 121D / 221D Electrical system key-switch

1946873

The key-switch (28, Fig. 1) is used to select the following functions:

Fig. 2 Fig. 1

Starting and stopping the engine

0 = All electrical consumers - with the exception of cab interior lighting, hazard warning system, radio, cab socket and lighting - without current, engine off.

Starting

1 = Electrical system ON. Warning lamps (2, 3 and 7, Fig. 2), pilot lamp (43, Fig. 4) and one of the pilot lamps (12 or 15, Fig. 2) are lit up, and the monitoring lamp (6, Fig. 2) is lit up when the parking brake is applied.

The central warning indicator (5) is lit up briefly and a brief acoustic warning is sounded.

Exhaust fumes are a health hazard.

Never start the engine except in the open air or on premises with an exhaust extraction system.

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

• Deactivate the travel direction selector by setting the switch (1, Fig. 4) to center position.

• Deactivate the immobilizer.

The automatic glow time control is switched on.

• Turn key in key-switch (28, Fig. 1) to position 1.

When the pilot lamp (43, Fig. 4) goes out, the key-switch can be set to position 2.

The warning lamps (2, 3, and 7, Fig. 2) and pilot lamps (6, Fig. 2, 12 or 15, Fig. 2 and 43, Fig. 4) are lit up.

2 = Engine start. All warning and pilot lamps and the acoustic alarm must be out when the engine is running.

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

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

The central warning indicator is lit up briefly and a brief acoustic warning is sounded.

Hold key in position 1 until the pilot lamp (43) goes out.

Depending on engine temperature, the preheating phase varies in length. No preheating is required when the engine is warm.

• Turn key to position 2. The engine starts up.

55

OPERATOR’S MANUAL 21D / 121D / 221D • Release the key; it returns to position 1. Increase engine speed shortly by depressing the speed spedal lightly. The warning lamps for alternator (2, Fig. 2), engine oil pressure (3) and brake pressure (7) go out.

The pilot lamps for the parking brake (6) and the selected gear (12 or 15) remain lit up.

Stopping the engine Never shut off the engine abruptly out of full load, but run at idling speed for ca. 3 minutes to allow for cooling.

If the warning lamps go out while the engine is running, substantial damage may be caused to the engine. Shut off the engine immediately.

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

• Non-stop starting must not be continued for more than 10 seconds. A one-minute interval is essential between starting operations.

Fig. 3

Engine does not start Never use additional starting aids, e.g. injection of starter liquid.

Risk of accidents through uncontrolled deflagrations.

If the engine fails to start up, repeat the starting procedure. If the engine fails to start up after 10 seconds of non-stop starting, switch key (28, Fig. 1) back to position 1 and wait 1 minute.

Switch key to position 0 and then make a fresh starting attempt.

• Set the working equipment down on the ground.

• Deactivate travel direction selector by setting the switch (1, Fig. 4) to center position. The pilot lamps (13 and 14, Fig. 2) must go out.

• Move control lever (25, Fig. 4) to 0-position.

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

The pilot lamp (6, Fig. 2) lights up.

For starting in winter or in the event of malfunctions, observe the instructions given in the engine operator’s manual.

The engine cannot be started by towing the loader, since the wheels are blocked by the hydrostatic drive of the loader.

Fig. 4

• Turn key-switch (28, Fig. 1) to 0. The engine is stopped.

• Withdraw key.

• Secure wheeled loader against inadvertent movements and unauthorized starting.

56

OPERATOR’S MANUAL 21D / 121D / 221D Ventilation and heating The driver’s cab is ventilated through the righthand knockout window and by a fan. The fan mixes fresh air into the circulating air.

Ventilation

1946863

Ventilation / fresh air The fresh air is drawn into the cab through the filter (Fig. 3).

Keep intake openings clean.

The rotating slats of the air outlets (Fig. 1 and Fig. 2) direct the air flow towards the windscreeen and rear window, to the side windows, and into the foot of the cab.

Fig. 3

The filter is located at the righthand side of the vehicle under the cab floor.

Fig. 1

The air flow is controlled with the rotary switch (40, Fig. 4).

Rotary switch (40) clockwise - maximum fresh-air intake.

Ventilation / recirculated air If the machine is used in a very dusty environment, the ventilation system can be switched to recirculation. In this case the air is drawn in through a suction opening in the driver’s cab.

Close cab door and window.

Fig. 2

Turn rotary switch (40) counter-clockwise to its limit stop - only recirculated air.

57

OPERATOR’S MANUAL 21D / 121D / 221D Heating

Fan

The heating performance depends on the engine temperature. Full performance can only be achieved when the engine has reached its operating temperature.

Fan operation for heating and/or ventilation is controlled with the rotary switch (38, Fig. 4).

Adjustment of heating performance The heating performance is selected with the rotary switch (39, Fig. 4).

Fig. 4

Rotary switch (39) clockwise (blue sector) - heating OFF. Rotary switch (39) counter-clockwise (red sector) - heating ON. Run the heating once a week at full performance for about 5 minutes, even if it is not needed over a prolonged period, in order to mix the coolant in the engine and in the heating system.

58

Position 0 = OFF Position 1 = low Position 2 = medium Position 3 = high

OPERATOR’S MANUAL 21D / 121D / 221D Horn, travel direction indicator, main beam and windscreen wiper / -washer

2913079

Fig. 2

Fig. 1

The following functions are elected with the lever (20, Fig. 1):

Position Function

Symbol

Remarks

1

Horn

Depress lever knob towards position 1

2

Travel direction indicator, right

Pull lever towards position 2. Pilot lamp (9, Fig. 2) lights up.

3

Travel direction indicator, left

Press lever towards position 3. Pilot lamp (1, Fig. 2) lights up.

4

Main beam

Push lever up towards position 4. Main beam with dipped beam switched on.

Pilot lamp (8, Fig. 2) lights up.

59

OPERATOR’S MANUAL 21D / 121D / 221D The following functions are selected with the rotary knob: 0 J I II

= = = =

Screen wiper OFF Intermittent wiping Wiper slow Wiper fast

• Switching on the windscreen wiper: - Rotary knob to position J (intermittent wiping)

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

When the engine hood has been opened, the reservoir is accessible at the right rear wall of the cab.

To top up, remover cap and add water.

Antifreeze must also be added in winter.

- Rotary knob to position I (wiper slow) - Rotary knob to position II (wiper fast).

• Switching off the windscreen wiper: - Rotary knob to position 0 • Switching on the windscreen washer: - Move lever (20, Fig. 3) into position 6 and hold in this position.

- Set windscreen wiper to position I. • Switching off the windscreen washer: - Release lever (20).

- Set windscreen wiper to position 0.

Fig. 3

60

Fig. 4

OPERATOR’S MANUAL 21D / 121D / 221D Lighting

1946864

The lighting can be controlled with the toggle switch (37, Fig. 1).

Fig. 1

Fig. 3

• Parking light ON

• Main beam OFF

- Press toggle switch (37) onto area with Symbol as far as 1st engagement.

Pilot lamp (10, Fig. 2) lights up.

- Push lever (20) up into position 4 again, then release again.

Fig. 2

• Dipped beam ON - Press toggle switch (37) onto area with Symbol as far as 2nd engagement.

Pilot lamp (10) goes out.

• Dipped beam / parking light ON - Press toggle switch (37) onto symbol-free area.

• Main beam ON - Switch on main beam with lever (20, Fig. 3).

Push lever (20) up into position 4, then release again.

Pilot lamp (8, Fig. 2) lights up.

Main beam can be switched on only when dipped beam is switched on.

61

OPERATOR’S MANUAL 21D / 121D / 221D Rear screen wiper / washer

1946865

Cigarette lighter / Socket outlet 1946866

Fig. 1

• Wiper on: - Press down toggle switch (36, Fig. 1) onto area with symbol as far as 1st engagement position.

• Washer on: - Continue activating toggle switch (36) onto area with symbol and hold in place.

Fig. 2

The cigarette lighter is on after being pushed into the socket (42, Fig. 2).

When the spiral is glowing, the lighter is ejected from the socket. Use immediately.

The socket outlet (42) can, for example, be used for connecting a handlamp.

• Switching off - Press toggle switch onto symbol-free area.

62

Using the socket with the engine stationary discharges the battery.

OPERATOR’S MANUAL 21D / 121D / 221D DRIVING Driving - Safety instructions

2905157

Have the working equipment raised only so far that it can still pass safely under overhead power lines.

Mount the transport securing devices.

Adjust the driver’s seat, the steering column and the mirror before setting off.

Close the cab door.

The machine is equipped with a safety belt for the operator. Fasten the belt.

Adjustment of steering column 2472464

Steering column - Safety instructions Do not adjust the steering column during driving.Concentrateon 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.

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

Never drive across slopes.

Take the utmost care on slippery, greasy ground.

Ensure that the wheels have sufficient grip; only then can the steering and braking system of the machine function properly.

Run the engine for ca. 2 to 3 minutes before setting off.

The engine may be operated under full load conditions only after it has reached its operating temperature.

63

OPERATOR’S MANUAL 21D / 121D / 221D Adjusting the steering column

Seat belt

2905416

2913080

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

• Press lever (Fig. 1) downwards; steering column moves to front position.

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

Seat belt - Safety instructions Always belt up before driving.

• Pull steering column into desired position.

Never run belt over rigid or fragile objects such as bunches of keys or spectacles. This may result in injury.

• Release lever to lock steering column.

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.

Fig. 1

Fig. 2

64

OPERATOR’S MANUAL 21D / 121D / 221D Control lever - Travelling / Working

1946867

The wheeled loader is equipped with a control lever (25, Fig. 1) with which the travelling and working modes are controlled.

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

Fig. 2

The pushbutton (3, Fig. 1) serves to switch over from creep to working speed and vice versa.

The respective pushbutton position is indicated by lamps (12 and 15, Fig. 2).

Fig. 1

The switch (1, Fig. 1) serves to select the direction of travel - forward or reverse - and is usedas follows: • Switch (1) in center position (position "0") travel direction selector OFF. Pilot lamps (13 and 14, Fig. 2) are off.

• Switch (1) forward - forward travel ON. Pilot lamp (14, Fig. 2) lights up (green).

12 = creep speed 15 = working speed When creep speed is selected, the loader speed is limited to the maximum admissible speed for this range. This is important for working operations requiring low speeds.

Selection of the working range automatically - as required - covers the creep range too.

• Switch (1) back - reverse travel ON. Pilot lamp (13, Fig. 2) lights up (yellow).

When the parking brake is applied, forward or reverse travel can only be preselected.

The forward (14) or reverse (13) direction of travel is indicated only when the parking brake is released.

The gears are changed only when the parking brake is released.

65

OPERATOR’S MANUAL 21D / 121D / 221D Driving

2800716

Warming up the machine

Braking and stopping

Warm-up is necessary:

To brake the machine during driving it is generally sufficient to release the accelerator pedal (24, Fig. 1), the travelling speed being efficiently reduced by the hydrostatic drive.

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

2913060

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.

66

Depress the brake pedal (22, Fig. 1) if the loader is to be braked more vigorously. Multiple-disk brakes in the rear axle actuated. Travel drive is reduced at the same time even if pedal (24, Fig. 1) is not released.

OPERATOR’S MANUAL 21D / 121D / 221D Driving Start

1946868

Travel direction and gears Observe the travelling function indicator symbols (12 - 15, Fig. 1) before driving.

The functions can be engaged "under load", i.e. the machine must not have been brought to a halt beforehand. Avoid shifting - even shifting to "0" - at higher machine speeds since the machine would be braked abruptly under these circumstances.

Reduce your speed first.

The brake pedal (22, Fig. 3) performs two functions.

Fig. 1

• Check that the steering column is blocked.

• Raise the working equipment slightly.

• Release the parking brake.

Fig. 3

• Sound the horn.

When the pedal is depressed slightly and with little force, the travel pump is tilted back to low output and the driving speed thus reduced (inching).

Increased force in depressing the pedal causes the multiple-disk brakes in the rear axle to brake the machine.

• Select the direction of travel with switch (1, Fig. 2) in control lever (25) and depress pushbutton (3) if needed.

This feature offers the possibility of performing controlled driving operations such as precision driving, soft starting, sensitive manoeuvering and controlled braking independent on engine speed.

For inching operations (slow driving), the travel drive needs less power than for driving without the inching function, leaving more power for the working hydraulics.

Fig. 2

Adjust the speed with the accelerator pedal (24).

67

OPERATOR’S MANUAL 21D / 121D / 221D Fast-speed variant (optional equipment)

30000003

Warning!

The Wheel Loaders with Fast-speed option are designed for a max speed of 22mph (35 km/h). When the max speed is exceeded damages may occur.

Activating fast speed

Disengaging fast speed

Fig. 1

Fig. 2

• Switch on or start up the machine

• Machine running, fast speed is activated.

• Engine running, working or creep speed activated.

• The machine must be stationary!

• Preselect the fast speed with rocker switch (36, Fig. 1). Switch in center position.

• Set rocker switch (36, Fig.1) to center position.

• Depress brake pedal firmly until pilot lamp (36) is ON.

• Depress brake pedal firmly until pilot lamp (36) is ON.

• Depress symbol side of rocker switch (36).

• Depress symbol side of switch (36).

• Pilot lamp (35a) OFF.

• Pilot lamps (12 and 15, Fig. 2) OFF. Pilot lamp (35a, Fig.1) ON.

• Pilot lamps (12 or 15, Fig.2) ON.

• Release brake pedal - pilot lamp (36) OFF. • Set rocker switch (36) to OFF. Fast-speed remains activated.

• Set off slowly.

• Release brake pedal - pilot lamp(36, Fig.1) OFF. • Set rocker switch (36) to OFF. • Fast speed is deactivated when the machine is stopped (engine off) and the working speed is activated.

• Set off slowly (working or creep speed activated).

68

OPERATOR’S MANUAL 21D / 121D / 221D Monitoring the indicators Observe the warning lamps (Fig. 1) while driving.

Wheeled loader operation is trouble-free if no warning lamp lights up, if the "Central Warning" (5) does not light up, and if no acoustic warning is sounded.

2913081

Hydraulic oil temperature When the hydraulic oil temperature is too high, warning lamp (16, Fig. 2) lights up, the "Central Warning" (5) lights up, and an acoustic warning sounds.

Fig. 1 Fig. 2

If one of the warning lamps lights up in conjunction with the "Central Warning" and if an acoustic warning signal sounds, the loader must be stopped immediately.

Stop the wheeled loader, shut off the engine, locate the cause and rectify or contact our local dealer.

Shut off the engine if necessary, locate the cause of the fault, and rectify or contact our local dealer.

69

OPERATOR’S MANUAL 21D / 121D / 221D Engine oil pressure

Alternator

When the engine oil pressure is too low, warning lamp (3, Fig. 3) lights up, the "Central Warning" (5) lights up, and an acoustic warning sounds.

In the event of an alternator malfunction, only warning lamp (2, Fig. 4) lights up.

Fig. 4 Fig. 3

Stop the wheeled loader, shut off the engine, locate the cause and rectify or contact our local dealer.

When the warning lamp (2) does not go out even with higher engine speed, shut off engine and locate and rectify the cause of the fault.

Air filter When the air filter is contaminated, warming lamp (4, Fig. 5) lights up. When warning lamp (4) lights up, the filter must be cleaned or replaced even if the replacement interval has not expired.

Fig. 5

70

OPERATOR’S MANUAL 21D / 121D / 221D Coolant temperature

Braking pressure

The coolant circuit is controlled by a thermostat.

The max. admissible temperature is ca. 105˚C.

If the braking pressure drops sharply while driving, the wheeled loader stops immediately.

The coolant temperature is monitored by indicator (19, Fig. 6).

At the same time, the warning lamp (7, Fig. 7) and the "Central Warning" indicator (5) light up, and the acoustic warning is sounded.

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

Locate the cause of the pressure drop and rectify before putting the loader back into operation, or contact our local dealer.

Fig. 6

When the coolant temperature indicator is in the green zone, the machine functions are in order.

When the coolant temperature indicator (19) moves into the red zone, the warning lamp (17) lights up, an acoustic warning is sounded, and the "Central Warning" (5) lights up, the coolant temperature is too high.

Stop the loader immediately and run the engine at idling speed to cool it down.

Fig. 7

Turn heating knob to Warm.

If the warning lamp (17) does not go out after some minutes of idling, the coolant temperature indicator (19) does not return to the green zone, the "Central Warning" (5) is still lit up and the acoustic warning is still sounding, the loader must be stopped immediately and the engine shut off.

Secure the machine, locate the cause of the fault and rectify or contact our local dealer.

71

OPERATOR’S MANUAL 21D / 121D / 221D Driving on public roads

2913062

Observe the relevant traffic and safety regulations in the country of use.

121D / 221D

When the vehicle is being driven on public roads, it must be equipped with first-aid kit (1, Fig. 4), warning triangle (2), fire extinguisher (4, Fig. 5) and warning beacon (3, Fig. 4).

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

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

Fig. 2

Before driving on public roads

• Cover up the bucket edge with a guard strip.

• Empty the bucket and bring into the marked position for transport (marking on left side of lifting frame) with the bucket edge pointing upwards (Fig. 1 and Fig. 2).

• Check brakes, steering, tyres and lighting system.

21D

• Secure the control levers for bucket operation and 3rd function (25 and 26, Fig. 3) against unintentional movements by means of blocking device (7) (cf. section "Control lever locking") • Switch off the floodlamps.

• Adjust the mirror.

Fig. 1

Fig. 3

• Check that the steering column is engaged.

• Close the cab door.

• Check driver’s seat for position and engagement.

• Fasten safety belt.

72

OPERATOR’S MANUAL 21D / 121D / 221D • First-aid kit (1, Fig. 4) and warning triangle (2) must be stowed away on the right beside the driver’s seat.

• The fire extinguisher (4, Fig. 5) can be fastened with clamps to the right column of the cab structure.

Fig. 4

Fig. 5

73

OPERATOR’S MANUAL 21D / 121D / 221D Recovering / towing of the machine

1946801

Recovery and towing, safety instructions Tow the machine with a tow rod or a tow rope only.

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 21D = 5000 kgs.

121D / 221D = 5800 kgs.

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

Fig. 1

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

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. 2

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

Towing lug

2905421

The towing lug (Fig. 1) is located at the rear of the machine.

Never use the towing lug to tow trailers.

Fig. 3

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

74

OPERATOR’S MANUAL 21D / 121D / 221D Towing

2800967

Towing must be done only at low travelling speed (ca. 5 km/h) and over a max. distance of 0.5 km to avoid irreparable damage to the travel motor through overheating.

Tow only as far as absolutely necessary to recover the machine from the hazardous area.

If the machine is towed over greater distances, the travel motor may be overheated and damaged.

Remove caps (1, Fig. 4) from valves for forward movement (3) or reverse movement (2).

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

Hold hex nut with an open-jawed wrench and turn in threaded bolt (4 or 5) with a hexagon-socket wrench until it is flush with the hex nut (6 or 7).

Tighten hex nut again.

Fig. 4

Turn in the threaded bolts (4 or 5) no further than specified above to avoid irreparable damage to vital parts of the valves.

After towing, slacken hex nut (6 or 7). Unscrew threaded bolt (4 or 5) as far as limit stop, then tighten hex nut (6 or 7).

If the loader is to be towed over longer distances, remove cardan shaft between the two axles and tow with the rear axle fitted clear of the ground or transport the loader on a low-bed trailer. Latch articulated joint.

75

OPERATOR’S MANUAL 21D / 121D / 221D Transport

2913078

Transport - Important information

Loading by crane

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.

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).

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

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").

Fig. 2

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

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

76

OPERATOR’S MANUAL 21D / 121D / 221D 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

77

OPERATOR’S MANUAL 21D / 121D / 221D WORKING OPERATION

2904316

Working operation - Safety instructions Read the sections "Fundamental safety instructions" and "Operation, safety instructions" carefully and observe the instructions given in them.

Inspect the site for underground gas, power and water lines before starting work. Any damage to such lines is a risk to life!

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

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

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 wheelmounted loader in such a way as to guarantee is stability.

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

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

78

At low temperatures, bring the engine down to moderate speed, then activate all hydraulic functions for about 10 minutes (bring to service temperature). For further instructions, see section "Lubricants".

Lower the working equipment immediately and shut off the engine when the hydraulic oil temperature, engine oil pressure, alternator and coolant temperature warning lamps light up, the central warning indicator lights up or an acoustic warning signal is sounded.

The attachment can be lowered while the engine is stationary.

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

OPERATOR’S MANUAL 21D / 121D / 221D 2800542

Before starting to work with the loader, the Operator should know operating procedures included in the safety standards and those which are forbiden otherwise he could be a cause for accidentes to himself or other people.

Following instructions are only a part of all norms and cautions which should be complied with while operating the loader.

• Do not allow any passenger to ride on the loader at any time.

Do not hesitate to contact your Dealer for any further explanation you may require about safety precautions detailed herein.

The symbol a in a figure highlights a practice which is forbidden or dangerous.

Figures show wheel loaders of the small-high range.

Never accelerate or move jerking off. This causes waste of fuel and release of harmful smokes in the atmosphere.

Always drive the loader as to avoid pollution as much as possible.

Note - Figures do not refer necessarily to specific models. Safety standards and cautions, however, apply to all models.

Fig. 1

• Never get on and off the loader while it is moving.

Always use the special handles and safety support points.

• Prior to starting the engine always ensure that: - the parking brake is applied, - the gearshift lever is in the neutral position, - the bucket control lever is in the neutral position and properly locked by the detent.

• Get acquainted with the loader and train practically. Never start the engine, nor operate the loader from any position other than sitting in the operator’s seat.

• Do not operate any control lever while not sitting in the operator’s seat.

• Stop the loader on level ground and apply the parking brake. Rest the bucket to the ground, block the wheels and remove the ignition key.

79

OPERATOR’S MANUAL 21D / 121D / 221D • Do not park the loader where the exhaust muffler or other hot parts of the machine may contact any flammable matter (leaves, paper, etc.).

• It is dangerous to drive with the bucket at a higher position than required even if it is empty.

Keep the bucket at a minimum clearance from the ground (40-50 cm).

• It is recommended to apply the brakes until a complete stop of the machine prior the reversing the motion.

• Do not "trifle" with the loader. Move the controls progressively. Do not jerk the steering wheel. Do not brake, start or steer sharply.

• Do not operate the bucket or other front attachment sharply. There is the danger to drop the load or overturn the loader.

Fig. 2

• Never use matches, a lighter or a torch to check fluid levels or for leaks. Never smoke while handling the fuel or lubricants.

• Do not operate the loader in premises where there are explosive gases or where the exhaust pipe or other hot parts of the machine, (such as the engine or silencer), may get in contact with flammable materials (lubricants, chemicals, leaves or waste paper).

• Never raise the bucket or other front attachment higher than necessary.

Keep the attachment at minimum distance from the ground during transfers.

See loader conditions during transfers on page 82.

Fig. 4

• Check that there is enough clearance for the loader, operator and load before passing under an overhead door.

Fig. 5 Fig. 3

80

OPERATOR’S MANUAL 21D / 121D / 221D • Work more slowly at night. During the night is is more difficult to evaluate distances and ground gradient. Switch on main lamps to let the staff see the loader moving.

• Stop and sound the horn, if necessary, before corners and wherever there is reduced visibility.

It is a good practice to have a flagman assisting you.

• When driving up or down a slope, the loader centre of gravity should always be uphill. That is, a loader with a full bucket should move with the bucket uphill, while a loader with an empty bucket should move with the bucket downhill.

- Do not stop abruptly.

Fig. 6

• Drive around obstacles which may cause the loader to overturn.

• Pay great attention, especially in using the bucket control lever, if you are operating a loader with an attachment which reduces visibility or handling a tall load hindering visibility.

It is a good practice to have a flagman assist you.

• Consider weather and ground conditions. Move slowly if it rains, snows or in case of fog as visibility is reduced. Possibily avoid working on rough, soft or muddy grounds. Should it be necessary, carefully inspect ground conditions beforehand.

Fig. 8

• Stop the loader before driving down a slope.

Make use of the engine braking action. Should the loader gain excess speed, press the brake pedal occasionally. Do not hold the brake pedal down as this can reduce or even nullify the braking action.

Fig. 9 Fig. 7

81

OPERATOR’S MANUAL 21D / 121D / 221D • Do not turn on a slop, nor nove crosswise or the loader may overturn.

• Inspect the working area before starting the work with the loader. Check for any rough surface which might cause you to lose control of the loader or the loader to overturn or get stuck.

Before driving across a beam bridge or a wooden wharf, check it is solid enough. The work manager should keep a log of inspection results.

Fig. 10

• Ensure that nobody is under, on, or near the loader before starting the engine. Sound the horn to warn that you are about to start the engine.

• Always look in the direction of travel and keep your path always under control. Sound the horn when approaching people. Accidents frequently occur immediately after start-up.

Fig. 12

• In case of loader faulty operation, drive it out of the transit area and then report to the manager to take necessary action. The loader should not be used until the problem has been corrected.

Fig. 11

• Find out about the power and weight of the loader and its attachment, if any. Comply with all transit rules, including speed limits.

Inform all the personnel involved about operating rules and procedures.

82

Fig. 13

OPERATOR’S MANUAL 21D / 121D / 221D • Be careful.

Do not drink spirits (keep in proper physical conditions before and during the work).

• Pay great attention during transfers and while cornering in densely populated areas.

Fig. 14

Fig. 15

• Before exiting the loader, remove the ignition key and take it with you. Otherwise, you might be liable for possible accidents caused by anyone using the loader without authorization.

83

OPERATOR’S MANUAL 21D / 121D / 221D Driving on public road

2800543

Road transfer

2913063

Never drive the machine on public roads with the bucket loaded.

Ensure that the bucket control levers are in the neutral position.

This is to avoid unwanted bucket control lever movement which may cause dangerous situations.

Check all fluid levels and tyre inflating pressure.

Retract attachments within the machine size and raise them minimum required not to hinder manoeuvering.

Check all signal lights for correct operation.

Some tyre types and tread grooves are not suitable for road transfer. Consult the tyre manufacturer.

Keep in mind braking clearances and adjust speed consequently.

Comply with all traffic regulations. In case of traffic slow-downs, pull to one side and let the other vehicles pass on.

After two hours of travel, stop the machine for half an hour to let the tyres cool down. During operation, tyre pressure increases. This is normal and pressure should not be reduced.

Keep the gauges under control to assess correct operation. Be escorted by a vehicle to warn the road users through appropriate warning means (flashing lights, signs, etc) that a loader is travelling on the road.

Should "rythmical oscillation" occur, slow down the machine using the brakes to eliminate it and resume travel at a lower speed.

Attention - During road transfers carefully observe the Law of the Road norms. Keep all loader lights in good operating condition. Immediately replace any burnt bulb.

Note - Precautions detailed in this manual may require changes and adjustments to road regulations in force in the different Countries.

84

Fig. 1

1 - Bucket lock lever and lifting frame lock lever 3 - Headlights 4 - Rotary beacon 5 - Tail lights 6 - License plate light 7 - Toothed bucket edge guard

OPERATOR’S MANUAL 21D / 121D / 221D STANDARD EQUIPMENT

2800566

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

He must also extend and retract the piston rods of all hydraulic cylinders several times at increased engine speed (pedal pressed down by abt. 2/3) and with the parking brake applied - to eliminate existing voids in the cylinders.

Control lever for bucket equipment

2913064

Control lever (25, Fig. 1) serves to initiate the working movements.

Fig. 1

Control functions (Fig. 1): 0 = Hold position 1 = Lifting 2 = Lowering 2a = Floating (lever engaged) 3 = Rearward tilting 4 = Dumping

85

OPERATOR’S MANUAL 21D / 121D / 221D Floating position of the bucket equipment

Combined functions

Never switch on the floating position function when the working equipment is in raised position.

The working would otherwise drop too fast.

The floating position function is not available in machines in which the pipe burst protection function cannot be switch off.

In machines in which the pipe burst protection function can be switched off, the floating position can only be activated when the pipe burst protection is off.

Floating position 2a permits levelling off base courses when the machine is reversing.

For levelling, let bucket sink down on the ground, shift control lever (25) to position 2a and allow to engage. The bucket now rests freely on the ground, loaded only by its own weight. Pulling the control lever back to position 2 disables the floating function.

Shift control lever from position 2a manually back into position 2. From all other positions, the lever returns automatically to "0".

Fig. 3

Combined functions (Fig. 3): 1/4 = lifting + dumping 2/4 = lowering + dumping 2/3 = lowering + rearward tilting When 2 functions are selected together, e.g. 1/4, 2/3 or 2/4, the two selected movements are performed at the same time.

The lifting frame can, for instance be raised in position 1/4 while the bucket is dumping. This is quite usefule when loading material onto vehicles.

After emptying the bucket, select combined function 2/3 Lowering and Rearward tilting, so that the bucket is already in the required digging position when it reaches the ground.

When two bucket movements are combined, the respective hydraulic circuits work are being connected in series. If the hydraulic system reaches its maximum admissible pressure in the combined mode, the bucket movements must be executed one after another.

Fig. 2

86

It is possible to pass from Lifting directly to Rearward tilting without going back to "0" before. Lifting is then suspended until the lever is shifted back to this function. The above-described mode (priority mode) facilitates loading of material at the working face.

OPERATOR’S MANUAL 21D / 121D / 221D Control lever - 3rd/4th function

Control lever locking

Control lever (26, Fig. 4) serves to switch additional hydraulic functions, e.g. hydraulic quickchange device, bottom-dump bucket, sweeper.

The control levers (25 and 26, Fig. 5) are equipped with a mechanical locking device which can be used to block the functions of the working hydraulics (e.g. during road travel).

Fig. 4

Fig. 5

Locking the control levers

Quick-change device The wheel loader is equipped with a hydraulic quick-change device. Control lever (26, Fig. 4) has the following functions: Lever (26) forwards - quick-change device unlock Lever (26) backwards - quick-change device lock

Pull up locking device (7, Fig. 5) slightly, turn left and release.

Unlocking the control levers To unlock the control levers pull locking device (7) upwards and turn right.

87

OPERATOR’S MANUAL 21D / 121D / 221D OPTIONAL EQUIPMENT Bottom-dum bucket

1946642

When the machine is operated with a bottom-dump bucket, lever (1, Fig. 6) must be set to position II (upwards).

Sweeper

2904995

Before setting off, lower the rotary cleaner to the ground and switch on while the wheel loader is stationary.

Observe the sweeper manufacturer’s operator’s manual.

Control lever (26) is used to initiate the following working movements eingeleitet: When the sweeper is attached, control lever (25, Fig. 2) must be in position "0". To switch over to rotary cleaner operation, push control lever (26, Fig. 4) forwards and lock in this position. After sweeper operation, control lever (26) must be brought back to position "0".

Fig. 6

Control lever (26, Fig. 4) forwards - bottom-dump bucket open Control lever (26) backwards - bottom-dump bucket closed With other equipment, the control lever must be moved accordingly.

Connection of hydraulic lines, refer to "Attaching the bottom-dump bucket" in the equipment chapter.

88

OPERATOR’S MANUAL 21D / 121D / 221D After daily operation

1946645

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. 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).

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 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. 1Apply the parking brake. The travel selector switches to neutral. Set control lever to position "0". Shut off engine. Remove gross dirt from the machine. Visual inspection: check hydraulic system for leaks. Visual inspection: check condition of machine, tyres and equipment. Protect the machine against unauthorized starting.

Withdraw key from ignition switch. Close windows.

Lock cab door and engine hood.

Fig. 1

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

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

89

OPERATOR’S MANUAL 21D / 121D / 221D WORKING EQUIPMENT Assembling working equipment - safety instructions

2913013

Personnel

Tools and auxiliaries

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

Tools, hoists, slings, chocks and other devices must be in a reliable, safe state.

The operator’s manual, and in particular the section headed "Fundamental Safety Instructions", must have been read and understood.

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

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

Metal splinters may cause injury when accessory bolts are being driven in or out. A brass or copper mandrel should therefore be used for this purpose, and goggles must be worn.

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

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

Personal protective gear and working clothing

Securing working equipment

Wear closely fitting working clothing when working on the machine.

Loose, wide garments may catch on machine parts and result in injury.

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

Wear a safety helmet, safety footwear and gloves.

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.

90

OPERATOR’S MANUAL 21D / 121D / 221D 2905636

Securing the machine Carry out work on the attachment only if the machine is secured as decribed 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 us.

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 conformity from attachments’s manufacturer are at hand.

If the wheel-mounted loader is equipped with a bucket for lightweight 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 quick-change device, ensure before beginning work that the quickchange device is safety locked with the working equipment.

1946672

The maximum operating pressure at the quick-change device and the hydraulic ports for attachments is: 200 + _5 bars (20.000 + _500 kPa).

91

OPERATOR’S MANUAL 21D / 121D / 221D ATTACHMENTS

1946701

Quick-change device The wheel loader can be used with various attachments. To permit the rapid exchange of the working equipment attached, the wheel loader is equipped with an incorporated hydraulic quickchange device.

Drive forwards to bring lifting frame (10) and bucket (11, Fig. 2) in mounting position (Fig. 2).

Do not raise the lifting frame in retracted position without attachment. Risk of damage to the toggle link and the connecting rod because of absent bucket limit stops.

After attachment of working equipment (bucket, equipment carrier, etc.) the lever (Fig. 1) must always be set to position II to prevent an inadvertent release of the quickchange device.

Bucket

Fig. 2

Drive wheel loader so that the upper pin (2, Fig. 3) of the lifting frame engages the suspension (4, Fig. 3) on the bucket.

Attaching the bucket When changing the working equipment, the pins (3, Fig. 3) must be maintained in the retracted position with control lever (26, Fig. 5).

After releasing the lever, the pins (3) are extended for reasons of safety.

The quick-change device control lever (1, Fig. 1) must be in position "I".

Fig. 1

Set bucket on the ground.

92

Fig. 3

OPERATOR’S MANUAL 21D / 121D / 221D When pin (2) is engaged, pull control lever (26, Fig. 5) briefly forwards (to unlock) and then push backwards to cause the lower pins (3, Fig. 4) to engage in the lifting frame as shown in Fig. 4.

Checking the bucket locking Raise bucket slightly (transport position). When pin (3, Fig. 6) is properly locked, pins (3) are visible at the outer edges (arrow).

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

Fig. 4

Lock up control lever (26, Fig. 5) with locking device (7).

Fig. 6

Detaching the bucket When changing the working equipment, the pins (3, Fig. 3) must be maintained in the retracted position with control lever (26, Fig. 5).

After releasing the lever, the pins (3) are extended for reasons of safety.

Fig. 5

Set bucket on the ground and unlock control lever (26).

Unlock the quick-change device. To do so, pull control lever (26) forwards.

Tilt lifting frame in such a way that pin (2, Fig. 7) can be withdrawn from under the bucket suspension hook by reversing the loader.

Fig. 7

93

OPERATOR’S MANUAL 21D / 121D / 221D Four-in-one bucket (Option)

1946702

Attaching the four-in-one bucket Attach the four-in-one bucket (bottom-dump bucket) as described under "Attaching the bucket".

Shut off the engine and depressurize the hydraulic system by actuating the control levers (25 and 26) until all working movements of the equipment have stopped.

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

The hydraulic hoses must not cross each other.

Fig. 1 = 21D Fig. 3

The hydraulic hoses must be connected in such a way that the following working movements are being performed when control lever (26, Fig. 4) is operated: Lever (26) forwards - four-in-one bucket (bottomdump bucket) open Lever (26) backwards - four-in-one bucket (bottom-dump bucket) closed Fig. 1

Fig. 2 = 121D / 221D

Fig. 4

If this is not the case, the hydraulic hoses (1 and 2) must be connected the other way.

Fig. 2

Pull lever (1, Fig. 3) upwards into position II.

94

OPERATOR’S MANUAL 21D / 121D / 221D The eyelet (3, Fig. 5) provided on the four-in-one bucket (bottomdump bucket) must only be used for transporting the bucket.

It must not be used for the transport of loads.

Detaching the four-in-one bucket (bottom-dump bucket) Set four-in-one bucket (bottom-dump bucket) on the ground.

Pull lever (1, Fig. 3) backwards into position I and unlock the quick-change device by means of control lever (26). Shut off the engine and depressurize the hydraulic system by moving the lever until all working movements of the equipment have stopped. Detach the hydraulic lines (1 and 2). Close the hydraulic lines and connections with the pertaining plugs.

Proceed as described under "Detaching the bucket".

Fig. 5

95

OPERATOR’S MANUAL 21D / 121D / 221D Equipment carrier with lifting forks

2913067

Attaching the equipment carrier

Removing the equipment carrier

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

Remove as described under "Detaching the bucket".

Lifting forks The total weight of the loader has an influence on its tilting moment.

The stability coefficient to be observed is determined by the condition of the working area.

Loads placed at a distance of more than 500 mm from the loader’s centre of gravity reduce the payload.

Fig. 1

The maximum admissible payloads for different tilting moments and stability coefficients are set out in the Technical Specifications section.

The payload is the load to be lifted with the fork including its packing.

Pallets, cases and means of suspension are part of the payload.

Fig. 2

Fig. 3

96

OPERATOR’S MANUAL 21D / 121D / 221D Working with lifting forks Lock control lever (26) with blocking device (7, Fig. 4).

Setting down loads During unloading, the loader must be in horizontal position. The place of unloading must neither be sloping lengthwise nor laterally.

Raise the load to the required height only just before reaching the place of unloading.

Do not leave the machine with the load in raised position.

During interruptions of the work, always set lifting forks down on the ground.

Always make sure the fork is inclined backwards when lifting loads. Always approach the place of unloading with the load in raised position.

Fig. 4

Taking up loads To take up the load, move up slowly towards the load. Bring the lifting forks to horizontal position and raise to the required height. Push the forks under the load or into the pallet bottom. Lift up the load, tilt the forks backwards and raise load to transport height. The transport height is the height between the ground the lower edge of the forks. It should not be greater than 30 cm.

Bring the forks to horizontal position, lower the load and set down. Lower the forks again after reversing the loader.

Transporting loads During transport, the fork carrier must always be tilted rearwards. Pull lever (25, Fig. 5) to position 3 (rearward tilt). When travelling uphill or downhill, the load must always face the uphill side.

Fig. 5

97

OPERATOR’S MANUAL 21D / 121D / 221D Floodlamps, front

1946869

The floodlamps are mounted at the top right and left on the cab.

Rotary beacon (option)

2747582

The rotary beacon (1, Fig. 1) is mounted by means of a magnetic foot on a marked area at the front left of the cab roof.

Fig. 1 Fig. 1

• Floodlamps ON. - Press toggle switch (34, Fig. 1) onto area with symbol.

A socket is provided at the front left of the lower cab area (Fig. 2).

• Floodlamps OFF - Press toggle switch (34) onto symbol-free area.

Floodlamps, rear (option)

1946870

The floodlamps are mounted at the top right and left on the cab.

Fig. 2

Fig. 2

• Floodlamps ON. - Press toggle switch (35, Fig. 2) onto area with symbol.

• Floodlamps OFF - Press toggle switch (35) onto symbol-free area.

98

OPERATOR’S MANUAL 21D / 121D / 221D Acoustic reversing signal (Back-up alarm) (option)

1946872

The wheeled loader can be equipped on request with an disconnectable acoustic reversing signal.

Fig. 3

• Rotary beacon ON - Press toggle switch (33, Fig. 3) onto area with symbol.

Fig. 4

• Rotary beacon OFF - Press toggle switch (33) onto symbol-free area.

The rotary beacon can be removed from the cab roof and put down by means of a magnetic foot on a marked area in the box left from the drivers seat.

When the loader is being driven on the highway, the acoustic reversing signal must be switched off.

• Acoustic reversing signal ON - Press toggle switch (32, Fig. 5) onto area with symbol.

• Acoustic reversing signal OFF - Press toggle switch (32) onto symbol-free area.

99

OPERATOR’S MANUAL 21D / 121D / 221D Pipe-break safety system (optional equipment)

2913070

Without shut-off possibility The control lever (25, Fig. 1) cannot be set to floating position (position 2a)

If these measures cannot be performed as foreseen (e.g. danger to life and limb of persons), proceed as follows: • Shift working equipment control lever immediately to position 0.

• Warn bystanders with the signal horn.

• Secure the area of the working equipment in such a way that nobody can stand below the equipment and the load or in the vicinity of the broken hydraulic line.

Lowering the working equipment to the ground will cause oil to flow out of the hydraulic line at the point of fracture. Take suitable measures to keep the amount of oil spilt on the ground as small as possible.

Fig. 1

The tipping and the two lifting cylinders can be equipped with pipe-break safety systems. These systems prevent the working equipment from uncontrolled lowering when a hydraulic line to the cylinders breaks.

The hydraulic port of the cylinder concerned is blocked off so that the hydraulic oil cannot escape from the cylinder.

When a hydraulic line is broken: • Shift the working equipment control lever immediately to position 0.

• Warn bystanders with the signal horn.

• Secure the area of the working equipment in such a way that nobody can stand below the equipment and the load or in the vicinity of the broken hydraulic line.

• Support the equipment to prevent it from lowering.

• Replace the broken hydraulic line (or have it replaced).

Only thereafter can the work be resumed.

100

• Place the working equipment gently on the ground.

• Collect escaping hydraulic oil. Dispose of oilsoaked cleaning rags, oil-binding agents and so on without polluting the environment.

• Replace the broken hydraulic line (or have it replaced) before continuing to work with the machine.

Only thereafter can the work be resumed.

OPERATOR’S MANUAL 21D / 121D / 221D PART 3 - INSPECTION AND SERVICING

Operator’s 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 knowhow relevant to the operation and the application of this or comparable machines.

Inspection and servicing personnel

Part 3 INSPECTION AND SERVICING

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

Repair personnel

Part 4 REPAIR WORK

Part 5 ANNEX

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

101

OPERATOR’S MANUAL 21D / 121D / 221D

BLANK PAGE

102

OPERATOR’S MANUAL 21D / 121D / 221D INSPECTION AND SERVICING - SAFETY INSTRUCTIONS

2913043

Operator’s manual

Securing working equipment

No inspection and servicing work may be carried out until the operator’s manual has been read and understood.

Pay special attention to the:

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

"Fundamental Safety Instructions" and all warnings and safety instructions attached to the machine.

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

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

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

The operator’s manual must be kept with the machine at all times.

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

The necessary know-how can be acquired in several days’ instruction.

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.

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.

103

OPERATOR’S MANUAL 21D / 121D / 221D

Cleaning jobs Clean the units within the working range before starting work.

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

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

Replace any damaged parts.

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

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

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

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

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

Wear gloves.

Observe the instructions on the packaging.

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

Never set foot within reach of the emerging oil jet.

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

Used oil may be harmful to the skin.

Clean soiled skin thoroughly with warm soapy water. Never use fuels or solvents for cleaning the skin.

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

Handling flammable liquids When handling flammable liquids: - never smoke, - keep away from unshielded light sources and naked flames.

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

Never attempt to extinguish burning liquids with water. Use - dry powder, - carbon dioxide or - foam extinguishers.

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.

104

Visible loss of oil Have any visible leakage repaired immediately.

Escaping oil is an environmental hazard.

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

OPERATOR’S MANUAL 21D / 121D / 221D

Relieving residual pressure in the hydraulic system

Environmentally compatible disposal

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

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

Residual pressure is relieved only gradually. If work is to be done on the hydraulic system as soon as the machine is stopped, the system must be depressurized: -

Set all equipment on the ground Switch off the engine Move all control levers and pedals repeatedly in all directions.

Never dispose of such substances with standard household refuse.

Empty substances into the containers provided for this purpose.

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

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

Sealing faces Screwed connections, piping, hydraulic hoses

Clean sealing faces prior to assembly.

Repair any leakages in the piping and hose system immediately.

Exhaust gases

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

Exhaust gases are a health hazard: never inhale them.

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

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

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

Never repair damaged piping; always replace it.

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

Tighten leaking screw plugs only when the system is depressurized.

Escaping oil is an environmental hazard.

105

OPERATOR’S MANUAL 21D / 121D / 221D

Handling batteries

Selecting oils and greases

Batteries give off explosive gases.

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

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

Battery acid is toxic and corrosive.

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

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

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

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

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

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

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

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

Filters Replace all filter elements or filter cartridges within the specified periods if cleaning is not explicity authorized.

All filters are coordinated carefully with the equipment. Original spares 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.

Disconnect first the negative pole, then the positive pole.

On completing work, reinstall all protective devices.

After work:

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

Connect first the positive pole, then the negative pole.

Carry out a performance test with the machine.

106

OPERATOR’S MANUAL 21D / 121D / 221D MAINTENANCE WORK

2800434

Securing the machine

Opening the engine hood

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

Prior to carrying out any servicing work in the engine compartment, open the engine hood (2, Fig. 1).

• Park machine on level and firm ground.

• Stand working equipment on the ground.

2747162

Press handle (1) and pull engine hood (2) upwards with the handle (1).

• Block articulated joint.

• Shut off engine.

• Apply the parking brake.

• 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 - safety instructions and cf. section "Electrical system safety instructions") Fig. 1

The engine hood (2) is kept in its limit position by pneumatic spring.

To close the engine hood (2), pull it down with the handle (1) until it locks.

107

OPERATOR’S MANUAL 21D / 121D / 221D SERVICING Draining hose for oil changes

2411336

Collect escaping oil and evacuate it without polluting the environment.

Operating-hours meter

2905175

The operating hours are shown on the meter (Fig. 1).

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

The engine, hydraulic oil reservoir and gearboxes may be equipped with special oil drain valves (1, Fig. 1).

These plugs permit to perform oil changes in a clean and non-polluting way.

Fig. 1

The operating-hours meter shows the total machine operating time.

Fig. 1

Carry out oil changes as follows: - Place a recipient for waste oil under the drain opening (for the capacity see under "Filling quantities").

- Choose the proper drain hose from the tool kit.

- Unscrew protective cap from oil drain valve.

- Screw on drain hose (2); the valve opens and the oil drains away.

- After the oil has drained away unscrew drain hose; the valve closes automatically.

- Screw protective cap back in place.

108

OPERATOR’S MANUAL 21D / 121D / 221D Inspection and servicing plans - instructions

2913017

Intervals

Change of engine oil

The inspection and servicing plans list all jobs which have to be done on the machine at regular intervals.

The intervals stated for changing the engine oil apply to fuels with a sulphur content < _ 0.5% and a permanent ambient temperature down to -10˚C.

The individual inspection and servicing plans are marked with letters providing a link between the operating hours (HOURS) recorded by the hoursrun meter of the machine and the inspection and servicing plans.

In case of higher sulphur content and/or a permanent ambient temperature of below -10˚C, shorter intervals are required (see engine operator’s manual).

Meanings: Plan

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

Do all jobs...

Oil / Greases

V

... once prior to initial commissioning.

N

... after initial commissioning.

The "Lubricants" section quotes the specifications of the oils and greases to be used.

T

... every 10 HOURS or every working shift1).

Meanings:

W

... every 50 HOURS or once a week1).

B

... every 500 HOURS

C

... every 1000 HOURS

D

... every 3000 HOURS

1)

whichever comes first.

HOURS = Operating hour

I

Oils for combustion engines and compressors

II

Oils for hydraulic systems

III

Oils for gearboxes and axles

V

Grease for bearings and pivoted connections

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

Servicing material The servicing material required for regular servicing work can be found in the spare parts list.

109

OPERATOR’S MANUAL 21D / 121D / 221D Plan V - once prior to initial commissioning

2913018

Component designation

Servicing activity

Engine

Check oil level

Cooling system Coolant level

Check

1 1

Lighting system

Check electrolyte level and charge condition 1) Check functioning

Warning, control and monitoring elements

Check functioning

Hydraulic system Oil reservoir System pressure

Check functioning Check oil level Check system pressure

Brake

Check functioning

Wheel Tyres Wheel nuts

Check pressure Check for tightness (torque wrench)

Axle Front axle Rear axle Transfer gearbox Planetary gearbox Rear axle suspension

Check oil level Check oil level Check oil level Check oil level Grease

Equipment Tilting cylinder bearing Lifting cylinder bearing Bucket bearing Quick-change device Bottom-dump bucket

Grease Grease Grease Grease Grease

Lines, fittings and connections

Check visually for leaks

Chassis Articulated joint

Grease

Lifting frame Lifting arm Toggle link Connecting rod

Grease Grease Grease

Steering Steering cylinder bearing

Grease

Electrical system Battery

1)

not applicable with maintenance-free battery

110

Oil / Quantity/ Grease Number

OPERATOR’S MANUAL 21D / 121D / 221D Plan N - After initial commissioning Component designation

Servicing activity

Oil / Quantity/ Grease Number

After 5 HOURS (once) Wheel nuts

Retighten

4x8

Every 4 HOURS: up to 250 HOURS Engine

Check oil level

After 30 - 50 HOURS (once) Engine Oil filter Idling speed V-belt tension Leaks Engine support fastening screws Valve play

Change oil Replace Check Check Check visually Check tightness (torque wrench) Check and adjust if necessary

Cooling system Coolant level

Check

Fuel system Fuel filter

Replace

Hydraulic system Return-flow filter Pressure

Check functioning Check visually for leaks Replace Check

Wheel Wheel nuts

Check tightness (torque wrench)

Axle Front axle Rear axle Transfer 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

1

1

1

111

OPERATOR’S MANUAL 21D / 121D / 221D Plan T - All 10 HOURS or each working shift (whichever occurs first) Plan W - All 50 HOURS or weekly (whichever occurs first) Component designation

Servicing activity

Oil /

Quanti- Plan ty/ Grease Number T

Plan W

Machine

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

•

•

Engine

•

V-belt

Check oil level in acc. with oil-checking chart Check

• •

Cooling system Coolant level

Check

•

•

Fuel system Water separator

Drain off water

1

•

•

Check for accumulated dust / empty collector Check visually for leaks

1

• •

• •

• • • •

• • •

Air-intake system Air filter - dust collector valve Suction and clean-air line Electrical system Battery Lighting system Battery and cable connections

Check electrolyte level and charge condition 1) Check functioning Check for condition and tightness

Warning, control and monitoring elements

Check functioning

Hydraulic system Oil reservoir Return-flow

Check visually for leaks Check oil level in acc. with oil-checking chart Check return-flow pressure

Brakes

Check functioning

Wheel Tyres Wheel nuts

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

Axle Rear axle suspension

Grease in acc. with lubricating chart

1)

not applicable with maintenance-free battery

112

1

1

• • • •

• • • • • • • •

OPERATOR’S MANUAL 21D / 121D / 221D Plan T - All 10 HOURS or each working shift (whichever occurs first) Plan W - All 50 HOURS or weekly (whichever occurs first) Component designation

Servicing activity

Oil /

Quanti- Plan ty/ Grease Number T

Plan W

Equipment Tilting cylinder bearing Lifting cylinder bearing Bucket bearing Quick-change device Bottom-dump bucket

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

• • • • •

Chassis Articulated joint

Grease in acc. with lubricating chart

•

Lifting frame Lifting arm Toggle link Connecting rod

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

Steering Steering cylinder bearing

Check functioning Grease in acc. with lubricating chart

• • • • •

113

OPERATOR’S MANUAL 21D / 121D / 221D Plan B - after every 500 HOURS

Plan D - after every 3000 HOURS

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

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

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

Servicing activity

Oil / Quantity / Plan Plan Plan Grease Number B C D

•

•

•

• • • • • •

• • • • • • • • •

• • • • • • • • •

1 1

•

•

1

•

•

• • • •

•

•

•

Servicing in acc. with W or T Engine Oil filter Valve play Alternator and starter Crankcase venting filter Heater plug Cooling system

Change oil in acc. with oil-checking chart 1) Replace Check and adjust if necessary Check Replace Check

1

Coolant

Check visually for leaks Check / clean Check anti-freeze 2)

Fuel system Filter Tank Injection valve Water separator

Replace Drain off impurities Check Clear

Electrical system Cable and connector

Check

Ait intake system Filterelement

Replace

1

•

•

•

Replace Replace Clean Change oil in acc. with oil-checking chart 3)

1 1

• •

• •

• • • •

• • •

• • •

Hydraulic system Return-flow filter Breather filter Oil cooler fins Oil reservoir Brakes Multiple-disk brake Braking pressure Accumulator pressure 1)

Check lining thickness Check1) Check1)

After 1 year at the latest Coolant change after 2 years at the latest 3) Hydraulic oil change after 3 years at the latest 2)

114

1

2

OPERATOR’S MANUAL 21D / 121D / 221D Plan B - after every 500 HOURS

Plan D - after every 3000 HOURS

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

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

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

Axle Planetary gearbox Front axle Rear axle Transfer gearbox Planetary gearbox

Servicing activity

Check oil level in acc. with oil-checking chart Change oil in acc. with oil-checking chart 1) Change oil in acc. with oil-checking chart 1) Change oil in acc. with oil-checking chart 1) Change oil in acc. with oil-checking chart 1)

Cardan shaft

Grease in acc. with lubricating chart

Heating Filter

Check for leaks Clean / replace

Driver’s cab Fastening screws Breather filter Hinges

1)

Check tightness Replace Grease in acc. with lubricating chart

Oil / Quantity / Plan Plan Plan Grease Number B C D

•

• • • • •

• • • • •

•

•

•

1

• •

• •

• •

1 2

• • •

• • •

• • •

2x2 1 1 1 2x2

Oil change after 1 year at the latest

115

OPERATOR’S MANUAL 21D / 121D / 221D LUBRICATING CHART - GREASE

Fig. 1

116

= Operating hours

2913071

OPERATOR’S MANUAL 21D / 121D / 221D Lubricating chart - grease (key to chart) Item.

Greasing point

1 2 3

Hydraulic system steering cylinder tilting cylinder lifting cylinder

4 5

Number

Lubricant properties 1)

Greasing every .... operating hours

2 2 2x1

50 50 50

Rear axle suspension

2

50

Chassis articulated joint

2

V 1)

50

6 7 8 9 10

Lifting frame lifting arms tie-rod rocker quick-change device lever

2x2 2 1 4 2

50 50 50 50 50

11 12 13

Working equipment bucket bearing bottom-dump bucket bottom dump bucket cylinder

2 2x2 2x2

50 50 50

14

Cardan shaft

2

500

15

Driver’s cab hinges

2x1

500

1) See "Lubricants V"

Joints and hinges

2411970

Grease or oil all joints and hinges in accordance with the inspection and servicing plan.

117

OPERATOR’S MANUAL 21D / 121D / 221D OIL INSPECTION PLAN

Fig. 2

118

= Operating hours

2913072

OPERATOR’S MANUAL 21D / 121D / 221D Oil inspection plan (key to chart) Pos.

Component

Number

Lubricant properties

Check oil level every .... operating hours

Change oil every .... operating hours

1

Engine

1

I

10

500

7

Hydraulic system

1

II

10

3000

10

Axles - front axle - rear axle - transfer gearbox - planetary gearbox

1 1 1 2x2

III III III III

------500

1000 1000 1000 1000

Refilling quantities - Oil Component

Engine

ca. 8.5

ca. 8.5

Hydraulic system

ca. 60

ca. 65

ca. 3.7 ca. 3.7 ca. 1.0 ca. 4 x 0.5

ca. 3.7 ca. 3.7 ca. 1.0 ca. 4 x 0.5

Axles front axle rear axle transfer gearbox planetary gearbox 1)

Refilling quantity1) (liters) 21D 121D / 221D

The consumables refilling quantities specified are approximate values intended as a planning help.

Each unit is equipped with suitable checking means such as dipstick, inspection glass or checking plugs permitting exact checking of the filling levels.

Refilling quantities - Other Component

Fuel tank Cooling system

Refilling quantity1) (liters) 21D 121D / 221D ca. 90

ca. 100

ca. 15.5

ca. 15.5

119

OPERATOR’S MANUAL 21D / 121D / 221D LUBRICANTS

I.

API:

Oils for internal combustion engines

2732720

American Petroleum Institute

ACEA: Association des Constructeurs Européen d’ Automobiles g.i.e.

CCMC: Committee of Common Market Automobile Constructors Engine pre-heating necessary. Cold-starting aid may be sufficient un upper range. Follow with a warming-up phase. When warming-up, increase engine speed and loading gradually.

When using single-range or other multi-range motor oils, and at temperatures lower than those stated, the oil recommendations of the engine manufacturer are to be observed. For directions, see engine instruction manual.

120

OPERATOR’S MANUAL 21D / 121D / 221D

II.

Oils for hydraulic system, mineral

2801009

Warming-up phase necessary before commencing operation.

Warm-up hydraulic system for approx. 10 minutes, running at half speed and with repeated.

121

OPERATOR’S MANUAL 21D / 121D / 221D

III.

Oils for axles and gearboxes (selection)

Oils of inferior quality may cause damage to axles and gearboxes.

Use only high-quality oils with additives in the prescribed amount (see "Specification").

API:

American Petroleum Institute

MIL:

US armed forces fuel specifications for engine and machine manufacturers

LS:

Limited slip

P+S:

Phosphorus and sulphur doping as with Anglamol 99

* e.g.: Titan Gear LS 90 Fina Pontonic LS 90 BP Energear LS 90 Ambra TX Fluid

122

2905902

OPERATOR’S MANUAL 21D / 121D / 221D

V.

Greases for bearing points and slewing rings

2732723

for centralized lubricating systems and tensioning systems, e.g. driving chain Minimum requirement Grease base

:

Lithium

Solid lubricant content (MoS2 or graphite)

:

max. 3%

NLGI - class

:

see above

Corrosion protection acc. ASTMD 17 43 (CRC)

:

code No. 1

123

OPERATOR’S MANUAL 21D / 121D / 221D ENGINE

2800440

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 2913020 up oil Bring engine oil to operating temperature.

• Park machine on a horizontal surface and protect against inadvertent movement.

• Shut off engine.

• Wait one minute, then pull out dipstick (1, Fig. 1).

Wipe dipstick (1) with a lint-free cleaning rag and re-insert into opening.

Wear working gloves.

Secure the machine as described in the section "Securing the machine".

Read and observe: "Inspection and Servicing, Safety Instructions".

Fig. 1

• Withdraw dipstick again. The oil level should now be between the markings. If the oil level is at or below the "min" mark, top up engine oil through filler pipe (3, Fig. 2).

Fig. 2

124

OPERATOR’S MANUAL 21D / 121D / 221D Changing the engine oil Risk of scalding through hot engine oil.

Collect escaping oil and discard in accordance with local environmental regulations.

Read and observe: "Inspection and Servicing - Safety instructions".

• Bring engine up to operating temperature.

• Park machine on a horizontal surface and protect against inadvertent movement.

• Shut off engine.

Fig. 4

To gain access to the oil drain plug, the cover at the rear below the loader must be unscrewed.

• Unscrew hex screw (13, Fig. 3), push grating backwards, then swing it downwards and take off.

Fig. 5

When the engine oil has drained off: • replace engine oil filter • unscrew draining hose (19) and screw cap back in place Fig. 3

Place a collecting receptacle under the drain plug. Capacity: see "Filling quantities" table.

Unscrew cap (5, Fig. 4), screw on supplied hose (19, Fig. 5) and drain off engine oil.

The handling of the draining hose is described under "Draining hose for oil change".

• fill in engine oil through the filler pipe (3, Fig. 2) until the oil level reaches the "max" mark • start up engine and run at idling speed for about 2 minutes • check oil level and top up to "max" mark if necessary.

• On completion of engine servicing work, refit cover (14, Fig. 3) on rear frame with hex screws (13).

125

OPERATOR’S MANUAL 21D / 121D / 221D Replacing the engine oil filter Risk of scalding through hot engine oil.

Collect escaping oil and discard in accordance with local environmental regulations.

Crankcase ventilation Unscrew screws (8, Fig. 7) and remove cap (9).

Remove membranes (10), washer (11) and spring (12).

The oil filter is equipped with a valve and a special tube to prevent oil from flowing back.

So use original filter cartridges only.

• Loosen filter cartridge (6, Fig. 6) with a strap wrench or similar tool and unscrew.

Fig. 7Release clamp (13, Fig. 8) on ventilation pipe (14) and remove ventilation pipe (14).

Fig. 6

• Clean filter head (7).

• Fill new filter cartridge (6) completely with unused, clean engine oil (this may take some time).

Fig. 8

• Apply clean engine oil to seal of filter cartridge (6).

• Clean recess of valve cover (15) for crankcase ventilation and ventilation pipe (14). Fit new membranes (10), washer (11) and spring (12) into recess of valve cover (15).

• Install new filter cartridge (6) and tighten only by hand without using tools.

During the trial run, check for perfect sealing of the oil filter cartridge (6). Then check oil level and top up if necessary.

Ensure that the crankcase ventilation components are installed in their correct position (see Fig. 7).

Incorrect assembly may result in damage to the engine.

Put cap (9) in place and fix with screws (8). Install ventilation pipe (14) and fasten with clamp (13).

Replace crankcase ventilation system after 2000 OPERATING HOURS. Our local dealer will be pleased to advise you.

126

OPERATOR’S MANUAL 21D / 121D / 221D Valve clearance

COOLING SYSTEM

1946673

Cooling agent specification The valve clearance is measured with a feeler gauge between the upper valve shaft and the rocker arm (Fig. 9) while the engine is cold. The correct clearance is 0.35 mm for intake valves and 0.35 mm for outlet valves.

The quality of the cooling agent is of great importance for the efficiency and the service life of the cooling system. The observance of the following hints ensures high cooling performance and protects the cooling system against frost damage and/or corrosion.

The protection against corrosion is especially important if the cooling system contains parts of aluminium. Therefore, use only agents on an ethylene glycol base as anti-corrosives. This agent must be mixed with water als clean and as soft as possible.

Fig. 9

The valve arrangement is shown in Fig. 10. The valve numbers refer to cylinder no. 1 at the front of the engine.

The mixture should consist of 50% water and 50% anti-corrosive. The cooling system is then protected down to temperatures of -30˚C to -35˚C. With an anti-corrosive concentration of less than 50%, the corrosion-protection effect is affected whereas a concentration of above 50% impairs the cooling performance.

The antifreeze content in the cooling agent must be checked before the winter begins.

The cooling agent is to be replaced completely every two years.

Risk of scalding due to hot cooling liquid.

Fig. 10

Risk of injury from hot parts of the engine and the radiator.

Read and observe "Inspection and servicing, safety instructions.

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

127

OPERATOR’S MANUAL 21D / 121D / 221D Checking the cooling liquid level

Changing the cooling liquid

Check the cooling liqid level every day.

Risk of scalding due to hot cooling liquid. Drain the cooling liquid only after it is cool enough.

Discard cooling liquid without polluting the environment Change the cooling liquid every two years .

Changing or draining of the cooling liquid is otherwise necessary only in the event of repairs or defects of the cooling system.

For this purpose, a drain plug (3, Fig. 2) is located under the radiator (2).

Fig. 1

• When the engine is at operating temperature, the coolant level must be visible between the MAX and MIN marks. If this is not the case, top up with cooling liquid.

Fig. 2

Unscrew the drain plug (3) and collect the cooling liquid in a recipient. Recipient capacity: see table of filling quantities.

After complete drainage, screw the drain plug (3) back in place. Fill in cooling liquid through the filler neck (1, Fig. 1).

After a short trial run, recheck the coolant level and top up, if necessary.

128

OPERATOR’S MANUAL 21D / 121D / 221D AIR-INTAKE SYSTEM Read and observe: "Inspection and Servicing - Safety instructions".

Risk of injury through hot engine components.

2913082

Clean or replace main filter element when the warning lamp (4, Fig. 2) lights up. The main filter element must be cleaned or replaced even if the replacement interval has not yet expired.

Carry out servicing and repair work only when the machine is secured as detailed under "Securing the machine".

Never start up the engine when parts of the air-intake system have been detached.

The engine may be damaged if unfiltered air is drawn in.

The wheeled loader is equipped with a dry-air filter (Fig. 1) consisting of a main filter element and a safety element. The dry-air filter is located under the engine hood.

Fig. 2

Dust-discharge valve Check that the discharge slot of the dust-discharge valve (8, Fig. 3) is not clogged. Remove any dust deposits by pressing the valve lips together.

Fig. 1

Fig. 3

129

OPERATOR’S MANUAL 21D / 121D / 221D Removing, checking and cleaning the main filter element Release clip fasteners (5, Fig. 4) and remove dust collector (6).

Inspection work prior to installing the main filter element:

Withdraw main filter element (1, Fig. 5) carefully.

• Check filter paper, using a bulb (Fig. 6).

Damaged areas can be seen where the light shines through the element. Replace main filter element immediately if damaged.

Fig. 4

Fig. 6

• Inspection of filter seal (13, Fig. 7). The main filter element must be replaced immediately if damaged.

• Visual inspection of air-intake line between filter and engine for leaks and tight fit. The air-intake line must show no sign of damage.

• Check connecting hose between filter and intake-air line for tight fit and integrity. Use only screw-type hose clamps.

Fig. 5

The safety element remains in place. Clean or replace filter element. Before installing a new main filter element, give the sealing surface of the element a thin coating of oil, Vaseline or similar lubricant. A new or cleaned main filter element is installed in reverse sequence.

When installing dust collector, watch for "TOP" mark.

Turn dust collector (6) slightly to left or right to engage the guide pin in the filter housing. Then close clip fasteners (5, Fig. 4).

Fig. 7

When a new or cleaned main filter element has been fitted, the warning lamp (4, Fig. 2) must go out.

130

OPERATOR’S MANUAL 21D / 121D / 221D Cleaning the main filter element

Checking / replacing safety filter

Dry-cleaning

Never start up the engine when the safety filter element has been removed.

Never clean filter elements by beating them against hard objects.

The main filter element must be replaced after 3 cleaning cycles, but not later than after one year of operation.

The filter element can be cleaned with compressed air if it is to be re-used immediately.

The pressure at the cleaning nozzle must not exceed 5 bars.

The unfiltered air then drawn in may damage the engine.

The safety filter element must be replaced if it becomes apparent during servicing of the dry-air filter that the main filter element is damaged or has been incorrectly serviced.

If the warning lamp (4, Fig. 2) goes on again immediately after the main filter has been serviced, the safety filter must be replaced.

Start by applying compressed air to the filter surface diagonally from outside (Fig. 8).

The safety filter must be replaced after 5 cleaning cycles of the main filter element, but not later than after 2 years of operation.

Fig. 8

Then apply compressed air to the inside of the element.

Cleaning is finished when no more dust is seen to emerge from the filter element.

Never beat the filter element against hard objects.

Fig. 9

Remove dust collector (6, Fig. 9) carefully after releasing the clip fasteners (5).

Never clean the filter with petrol or with flammable or hot liquids.

131

OPERATOR’S MANUAL 21D / 121D / 221D Withdraw main filter element (1, Fig. 10) carefully.

Checking air-intake lines Unfiltered air must not be allowed into the engine, so: • check all hoses and pipes for leaks and • check that all clamps are in place and have a tight fit.

Fig. 10

The safety filter element (2, Fig. 11) can then be withdrawn. Before installing a new safety filter element, give the sealing surface of the element a thin coating of oil, Vaseline or similar lubricant.

Fig. 11

Before installing a new safety filter element, the outlet nozzle of the filter housing and the manually accessible part of the air-intake line must be checked for dust deposits by inserting a finger inside the line. If dust is found in the air-intake line to the engine, contact your dealer immediately.

132

OPERATOR’S MANUAL 21D / 121D / 221D FUEL SYSTEM When working on the fuel system: - shut off the engine - avoid open fire - do not smoke Collect escaping fuel and discard without polluting the environment.

2905439

• Clean the outer sides of the fuel filter (5, Fig. 1) carefully.

• Tighten screw (14).

• Hold the filter bottom (15, Fig. 2) and slacken screw (14).

• Pull filter bottom (15) down.

Discard used filter cartridges without polluting the environment.

• Withdraw filter cartridge (5) and discard without polluting the envoiroment.

Diesel fuel may cause skin injury.

Wear protective gloves or use a barrier cream.

• Clean filter head and filter bottom (15).

Read and observe the "Safety Instructions".

• Replace seals (6 and 7) and the o-ring (9, Fig. 2) and smear slightly with clean fuel.

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

Fuel filter Filter cartridges delivered as spare cartridges have an internal seal (7, Fig. 2) held in place by a plastic ring.

Incorrect installation of the seals may cause damage the injection pump.

Fig. 2

• Hold filter bottom (15) under the new filter cartridge (5) and attach to the filter head. Make sure filter cartridge (5) sits properly on sealing ring (7).

• Vent the fuel system.

Fig. 1

133

OPERATOR’S MANUAL 21D / 121D / 221D Water pre-separator

Cleaning the fuel tank

Draining off water

Risk of explosion

Drain off the water from the water pre-separator (1, Fig. 3) every day.

Do not use white spirit, household kerosene or other solvents.

Use diesel fuel for cleaning and flushing.

Use up as much fuel as possible to empty the tank.

Unscrew plug (8, Fig. 4) at the bottom of the fuel tank draining off any remaining fuel by collecting it in a suitable recipient. Filter the collected fuel for re-use or discard without polluting the environment. Flush tank with diesel fuel.

Screw plug (8) back in place and fill in fuel through the filter sieve in the filler opening.

Fig. 3

To do so, open plug (2,Fig.3) and allow water to drain into a suitable recipient.

Close plug (2).

Cleaning the water pre-separator Clean water pre-separator (1) in accordance with Maintenance Plan B. To do so, loosen screw (3), remove recipient (4) and clean. Refit recipient (4) and tighten screw (3).

Fig. 4

Vent the fuel system in accordance with the Engine Operating Instructions.

134

OPERATOR’S MANUAL 21D / 121D / 221D Injection nozzles If your skin comes into contact with high-pressure fuel seek medical assistance immedialety.

Keep a sufficient distance from moving parts of a running engine.

Some moving parts cannot be seen clearly when the engine is running The injection nozzle do not require regular servicing. The nozzles should always be replaced and not cleaned. Replacement is, however, necessary only when an injection nozzle is defective. The main problems indicating the necessity of injection nozzle replacement are listed below: Engine cannot be started at all or started only with difficulties.

Insufficient engine power.

Engine misfirin or running erratically.

High fuel consumption.

Black exhaust smoke.

Engine knocking or vibrating.

Engine overheating.

To find out the defective injection nozzle, let the engine run at high idling speed. Slacken the union nuts at the injection lines of each injection pump one after another and retighten. Do not slacken the nut by more than a half turn. When the the union nut of the defective nozzle is slackened, the engine speed will change only slightly or not at all.

135

OPERATOR’S MANUAL 21D / 121D / 221D ELECTRICAL SYSTEM

2904905

Safety instructions 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".

Use only measuring instrument for voltage and continuity testing, never use a test lamp.

Never "tap against ground".

This causes a short circuit with consequent damage to the generator or to the electronics of the PCS.

Alternator, instructions

2913021

Switch off the engine before disconnecting electrical connections at alternator, regulator or batteries to prevent damage to the alternator and regulator.

When connecting the batteries, be sure not to switch over the cables (pay attention to polarity).

Voltage tests and continuity tests must be performed ONLY with appropriate instruments.

A test lamp must not be used.

Never "tape against ground".

This causes a short circuit with consequent damage to the alternator and regulator.

When the engine is being started up, the alternator is controlled (preexcited) by an electronic circuit.

This ensures that the alternator can discharge power.

The circuit is an integral part of the central electronic system on the control console.

Correct alternator functioning is indicated by a LED on the control console (charging control). This LED must light up when the keyswitch is switched on; it goes out when the engine is running.

If this is not the case, there is a fault in the alternator circuit or the control console.

The cause of the fault must be located and rectified as quickly as possible t o prevent further damage.

Contact our local dealer for assistance.

136

OPERATOR’S MANUAL 21D / 121D / 221D Battery main switch (option)

2905441

The battery main switch (1, Fig. 1) is located under the engine hood on the right, close to the battery.

Battery

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.

Never set battery main switch to OFF when the engine is running.

Electronic components may be irreparably damaged by voltage peaks.

The entire electrical system is disconnected from the battery with the battery main switch (1). The switch positions shown in Fig. 1 have the following meaning: I = ON II = OFF In OFF position, the battery main switch (1) prevents

Fig. 2

• unauthorized starting of the engine • inadvertent discharge of the battery.

Fig. 1

137

OPERATOR’S MANUAL 21D / 121D / 221D Battery - checking the fluid level

2411957

(Not applicable to maintenance-free batteries)

Battery - checking the charge

• Unscrew the caps.

The acid temperature should be 20˚C.

• If checking inserts are installed, the battery fluid must reach the bottom of the inserts.

• Unscrew the battery caps (Fig. 1).

• 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.

• 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.

• If the fluid level is too low, top up with distilled water only.

Fig. 1

Acid density in kg / dm3

138

Charge

Normal

Tropics

1.28

1.23

charged

1.20

1.12

half-charged, recharge

1.12

1.08

discharged, recharge at once

OPERATOR’S MANUAL 21D / 121D / 221D Removing and installing the battery Shut off the engine before removing batteries to prevent damage to the alternator and regulator or to electronic modules.

2905177

Before installing the new battery, polish the contact surfaces of the battery terminals and of the pole terminals.

• Install new battery.

Turn key-switch for electrical system to "0" and withdraw key.

• Screw battery holder (1) in place.

Detach and attach the pole terminals in the given sequence.

• Connect pole terminal to positive pole of battery.

Failure to observe this sequence may result in short-circuits.

Tighten clamping screws of pole terminals without using force, as this would cause damage.

• Detach pole terminal at negative pole of battery.

• Detach pole terminal at positive pole of battery.

• Insulate pole terminals.

• 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

139

OPERATOR’S MANUAL 21D / 121D / 221D HYDRAULIC SYSTEM Position the wheeled loader on a horizontal surface and set the working equipment down on the ground.

2747471

Return flow filter The hydraulic system is equipped with a returnflow filter (3, Fig. 2).

Apply the parking brake after shutting off the engine.

Depressurize the hydraulic system by actuating the control levers for the working equipment with the engine shut off until the working equipment stops performing working movements.

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

Read and observe "Inspection and servicing - Safety instructions".

Hydraulic oils are harmful to the skin. Wear gloves and heavy-duty working clothing.

Checking the hydraulic oil level For checking the hydraulic oil - the working attachments must be lowered to the ground - the engine must be off - the hydraulic oil must be cold.

The oil level should be visible at the center of the inspection glass (1, Fig. 1). Top up with hydraulic oil if necessary. For this purpose, unscrew cap (6) of breather filter and add hydraulic oil.

Fig. 2

A bypass valve installed in the system protects the return-flow filter from excessive pressure.

There is no filtering, however, when the bypass valve is open. The filter insert must therefore be replaced in good time.

The return-flow pressure is indicated on the pressure gauge (4). If the needle of the return-flow pressure gauge is in the red zone when the engine in running and when the hydraulic oil is at operating temperature, the filter insert must be replaced even if the replacement interval has not yet expired.

Replacing the filter Clean the return filter (3, Fig. 2).

Unscrew cap (2).

Check seal (11, Fig. 6) for damage.

Replace damaged seals.

Pull pre-filter (12, Fig. 3) by the handle (13) out of filter housing (3).

Fig. 1

Fig. 3

140

OPERATOR’S MANUAL 21D / 121D / 221D Clean pre-filter (12) and check for damage. Replace seal (15, Fig. 4) if damaged. When filter sieve (14) is damaged, the pre-filter (12) must be peplaced.

• Apply clean hydraulic oil on seal (11, Fig. 6) of cap (2).

Fig. 6 Fig. 4

Remove filter element (16, Fig. 5) from filter housing (3) and discard without polluting the environment.

• Screw cap (2) onto filter housing (3).

During the test run, check for perfect tightness of the cap (2).

Breather filter The breather filter (Fig. 5) provides for air intake and discharge to and from the hydraulic tank when the hydraulic oil level fluctuates.

Fig. 5

• Apply clean hydraulic oil on the seals (17) of the new filter element (16).

• Slide filter element (16) into filter housing (3).

Fig. 7

• Apply clean hydraulic oil on seal (15, Fig. 4) of pre-filter (12).

• Install pre-filter (12, Fig. 3) in filter housing (3) and tilt over handle (13).

The breather filter contains a filter element to prevent dust and foreign matter from penetrating and oil from splashing out. This element cannot be replaced or cleaned.

So replace the entire breather filter according to maintenance schedule D.

141

OPERATOR’S MANUAL 21D / 121D / 221D Hydraulic reservoir Changing the hydraulic oil • Set working equipment down on the ground.

• Shut off engine and apply parking brake.

Risk of scalding from hot hydraulic oil.

Bleeding of the system is required after each oil change, after hydraulic system malfunctions or after protracted downtimes.

Working hydraulic system

Collect escaping hydraulic oil and discard in accordance with local environmental regulations.

Check oil level in hydraulic reservoir and top up if necessary. Start engine and run at idling speed for a few minutes. Extend and retract piston rods of all hydraulic cylinders several times.

Read and observe "Inspection and servicing - Safety instructions".

Steering hydraulic system

Never start up the engine when the hydraulic reservoir is empty.

Secure the machine against unauthorized starting.

To empty the reservoir, unscrew the plug at the combi-radiator.

Place a waste-oil receptacle below the hydraulic reservoir. Receptacle capacity: see "Refilling quantities" table.

Unscrew cap (2, Fig. 2) of return-flow filter and withdraw filter carrier (12). Clean the base and interior of the reservoir through the opening with hydraulic oil or flushing oil. Screw plug back in place.

Filling the hydraulic reservoir with oil Unscrew breathing filter. Fill in new hydraulic oil with a hand pump or an oil can, using a filling funnel with built-in filter gauze until the oil reaches the upper mark of the inspection glass.

Screw cap (2) back in place and bleed the entire system.

142

Bleeding the hydraulic working and steering systems

With the engine running, turn the steering wheel to the right and left as far as the limit stops.

Repeat this procedure until there are no more bubbles to be seen in the reservoir and the steering is working properly and noise-free.

After bleeding, check hydraulic oil level once again and top up if necessary.

OPERATOR’S MANUAL 21D / 121D / 221D OPTIONAL EQUIPMENT Environmentally compatible hydraulic fluid (biodegradability) Environmentally compatible hydraulic fluid, operating instructions The hydraulic system of this machine can be filled ex works with environmentally compatible, synthetic hydraulic fluid (non-standard). Stickers with corresponding instructions are then attached to the machine.

For the initial filling, use only: PANOLIN HLP SYNTH 46 A change from mineral hydraulic oil to this synthetic hydraulic fluid can, however, be made at a later date.

Environmentally compatible hydraulic fluid, too, must not be simply poured away but disposed of in the same way as used oil.

If hydraulic fluid seeps into the ground, the machine owner and the competent authorities must be informed.

HLP SYNTH 46 is suitable only for hydraulic systems.

As HLP SYNTH 46 is not soluble in water, condensate may be deposited in the hydraulic oil tank.

It must therefore be drained off at regular intervals and after lengthy downtimes, then disposed of in the same way as used oil.

2913022

Environmentally compatible hydraulic fluid, conversion Read and note: "Inspection and Servicing, Safety Instructions".

- Bring hydraulic system to operating temperature.

- Retract all hydraulic cylinders.

- Drain off hydraulic oil (see operator’s manual, section 3 "Inspection and Servicing").

- Fill hydraulic oil tank with HLP SYNTH 46 up to halfway mark.

- Activate all hydraulic functions including travelling for about 30 minutes. The hydraulic system is flushed.

- Then drain off the hydraulic fluid.

It can be used repeatedly for flushing. Otherwise it must be properly disposed of. A disposal expert must be consulted in this case, as this is a mixture of synthetic hydraulic fluid and mineral hydraulic oil.

- Change all filters in the hydraulic system.

- Fill the hydraulic oil tanks with new HLP SYNTH 46.

Use only HLP SYNTH 46 for changing or topping up the hydraulic fluid.

The hydraulic fluid must not be mixed with hydraulic oils or hydraulic fluids by other manufacturers, as this affects its biodegradability.

Operating equipment and attachments driven with mineral hydraulic oil must not be mounted until thoroughly emptied, cleaned and flushed.

The serviceability of the hydraulic fluid even beyond the normal change intervals can be determined by means of an analysis.

See: "Environmentally compatible hydraulic fluid, sampling".

Fig. 1

Fix an instruction sticker (Fig. 1): - in the cab, - on the hydraulic oil tank and - on the additional hydraulic operated equipment.

143

OPERATOR’S MANUAL 21D / 121D / 221D - Start up the machine. Check level in hydraulic tank according to servicing plan.

- The hydraulic fluid may dissolve deposits in the hydraulic system.

So change all filters 30 - 50 operating hours after making the change.

Make further filter changes according to servicing plan.

- Take a sample of the hydraulic fluid after 30 50 operating hours and send in for a analysis.

(See section: "Environmentally compatible hydraulic fluid, sampling").

Environmentally compatible hydraulic fluid, sampling Complete sets are compiled for hydraulic fluid analysis. They contain all necessary parts.

Sets are available from our central Parts Service.

- Take a first sample after 30 - 50 hours of operation with environmental hydraulic fluid.

The sample must be sent in for analysis.

- We recommend to take another sample after every 1000 OH or once a year and to send the sample in for analysis.

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.

Should you have any problems or queries, apply to our aftersales service department.

144

OPERATOR’S MANUAL 21D / 121D / 221D

II.

Oils for hydraulic system, synthetic (biodegradability)

2905625

Warming-up phase necessary before commencing operation.

Warm up hydraulic system for approx. 10 minutes by running engine at half speed and by actuating all control valves repeatedly.

145

OPERATOR’S MANUAL 21D / 121D / 221D AXLES

2801991

Safety instructions Position the machine horizontally and stand working equipment on the ground.

Shut off engine and apply the parking brake.

Secure the machine against unintentional movements by placing a chock under one of its wheels.

Front axle The front axle shares a common oil supply with the two planetary gears (wheel hubs). Therefore, it is sufficient to check only the oil level in the two planetary gears. See "Planetary gears, checking the oil level". If the oil level in the front axle is to be checked anyway, proceed as follows:

Checking of oil level

Risk of scalding caused by hot oil.

• Unscrew checking and filling plug (1, Fig. 1).

The oil level must reach up to the opening. If this is not the case, fill in oil until it emerges from the opening.

Collect escaping oil and evacuate it without polluting the environment.

• Screw checking and filling plug (1, Fig. 1) back in place.

Secure the machine against unauthorized starting.

Read and observe the "Inspection and servicing - Safety instructions" section.

Secure the machine as described in the "Securing the machine" section.

Fig. 1

Changing of oil • Place a collecting container under the front axle. For the required capacity, refer to the "Refilling quantities" table.

• Unscrew drain plug (2, Fig. 1). Screw drain plug (2) back in place after the oil has drained away completely. Drain off oil also from the planetary gearbox (cf. section "Planetary gearbox").

• Now fill in oil as described under "Checking of oil level".

Renew damaged sealing rings.

146

OPERATOR’S MANUAL 21D / 121D / 221D Rear axle

Transfer gearbox

The rear axle shares a common oil supply with the two planetary gears (wheel hubs) and the transfer gearbox. Therefore, it is sufficient to check only the oil level in the two planetary gears. See "Planetary gears, checking the oil level". If the oil level in the rear axle is to be checked anyway, proceed as follows:

The transfer gearbox shares a common oil supply with the rear axle and the two planetary gears (wheel hubs). Therefore, it is sufficient to check only the oil level in the two planetary gears. See "Planetary gears, checking the oil level". If the oil level in the transfer gearbox is to be checked anyway, proceed as follows:

Checking of oil level

Checking of oil level

• Unscrew checking and filling plug (3, Fig. 2).

The oil level must reach up to the opening. If this is not the case, fill in oil until it emerges from the opening.

• Unscrew checking and filling plug (5, Fig. 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.

• Screw checking and filling plug (3) back in place.

Fig. 3

Fig. 2

Changing of oil • Place a collecting container under the rear axle. For the required capacity, refer to the "Refilling quantities" table.

• Unscrew drain plug (4, Fig. 2), collect waste oil and evacuate it without polluting the environment. Screw drain plug (4) back in place after the oil has drained away completely. Drain off oil also from the planetary gearbox (cf. section "Planetary gearbox").

Changing of oil • Place a collecting container under the transfer gearbox. For the required capacity, refer to the "Refilling quantities" table.

• Unscrew drain plug (6, Fig. 3). Screw drain plug (6) back in place after the oil has drained away completely. Fill in oil as described under "Checking of oil level".

• Now fill in oil as described under "Checking of oil level".

Renew damaged sealing rings.

147

OPERATOR’S MANUAL 21D / 121D / 221D Planetary gears The planetary gears share a common oil supply with the front axle or the rear axle including the transfer gearbox. Therefore it is usually sufficient to check only the oil level in the planetary gears.

Checking the oil level • Park the machine on level ground. To allow for oil level balancing in the axles, wait ten minutes before checking.

Changing of oil • Place a collecting container under the planetary gear. For the required capacity, refer to the "Refilling quantities" table.

• Turn the wheels in such a way that screw (7, Fig. 4) is in the 6 o’clock-position (position I).

Remove screw (7) and re-insert it after the oil has drained away completely. Now fill in oil as described under "Checking of oil level".

• Turn the wheels in such a way that screw (7, Fig. 4) is in position II. Unscrew checking and filling plug (7). The oil level must reach up to the lower edge of the opening. If this is not the case, fill in oil until it emerges from the opening. Screw plug (7) back in place.

• Repeat checking after about 10 minutes and top up oil again, if needed.

Fig. 5

Fig. 4

148

OPERATOR’S MANUAL 21D / 121D / 221D BRAKES

2913023

Working on brakes, safety instructions

Checking the brake disks

2913025

Every time the oil is changed in the rear axle, check the thickness of the brake disks.

• Stop machine as detailed in the section "Securing the machine".

Personnel Never do inspection and servicing work on brakes unless you are qualified to work on brake systems.

• When gearbox oil is drained off, unscrew screws (4, Fig. 1).

• Apply parking brake.

If in doubt, have the work done by our Dealer.

Read and take note of the section: "Inspection and servicing, safety instructions".

Securing the machine Never do inspection and servicing work on brakes unless the machine is secured as detailed in the section "Securing the Machine".

Fig. 1

Parking brake

2913024

The parking brake requires minimum servicing and is set to engage after 4 detents of the hand brake. If the braking action decreases, check the thickness of the brake linings and consult our dealer if necessary.

Reducing braking pressure

• Check for wear. The interior disks with friction lining must be replaced if they are worn down to a minimum (see Fig. 2) of 4.5 mm.

Consult our dealer.

2800793

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. 2

149

OPERATOR’S MANUAL 21D / 121D / 221D Bleeding the braking system The system must be bled when air has penetrated into the line system. This occurs when brake lines are loosened or parts of the braking system are replaced or dismantled.

2913073

• Vent (5) at inching valve.

Fig. 3 applies to the 21D loader.

Two persons are needed to bleed the braking system.

Bleeding must be done in the following sequence: • Right vent valve at rear axle.

Fig. 3

Fig. 4 applies to the 121D / 221D loader.

Fig. 1

• Left vent valve (1, Fig. 1) at rear axle.

• Vent (4, Fig. 2) at connecting valve (on brake side).

• Vent (3) at connecting valve (on pedal side).

Fig. 4

Fig. 2

150

OPERATOR’S MANUAL 21D / 121D / 221D Bleeding For bleeding, a hose (2) must be attached to the respective bleeding valve and the other end let into a suitable vessel filled with hydraulic oil (for example Fig. 5).

Fig. 5

While the first person now operates the brake pedal and keeps it pressed down with the engine running, the second person opens the vent by ca.

1/2 turn and closes it only when the hydraulic oil emerges bubble-free in the vessel. Only then does the first person release the brake again.

To ensure that all air is definitely removed from the system, this procedure must be carried out at least twice.

151

OPERATOR’S MANUAL 21D / 121D / 221D TYRES AND WHEELS

1946824

Tyres and wheels - Safety instructions Risk of injury

Tyre pressure

Heat-induced combustion of gas inside the tyre may lead to explosions in air-inflated tyres. This heat may be due, for instance, to frequent use of the brakes or to welding work carried out on the machine. A heat-induced tyre explosion is more violent than that occuring during normal bursting of tyres. Such an explosion can eject parts of the tyre and the rim over several hundreds of meters. Exploding and/or bursting tyres and ejected parts of tyres and rims may cause severe or sometimes even fatal injuries.

-

Therefore: - If a tyre is suspected to be too hot, secure the machine and wait some distance away until the tyre has cooled down.

- Before inflating the tyre, check the tyre itself, the rims and rim components for damage, penetrated foreign objects and perfect fit.

- Have detected faults always rectified immediately by specialized workshops.

- If you are in doubt about the safe condition of the tyre, the rims or rim components, do nothing yourself but have the complete wheel removed by a special workshop.

Changing of tyres, rims or rim components requires special tools and procedures and must therefore always be carried out by a workshop with special equipment for this kind of work.

- Never carry out works on rims and tyres unless you are qualified to do so.

152

-

-

-

-

-

Check the tyre pressure only when the tyre is cold; the pressures indicated are higher when the tyre is warm.

Use a tyre inflator with a long filling hose, snap-on valve and pressure gauge (Fig. 1).

Use only compressed ambient air for inflating the tyres. Never use flammable gases: risk of explosion.

When inflating the tyre, keep at some distance from the wheel facing in the direction of travel.

Watch the tyre and the gauge of the filling gear permanently during inflation and never exceed the specified tyre pressures.

Place a safety cage around dismantled wheels.

When pumping up, make sure all persons are well clear of the tyre.

Always pump up the tyre to the specified air pressure: - Excessive tyre pressure makes for poor off-the-road handling with a risk of bursting tyres.

- Insufficient tyre pressure causes greater tyre wear and affects the stability of the machine.

OPERATOR’S MANUAL 21D / 121D / 221D 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 ususal.

- Use filling equipment with long filling hose, self-fixing nozzle and pressure gauge.

- Inflate the tyres with compressed ambient air only. Never use inflammable gases: Risk of explosion.

- Keep away from the tyre during inflation and always stand besides the tyre tread.

- Keep an eye on the tyre and and on the pressure gauge of the filling equipment when inflating the tyre. Never exceed the prescribed tyre inflation pressures.

- Place a safety cage around dismantled wheels.

- Make sure nobody is standing near the tyre when it is being inflated.

1946841

Always inflate the tyres to the prescribed pressure: - Excessive pressures result in poor off-road handling properties and tyres may burst.

- Insufficient tyre pressures lead to increased tyre wear and to inadequate stability of the machine.

Wheel-nuts Always tighten the wheel-nuts with a torque wrench. Recheck with a torque wrench for tightness after several hours of operation.

Driving on roads When driving on the road check that the tyres have the prescribed minimum tread and the correct air pressure.

Always make sure that both axles are equipped with tyres of the same size and same degree of wear.

Tyres with different diameters may cause damage to the differentials.

To avoid excessive tyre wear: - inflate to the correct air pressure, - do not start or brake abruptly, - take corners slowly.

Clean the tyres and the gaps between the tyres before driving on public roads. This helps to avoid putting other road users at risk from soiled traffic lanes or from lumps of soil or stones ejected from the wheels.

153

OPERATOR’S MANUAL 21D / 121D / 221D Checking the tyre pressure - Reinflat1946825 ing the tyre Read and observe: "Tyre inflation pressure - Safety instructions".

• Park the machine on firm and level ground.

• Stand the working equipment on the ground.

• Apply the parking brake.

• Shut off the engine.

• Attach the self-fixing nozzle of the filling equipment to the tyre valve (Fig. 1).

• Inflate all tyres with the prescribed pressure (see: "Table of tyre inflation pressures")

Fig. 1

154

OPERATOR’S MANUAL 21D / 121D / 221D Tyre pressure

2913074

The machine can be equipped with various tyres.

The following tyre pressures are valid for the 21D loader: Tyre size

Front axle Working operation Lifting fork Tipping and and other loading equipment bucket

The following tyre pressure are valid for the 121D / 221D loaders:

Rear axle

Tyre size

10.5-18MPT TL 12PR 122E

X*

3.0 bar

1.75 bar

12.5 R20MPT 10PR 132G

12.5-18MPT TL 8PR 125E

X*

2.5 bar

1.75 bar

12.5-20MPT TL 10PR 129E

3.5 bar

3.0 bar

12.5-R20MPT TL 12PR 132G

3.0 bar

15.5/55 R18 MPT TL 14PR 134E

Front axle Working operation Lifting fork Tipping and and other loading equipment bucket

Rear axle

X*

3.5 bar

2.5 bar

14.5-20MPT 10PR 132G

3.5 bar

3.0 bar

1.5 bar

1.5 bar

14.5 R20 MPT 10PR 132G

3.5 bar

3.0 bar

2.0 bar

2.5 bar

1.5 bar

335/80 R20 EM147 A2136B

X*

3.5 bar

2.0 bar

4.0 bar

3.5 bar

1.75 bar

335/80 R20xMPT 134G Michelin

X*

3.2 bar

2.2 bar

335/80 R18 XM 27 MPT TL 132G

3.5 bar

3.0 bar

1.4 bar

365/80 R20 EM157 A2141B

3.5 bar

3.0 bar

2.0 bar

335/80 R18 EM TL 134B 145A2

3.5 bar

3.0 bar

1.75 bar

375/75 R20xMPT 136G Michelin

3.5 bar

2.6 bar

1.4 bar

335/80 R20 MPT TL 139G 153A2

3.0 bar

2.5 bar

1.5 bar

405/70 R20xMPT 136G Michelin

3.5 bar

2.6 bar

1.4 bar

335/80 R20 EM TL 147A2 136B

3.0 bar

2.5 bar

1.5 bar

16/70-20MPT 10PR 137G

2.5 bar

2.0 bar

1.5 bar

335/80 R20 XM27 MPT TL 134G

3.1 bar

2.6 bar

1.4 bar

16/70-20EM 10PR 157 A2141B

2.5 bar

2.0 bar

1.5 bar

365/70 R18 EM TL 135B 146A2

3.25 bar

2.75 bar

1.5 bar

405/70 R20 EM155 A2143B

3.0 bar

2.5 bar

1.5 bar

* Unsuitable for use with lifting forks

* Unsuitable for use with lifting forks.

Before undertaking longer drives on the road, the tyre pressure of the front wheels must be adapted to the pressure of the rear wheels to increase the driving comfort.

155

OPERATOR’S MANUAL 21D / 121D / 221D Changing a wheel Read and observe the section on: "Wheels and tyres - Safety instructions".

"Tyre pressure - Safety instructions" • Park the machine on firm and level ground.

Block the articulated joint.

Apply the parking brake.

• Loosen the wheel nuts on the wheel to be changed by about one turn.

• Jack up the axle with the damaged wheel until the wheels are clear of the ground.

Front axle: Push up the wheel loader with the bucket (Fig. 1).

Rear axle: Lift the wheel loader with a jack or a winch.

• Place supports under both ends of the lifted axle to prevent it from dropping e.g. with squared timber (Fig. 1).

2913028

Fit the new wheel: - Inflate the tyre with a pressure of ca. 1 bar.

- Observe the instructions set out in the "Wheels - Tyre tread position" section.

- Do not damage the threads of the wheel studs. Tighten the wheel nuts by hand. Remove the support from under the lifted axle and lower the axle. Tighten the wheel nuts crosswise with the prescribed torque. For torque values cf. "Fastening of wheels" Inflate the tyres with their correct pressure.

See "Tyre pressures" and "Tyre pressure Safety instructions". Check the wheel nuts after five operating hours with a torque wrench for tightness.

Fastening of wheels Check the wheel nuts after 5 OPERATING HOURS for tightness and retighten with a torque wrench.

Check all wheels in acc. with servicing plan W for tightness. Retighten the wheel nuts, if necessary.

Tightening torque 450 Nm.

Tyre tread position Pay attention to the tread position when fitting the wheels (Fig. 2). Fig 2 shows the normal tread position for best traction results during froward travel.

Fig. 1

• Secure the machine as described in the "Securing the machine" section.

• Deflate the tyre.

• Unscrew the wheel nuts and remove the defective wheel taking care not to damage the threads of the wheel studs.

Do not lose centering rings, lockwashers and wheel nuts. They are need to refit the wheel.

156

Fig. 2

In some special cases, another tread position may prove more favourable. In these cases, please contact our service.

OPERATOR’S MANUAL 21D / 121D / 221D LUBRICATING THE GREASING 2800602 POINTS Read and observe the "Inspection and servicing - Safety instructions" chapter.

DRIVER’S CAB VENTILATION

2905443

Filter Change filter in accordance with maintenance schedule "B" or more often under increased exposure to dust.

Before beginning the greasing operations: - Set working equipment on the ground with the bucket tilted forwards (Fig. 1).

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

Always dispose of greasy cleaning rags separately from other waste.

Fig. 1

• Slacken knurled-screws (1, Fig. 1).

• First turn cover (2) down (arrow I) until filter element is free, then withdraw forwards (arrow II) • Remove filter element and discard in accordance with local environmental regulations.

• Insert new filter element.

Fig. 1

• Push in cover (2) as far as limit stop and tighten screws.

The greasing points on the working equipment and the machine are lubricated with a hand-operated grease-gun.

• Withdraw protective cap from greasing nipple.

• Clean the greasing nipple.

• Press the filling 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 on the greasing nipple.

157

OPERATOR’S MANUAL 21D / 121D / 221D 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.

• Set working equipment down on the ground, retracting piston rods of hydraulic cylinders as far as possible.

• 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 operator’s manual) • 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 operator’s manual).

• 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.

158

2411346

• Keep battery / batteries clean and dry externally.

OPERATOR’S MANUAL 21D / 121D / 221D RECOMMISSIONING

2747203

Before recommissioning the machine after a longer downtime observe the following points: • Remove engine preservation. Fill in new engine oil.

Removal of engine preserving agents (see engine operator’s manual) • Remove anti-corrosion agent from the grooves of the V-belt pulley.

• Check oil level in the hydraulic reservoir.

• Mount V-belts and adjust tension after a brief operating period.

• Check oil level in the frontaxle and the rearaxle.

• Remove closures from intake and exhaust openings.

• Check oil level in the transfer gearbox.

• Start up engine.

• Check oil level in the planetary gears.

• Check battery charge condition.

• Install battery and reconnect to the electrical system.

• Set battery main switch to ON. • Check tyre pressure.

• 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.

159

OPERATOR’S MANUAL 21D / 121D / 221D

BLANK PAGE

160

OPERATOR’S MANUAL 21D / 121D / 221D PART 4 - REPAIR WORK

Operator’s 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 knowhow relevant to the operation and the application of this or comparable machines.

Inspection and servicing personnel

Part 3 INSPECTION AND SERVICING

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

Repair personnel

Part 4 REPAIR WORK

Part 5 ANNEX

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

161

OPERATOR’S MANUAL 21D / 121D / 221D

BLANK PAGE

162

OPERATOR’S MANUAL 21D / 121D / 221D REPAIR WORK - SAFETY INSTRUCTIONS

2913029

Operator’s manual

Prestressed units

Never carry out repair work without having read and understood the operator’s manual.

Never open defective prestressed units but replace them as an entirety.

Pay special attention to:

In exceptional cases, open only when the system and the operating sequence are precisely known and any special tools required are available.

"Fundamental Safety Instructions", "Inspection and servicing - safety instructions" and all warnings and safety instructions attached to the machine.

The descriptions of job sequences provide only experienced personnel with the necessary instructions.

The operator’s manual must be kept with the machine at all times.

Repair personnel Repair personnel must have knowhow and experience relevant to repairing this or comparable machines.

In the absence of such know-how, meticulous training must be given by experienced repair personnel.

The operator’s manual contains no information on this point.

Dismantling components Never dismantle while the machine is at operating temperature.

Oils, greases, brake fluid or coolants may have a high temperature and result in burning or scalding.

Leave time for the machine to cool down.

Before starting work, depressurize piping and hoses, cylinders, radiator, hydraulic tank, air-brake reservoir and other systems or units.

Replace defective components in good time to prevent major damage.

Blocking the articulated joint

Clean the defective component carefully before dismantling it.

When carrying out repair work in the pivoting range, block the articulated joint. Remove the block on completing work.

Mark the dismantled parts in the correct sequence to facilitate assembly.

When dismantling the component, close off exposed hose and piping connections, exposed drill holes and housing carefully to prevent any dust from penetrating.

Never remove lead seals Never change the rated pressure of pressure relief.

Never remove lead seals from pressure relief valves and accumulators.

163

OPERATOR’S MANUAL 21D / 121D / 221D After the repair work To prevent corrosion, coat all bright metal machine parts with a grease film.

On completing the work, reassemble all protective devices, covers, and sound- and vibration-insulation material.

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

ENGINE Engine - repair instructions

2913030

Read and observe: "Repair, safety instructions" and operator’s manual for engine before working on the engine.

Risk of injury from rotating or hot engine parts!

Switch off engine and leave to cool down.

Check the repaired components and all machine functions with a trial run.

Do repair work only if machine is secured as described in section "Securing the machine" of these operator’s manual.

Never release the machine for recommissioning until it is fully functioning.

Check and change V-belts only when engine is stationary.

Repair work on the engine demands extensive know-how and special tools.

In cases of doubt, have the repair work carried out by our dealer.

Replacing V-belts

2905160

Replacing alternator / coolant pump Vbelts This repair work is detailed in the engine operator’s manual.

164

OPERATOR’S MANUAL 21D / 121D / 221D Assisted starting (jump-starting) 2905170 Safety instructions 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.

Risk of injury from splashing acid and battery gases.

Never lean over the batteries when jump-starting a vehicle.

Wear goggles.

Never use assisted starting when the batteries are defective or frozen.

Never connect batteries (battery assemblies) unless they have the same voltage.

Use only tested jumper cables with insulated terminal clips and an adequate lead diameter.

Ensure that the bodies of the supplying and receiving machines are not in contact. Otherwise a current flow might result from connecting the positive poles. Risk of shortcircuiting.

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".

165

OPERATOR’S MANUAL 21D / 121D / 221D 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).

Fig. 1

In this case the machine must not be started, as the alternator would then be damaged.

Starting the engines

Install a functional battery before jump-starting.

• Start the engine of the supplying machine and run it with stepped-up revolutions.

• Switch off all electrical consumers in receiving machine and turn key-switch to 0 .

• Start the engine of the receiving machine. If the engine does not start up after 15 seconds, wait one minute before re-starting.

• 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 battery (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).

166

• Once the engine has started up, proceed as follows: - Continue running both machines in no-load operation for about two or three minutes with the jumper cables still connected.

- 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 checked to determine why the batteries were discharged.

OPERATOR’S MANUAL 21D / 121D / 221D ELECTRICAL SYSTEM

2905038

The fuses are housed in the rear wall of the cab, to the left of the driver’s seat.

Top fuse assembly (Fig. 2) F1 A 7,5A left high beam light

Fuses

B 7,5A right low beam light fuse Shut off the engine and set the key-switch to "0" before removing any fuses.

Replace defective fuses only with fuses with the same current rating.

C 15A horn fuse F2 A

5A

solenoid Y42 & S42.1 switch fuse

B 7,5A hand brake & indicator lamps fuse C 15A rear working lights fuse

Fuses in cab The fuses are accessible after removal of the cover (1, Fig. 1).

F3 A 10A wiper motors & radio fuse B 10A brake lights & direction lights fuse C 7,5A reversing lights & back up alarm fuse F4 A 7,5A engine stop B 7,5A glow timer & speedometer C

5A

forward & reverse solenoid

Bottom fuse assembly (Fig. 2) F5 A 10A reserve fuse B 10A reserve fuse Fig. 1

C 10A immobilizer F6 A 7,5A right high beam light B

5A

F/R switch & crawl gear fuse

C 7,5A left low beam light fuse F7 A 10A driver seat fuse B 15A blower motor fuse C 10A radio & cigarettes lighter fuse, cab interior lamp

Fig. 2

F8 A 10A warning lights B

5A

front left & rear right tail lights fuse

C

5A

front right, rear left tail lights

F9 A 15A front working lights fuse B 10A rotary beacon fuse C 10A reserve fuse

167

OPERATOR’S MANUAL 21D / 121D / 221D Replacing fuses

Replacing bulbs

Remove screws (2, Fig. 1) and cover (1).

Withdraw defective fuse and insert a new one with the same current rating.

Put on cover and tighten screws.

Fuses in engine compartment (Fig. 3) 2 fuses for the preheating control are located close to the air filter.

2905444

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 Glow Fuse

80 A

F1.7 30/M Stop Fuse

30 A

168

OPERATOR’S MANUAL 21D / 121D / 221D Lighting

Headlamp

2905163

Remove the 4 rear screws (Fig. 2).

Fig. 1

1 - Headlamp

Fig. 2

2 - Turn signal lamp

Remove plug (1, Fig. 3) and rubber cap (2).

3 - Tail lamp, braking lamp, signal lamp and reversing lamp

Release spring clip.

4 - Floodlamp, front 5 - Floodlamp, rear (option) 6 - Rotary beacon (option)

Fig. 3

Take bulb (6, Fig. 4) out of holder (7) and put in a new one.

Fig. 4

Re-assembly in reverse sequence.

169

OPERATOR’S MANUAL 21D / 121D / 221D Turn signal lamp

Tail/brake signal lamp

Remove screws (Fig. 2) and take off lens (9, Fig. 5).

Unscrew caps (Fig. 6) from lamps. The bulbs are then accessible.

Fig. 5

Fig. 6

Replace defective bulb. Re-assembly in reverse sequence.

11 - Reflector, red 12 - Rear lamp, Braking lamp 13 - Turn signal lamp 14 - Reversing lamp

Fig. 7

170

OPERATOR’S MANUAL 21D / 121D / 221D Cab interior lamp

Floodlamp

Withdraw cover (Fig. 8) and replace defective bulb. Re-assembly in reverse sequence.

Remove screws (13, Fig. 9) and withdraw lamp unit (14) carefully.

Fig. 8

Fig. 9

Release spring clip (15, Fig. 10).

Fig. 10

Remove bulb (16, Fig. 11) from holder (17) and replace with new bulb. Re-assembly in reverse sequence.

Fig. 11

171

OPERATOR’S MANUAL 21D / 121D / 221D Rotary beacon (option)

1946970

Replacing the lamp Hold rotary beacon (1, Fig. 1) at the base, depress lever (2) by a small amount, turn lamp cover (3) in the direction of the arrow and lift.

Put on lamp cover (3, Fig. 3) and turn in the directionof the arrow until it engages.

Fig. 3 Fig. 1

Snap clamp (4, Fig. 2) forwards and replace lamp (5). Snap clamp (4) back in place.

Fig. 2

172

OPERATOR’S MANUAL 21D / 121D / 221D WELDING OPERATIONS

2913031

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 - may develop health-hazardous gases, vapours, mist or dust during welding operations must be carried out only under expert supervision and only by experienced persons authorized to do such work.

Should you have any problems or queries, apply to our aftersales service department.

Prior to any welding operations on the machine: - Disconnect the battery, first the negative terminal and then at the positive terminal.

- Disconnect the positive terminal at the alternator.

- Protect the disconnected terminals and plugs from short-circuiting and soiling by covering them with foil or adhesive tape.

Apply the welding current terminals very close to the welding point.

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.

173

OPERATOR’S MANUAL 21D / 121D / 221D HYDRAULIC SYSTEM

2913032

Replacing hydraulic hoses - Safety instructions Before unscrewing hydraulic hoses: Depressurize the hydraulic system!

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.

Replace damaged and leaking hydraulic hoses with new ones.

Use original spares only. These are coordinated with the respective function.

Never re-use used hoses.

Dispose of leaked oil and oily wastes in the interests of environmental protection. They must be prevented from penetrating soil or reaching water.

Hydraulic hoses should be replaced after a six-year period of use to prevent an increased risk of failure.

174

2904150

Fig. 1

OPERATOR’S MANUAL 21D / 121D / 221D BRAKES

2800627

Safety instructions Personnel Never do repair work on brakes unless you are qualified to work on brake systems.

If contact with the skin cannot be avoided, protect the skin with a barrier cream.

Contact with the skin must 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".

Block the articulated joint when carrying out work on the brake system.

Health protection Always store hydraulic oil in the original containers.

Swallowing hydraulic oil is a severe health hazard.

Disposal Never let hydraulic oil penetrate into the soil; it contaminates the ground water.

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.

If hydraulic oil is swallowed, not induce vomiting immediately and go straight to a hospital or doctor.

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.

175

OPERATOR’S MANUAL 21D / 121D / 221D Checking the braking pressure

2913083

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

If - the Central Warning lamp does not go out, - the acoustic warning goes on sounding, - the braking pressure is less than 45 bars,

• Reduce braking pressure by applying brake pedal 10-15 times. The braking system is depressurized when the pedal can be applied with no great resistance.

• Connect pressure gauge (measuring range up to 200 bars) by detaching the closing cap (1, Fig. 1) of the measuring connection (2) at the brake valve (3) and connecting the pressure gauge (4).

Thread size: M 16 x 2

there is a fault in the braking system.

In this case, dealer.

contact our

local

Replacing the brake disks Brake disks must be replaced in matched sets only.

Place new disks in gearbox oil LS 5-90 for about 1 hour before installing them. Otherwise the brake linings will wear very rapidly due to dry braking.

Fig. 1

• Check that parking brake is applied and gearchange lever in neutral position.

• Start up engine and wait until minimum pressure required is reached. This is the case when the Central Warning lamp (5, Fig. 2) and the warning lamp (7) go out and the acoustic warning is no longer sounded.

• Check brake pressure. The reading on the pressure gauge (4, Fig. 1) must be more than 45 bars.

Fig. 3

Fig. 2

176

OPERATOR’S MANUAL 21D / 121D / 221D Checking the accumulator pressure

Checking the preloading pressure

2913084

2913085

Secure machine as described in "Securing the machine".

Secure machine as described in "Securing the machine".

• Reduce braking pressure.

• Unscrew closing cap (8, Fig. 1) from measuring connection (9) (M 16 x 2) on valve (10).

• Unscrew closing cap (8, Fig. 1) at measuring connection (9) (M 16 x 2) on valve (10).

Fig. 1 Fig. 1

• Screw on pressure gauge with a pressure of 200 bars.

• Start up engine and wait until braking pressure is reached. The acoustic warning signal stops sounding and the central warning lamp (5, Fig. 2) goes out.

• Screw on pressure gauge.

• Start up engine and wait until braking pressure is reached. The acoustic warning signal stops sounding and the central warning lamp (5, Fig. 2) goes out.

Fig. 2 Fig. 2

• The reading on the pressure gauge must be 150 bars.

• If accumulator pressure is below this value, check preloading pressure of accumulator.

• On reaching braking pressure: engine OFF. • Depress the brake pedal several times, observing the reading on the pressure gauge.

• On each actuation of the pedal, the accumulator pressure decreases slightly. A sharp drop in pressure indicates that the pre-loading pressure value of 50 bars has been reached.

• If the pressure is below 50 bars, replace the accumulator.

177

OPERATOR’S MANUAL 21D / 121D / 221D On finishing work, • reduce braking pressure, • unscrew pressure gauge, • screw closing cap onto measuring connection.

ACCUMULATORS Safety instructions

2800629

Accumulators are installed in the hydraulic system. These accumulators contain nitrogen under high initial pressure.

Even when the hydraulic pressure in the system is reduced, the nitrogen remains in the accumulator.

The accumulators are completely safe in operation. If incorrectly handled, however, there is a risk of explosion.

So: - Never handle accumulator mechanically, never weld or solder it.

- 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 accumulator 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.

178

OPERATOR’S MANUAL 21D / 121D / 221D WORKING EQUIPMENT

2904067

Bucket Replacing of teeth Read and observe the section on "Repair work - 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.

Wear your personal protective equipment and goggles.

Fig. 2

• Clean inside of housing and remove dirt and corrosion • Insert new tooth (3) into housing (4, Fig. 3).

The tooth must be in contact with the housing at the arrowed place (Fig. 4).

• Drive out tooth safety latch (1, Fig. 1) using a chisel (2) or a piece of flat iron.

Fig. 3

Fig. 1

• Drive tooth out of housing (3, Fig. 2) using a chisel.

• Drive new safety latch (1, Fig. 4) into opening (5) of housing (4). The latch can be fitted from either side of the tooth.

Fig. 4

179

OPERATOR’S MANUAL 21D / 121D / 221D Bucket limit stops Make sure nobody is standing under the lifting frame.

2913034

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.

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.

Any greater deviation can otherwise be compensated by plates.

Fig. 2

The space between the toggle link and lifting frame limit stop can be compensated by plates.

180

OPERATOR’S MANUAL 21D / 121D / 221D Lifting forks

2913075

Fork prongs must be repaired in specialized repair shops only.

Checking of fork prongs The fork prongs must be checked: • at regular intervals at least, however, once a year; • if remaining deformations are detected.

Each fork prong is identified in the upper part of the fork guide with the admissible carrying capacity and the pertaining center-of-gravity distance.

Checking of carrying capacity and checking for the presence of cracks: • Measure the distance L2 between check marks 1 and 2 (Fig. 1).

• Test each fork prong independently by applying the highest admissible load (max. carrying capacity) at the pertaining center-of gravity distance.

Continuing to use a fork prong with a lower carrying capacity than indicated is admissible on condition that: • the mark indicating the old carrying capacity has been replaced clearly and distinctly by the new carrying capacity.

• the fork prong successfully passes a load test with the new carrying capacity without remaining deformation.

Checking of wear The table below gives the most important prong dimensions (width B and thickness H) for wheelmounted loaders.

Loader Type

BxH mm x mm

Hmin mm

21D 121D 221D

100 x 45

41

• Measure width B and thickness H of each prong (Fig. 2).

• Compare the measured values with the B x H values in the abov table.

• Renew fork prong immediately if thickness H is less than the admissible minimum value Hmin.

Fig. 1

• Remove load.

Also check the fork locking system at regular intervals for perfect functioning.

• Measure distance L2 again.

• Renew prong if measured distance L2 (see table) exceeds the admissible max. value L2 max.

L2 max. = 102 % of L2.

L

L2

L2 max.

< 1 000 mm > 1 000 mm

500 + _ 2 mm 1 000 + _ 2 mm

510 mm 1 020 mm

After successful testing check each prong with suitable means (e.g. dye-penetration test) for the presence of cracks. Renew cracked prongs immediately.

Fig. 2

181

OPERATOR’S MANUAL 21D / 121D / 221D

BLANK PAGE

182

OPERATOR’S MANUAL 21D / 121D / 221D PART 5 - ANNEX

Operator’s 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 knowhow relevant to the operation and the application of this or comparable machines.

Inspection and servicing personnel

Part 3 INSPECTION AND SERVICING

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

Repair personnel

Part 4 REPAIR WORK

Part 5 ANNEX

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

183

OPERATOR’S MANUAL 21D / 121D / 221D

BLANK PAGE

184

OPERATOR’S MANUAL 21D / 121D / 221D TROUBLESHOOTING

2800646

Instructions on troubleshooting

Layout of fault table

Faults are often due to the machine not being correctly operated or serviced.

Fault

For this reason, it is vital to read through the relevant section of the operator’s manual once again before rectifying any faults.

If you are unable to detect the cause of the fault or rectify it, apply to the Dealer after-sales service.

Describe the fault and all accompanying circumstances as precisely as possible when calling on the Dealer after-sales service. Exact data allow for fast troubleshooting.

Never do any jobs for which you are not qualified.

This fault table lists all faults which have been reported to date and outlines their possible causes and rectifying measures. In exceptional cases, a described fault may also have a different cause.

The fault is described here as the outcome of an observation or a previous activity.

Therefore make careful observations.

Study the problem carefully, First think, then act.

Ask yourself the following questions: - Which warning signals preceded the fault?

- What repair and servicing work was carried out previously?

- Has this defect already occurred?

- Is it one or several simultaneously occurring faults?

Possible causes The possible causes of the observed fault are outlined in this group. They are arranged in order of probability, i.e. the possible cause occurring in most cases heads the list.

Measure This describes the troubleshooting procedure.

Section This specifies where information on troubleshooting is given in the operator’s manual. If there is no entry, the Dealer after-sales service should be consulted.

185

OPERATOR’S MANUAL 21D / 121D / 221D Engine

2913036

Fault Engine fails to start or starts only with difficulty Engines starts but runs unevenly or intermittently Engines gets too hot, temperature warning is activated Engine power insufficient Engine not working on full cylinder capacity

Remedial action Check Adjust Replace Top up Lubricate Clean Contact Service

P E W A S R SE

Engine without oil pressure or oil pressure too low Engine oil consumption too high Engine emits blue smoke Engine emits white smoke Engine emits black smoke Cause

•

•

• • •• •• ••• • • •• • • •• • •• • • • • • • • •• • • • •• ••••• •• •

186

Chapter reference

Temperature below limit starting temperature

P

Oil level too low

A

Oil level too high

S

Inclination of engine too great

P

Wrong SAE class of engine oil and incorrect oil quality

Lubricants

W

Fuel quality does not correspond to operator’s manual specification Air filter contaminated/turbocharger defective

Air-intake system

W W

Air filter maintenance switch / indicator defective Oil cooler / cooling fins dirty

W

Engine operator’s manual

R

Cooler fan defective, V-velt broken or loose

P/W

Heating up of cooling air / heat build-up

P

Battery defective or not charged

Electrical system

P

Loose or corroded cable connectors in starter circuit

P

Starter defective or pinion not in engagement

P

Incorrect valve clearance setting

Engine operator’s manual

E

Leaks in injection line

P

Injection valve defective

P/W

Coolant liquid level to low

Cooling system

P/A

OPERATOR’S MANUAL 21D / 121D / 221D Combustion engine start / stop Fault Engine does not turn Starter not working Engine fails to start Engine fails to start, heater and cooling air fan not operational Engine cannot be shut off, warning lamps go out

• • • • • • •

2913037

Remedial action Check Adjust Replace Top up Lubricate Clean Contact Service

P E W A S R SE

Cause

Chapter reference

Gearshift / travel direction lever not in neutral position

Travelling

P

Cf. troubleshooting section of engine operating instructions

Electrical system

P

Fuse blown

P

Shut-off solenoid jamming

SE

Engine internally blocked

SE

Combustion engine blocked at power output side

SE

187

OPERATOR’S MANUAL 21D / 121D / 221D Steering system

2913040

Fault Steering wheel hard to turn, working equipment not operational Steering wheel hard to turn when driving on level ground Steering inexact, permanent correction required Steering wheel easy to turn at limit stop Steering wheel turns fast for a short moment during fast steering action (steering discontinuous)

Remedial action Check Adjust Replace Top up Lubricate

P E W A S

Clean Contact Service

R SE

Steering wheel continues to turn after being released Cause

• • • • • • • • • • •

188

Chapter reference

Hydraulic oil level too low

P,A

Air in hydraulic system

SE

Internal leaks in steering valve/steering cylinder

SE

Pressure setting too low

SE

Oil delivery insufficient

SE

Locking differential or steering mechanism sluggish

SE

Steering valve jamming

SE

Pump drive coupling defective

SE

OPERATOR’S MANUAL 21D / 121D / 221D Working equipment

2913039

Fault Lifting, tipping and steering functions not available Lifting and tipping functions not available; combustion engine audibly loaded Lifting and tipping functions not available, combustion engine not loaded Control lever for bucket equipment does not remain latched in floating position Tipping and lifting times too long

Remedial action Check Adjust Replace Top up Lubricate Clean Contact Service

P E W A S R SE

Tipping or lifting time too long Lowering time too long, lever cannot be latched in floating position Considerable tipping movement when engine is stationary and control lever is not actuated Considerable lowering movement when engine is stationary and control lever not actuated Lifting or tipping movements with engine running and control lever not actuated Lifting power insufficient Rearward tilting power insufficient Heavy choking of engine when lifting and tipping movements approach limit stop

Cause

•

•

Hydraulic oil level too low

• •• ••••• •• •• • • • • •• •• • ••• • • •

Chapter reference Hydraulic system

P, A

Kinematics failure (working equipment components deformed), limit stop incorrect

SE

Operating kinematics of control distributor valve defective

SE

Primary pressure setting too low

SE

Secondary pressure setting too low

SE

Max. engine speed too low

SE

Internal leaks in control distributor valve or in cylinders

SE

Travel of control distributor piston insufficient

SE

Zero positioning of control piston(s) defective

SE

Pump flow rate insufficient

SE

Control piston locking in distributor valve defective

SE

Pump drive coupling defective

SE

Primary pressure setting too high

SE

189

OPERATOR’S MANUAL 21D / 121D / 221D Transmission

2913041

Page 1 of 2

Fault No forward travel, no reversing, working and steering hydraulic functions not available No forward travel, no reversing; horn and windscreen washer functions not available No forward travel, no reversing; combustion engine runs unloaded No forward travel, no reversing, central warning lamp illuminated No forward travel, no reversing, stop light illuminated No forward travel, no reversing, combustion engine loaded

Remedial action

Check Adjust Replace Top up Lubricate Clean Contact Service

P E W A S R SE

No forward travel or no reversing Loader sets off on level ground only when engine speed is relatively high, unusual noises Insufficient acceleration or pushing force in both travel directions Combustion engine speed dropping off heavily during acceleration or pushing Max. travelling speed cannot be reached Max. travelling speed cannot be reached, abrupt deceleration at fast speed reduction of combustion engine Abrupt deceleration at fast speed reduction of combustion engine Loader does not respond to gearshift operations Oil heats up strongly and emerges from tank breather, cooling air fan permanently in operation Oil heats up strongly and emerges from tank breather

• •

•••• • ••• • • •

•

• • •

190

•

•

Cause

Chapter reference

Hydraulic oil level too low

Hydraulic system

P, A

Parking brake applied

Driving

Feeder-circuit filter contaminated

Feeder-circuit filter

P P, W

Incorret tyre pressure

Tyres

Oil has wrong viscosity

Lubricants

Cooler dirty

Hydraulic oil cooler

Oil temperature too high

Travel drive mal function

P

Tyres have considerably differing diameters

Wheels and tyres

P

Fuse defective

Fuses

Pressure of stored-energy braking system too low

W SE

Parking brake switch jamming in OPEN position

SE

Travel direction switch defective

SE SE

Travel direction solenoid defective

P, A W R

OPERATOR’S MANUAL 21D / 121D / 221D Transmission

Page 2 of 2

Fault No forward travel, no reversing, working and steering hydraulic functions not available No forward travel, no reversing; horn and windscreen washer functions not available No forward travel, no reversing; combustion engine runs unloaded No forward travel, no reversing, central warning lamp illuminated No forward travel, no reversing, stop light illuminated No forward travel, no reversing, combustion engine loaded

Remedial action

Check Adjust Replace Top up Lubricate Clean Contact Service

P E W A S R SE

No forward travel or no reversing Loader sets off on level ground only when engine speed is relatively high, unusual noises Insufficient acceleration or pushing force in both travel directions Combustion engine speed dropping off heavily during acceleration or pushing Max. travelling speed cannot be reached Max. travelling speed cannot be reached, abrupt deceleration at fast speed reduction of combustion engine Abrupt deceleration at fast speed reduction of combustion engine Loader does not respond to gearshift operations Oil heats up strongly and emerges from tank breather, cooling air fan permanently in operation Oil heats up strongly and emrges from tank breather

Cause

•

•

• • •

•

•

• • •• • •• ••• •••• ••• • •••

Chapter reference

Working speed range solenoid defective Brake actuation jamming

• •

Fuse defective

Fuses

Temperature switch or fan motor defective Engine speed too low

Engine manual

Engine power insufficient

Engine manual

Friction losses in axle drive or brake too high Malfunction in control-pressure circuit of travel pump Malfunction in high-pressure circuit of transmission Malfunction in feeder-pressure circuit of travel pump Malfunction of travel motor regulator Front axle, rear axle or brake blocked No frictional contact between travel motor and rear axle Pump drive coupling defective

SE SE W SE E P SE SE SE SE SE SE SE SE

191

OPERATOR’S MANUAL 21D / 121D / 221D Brake system

2913042

Fault No braking or insufficient braking action of loader Loader braking action too strong Sensisitive braking by means of inching function not possible Max. accumulator pressure not reached Noise during braking Cause

• • • • • • • • • • • • • •

192

Remedial action Check Adkust Replace Top up Lubricate Clean Contact Service

P E W A S R SE

Chapter reference

Leaks in brake system

SE

Inching valve setting incorrect

SE

Brake disks worn out

Brakes

P

Malfunction of pedal-operated braking valve

SE

Braking pressure setting incorrect

SE

Malfunction of inching valve

SE

Malfunction of accumulator charging valve

SE

Pump defective

SE

Wrong oil grade Malfunction of pre-pressurizing valve

Lubricants

W SE

OPERATOR’S MANUAL 21D / 121D / 221D ABBREVIATIONS A abt. acc.

Ah

Ampere (SI base unit of electric current) about according to Ampere hours (SI base unit of quantity of electricity) API American Petroleum Institute approx. approximately bar

unit of pressure measurement (1 bar = 14.5 psi)

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 CV / Ch metric horsepower ca. about dB(A) dia.

DIN

e.g. etc.

Decibel (Sound intensity according to measuring method A) Diameter German Standardisation Organization (Deutsche Industrie Norm) for example etcetera

fig.

FOPS

Figure, serial number of illustration Falling objects protective structures

HD HP Hydr.

Heavy duty Horsepower (1 hp = 0.7457 kW) Hydraulic, Hydraulics

2800670

i.e. incl.

ISO

id est = that is including, inclusive of International Standardisation Organisation

kg Kilogram (unit of mass) 3 kg/dm Kilograms per cubic decimeter (= unit of specific density) km/h Kilometers per hour kNm KiloNewtons per meter (1 kNm = 1000 Nm) = unit of torque kW Kilowatt (1 kW = 1.36 HP) l Lb/in2 LED l/min LpA LwA

Liter Pounds per square inch (= psi) Light-emitting diode Liters per minute Sound pressure at workplace Sound power level of the machine in stationary operation

m mA max. min. min-1 mm

Meter Milliampere (= 1/1000 A) maximal, maximum minimal, minimum Revolutions per minute Millimeter (= 1/1000 m)

N N, kN NLGI

Normal, standard version Newton, kiloNewton (unit of force) National Lubricating Grease Institute (USA) - lubricant classification acc. to DIN 51 818 Nm Newtonmeter (unit of torque) No./Nos. number/numbers

193

OPERATOR’S MANUAL 21D / 121D / 221D ABBREVIATIONS op. inst. Operating Instructions PS Qty. R, r resp.

ROPS rpm

Metric horsepower (1 PS = 0.74 kW) Quantity Radius Respectively Roll-over protective structures Revolutions per minute (= min-1)

SAE sec.

Society of Automotive Engineers (USA) Second

t typ.

Metric ton (= 1000 kg) Typical

V VDMA

Volt (unit of electric voltage) Association of German Machinery and Systems Manufacturers

W

Watt (unit of electric power)

˚C

Degrees Celsius (temperature)

> <

greater than less than

194

Battery main switch .................................... 54, 137

A

Battery storage ................................................ 158

ABBREVIATIONS .................................... 193, 194

Bleeding............................................................ 151

ACCUMULATORS .......................................... 178

Bleeding the braking system ............................ 150

Acoustic reversing signal (Back-up alarm) ........ 99

Bleeding the hydraulic working and steering systems ............................................................ 142

Activating fast speed .......................................... 68 Blocking the articulated joint .............................. 77 Adjusting the operator’s seat .............................. 40 Bottom-dum bucket ............................................ 88 Adjusting the right armrest .................................. 42 Brake system .................................................... 192 Adjusting the steering column ............................ 64 Brakes ................................................................ 16 Adjusting the weight-oriented suspension .......... 40 BRAKES .................................................. 149, 175 Adjustment of steering column .......................... 63 Braking and stopping .......................................... 66 After daily operation............................................ 89 Braking pressure ................................................ 71 After-Sales-Service .............................................. 3 Breather filter .................................................... 141 Air filter .............................................................. 70 Bucket ........................................................ 92, 179 AIR-INTAKE SYSTEM...................................... 129 Bucket limit stops.............................................. 180 Alternator ............................................................ 70 Alternator, instructions ...................................... 136

C

Assembling working equipment - safety instructions ............................................................ 90

Cab interior lamp .............................................. 171

Assisted starting (jump-starting) ...................... 166 Assisted starting (jump-starting) - Safety instructions .......................................................... 165

Cab interior lighting ............................................ 39 Carry out visual inspection ................................ 89 CE Mark.............................................................. 30

Attaching the bucket .......................................... 92

Centre of gravity position during transport .......... 31

Attaching the equipment carrier .......................... 96

Change of engine oil ........................................ 109

Attaching the four-in-one bucket ........................ 94

Changing a wheel ............................................ 156

Attachments........................................................ 35

Changing the cooling liquid .............................. 128

ATTACHMENTS ................................................ 92

Changing the engine oil .................................... 125

Axle number ...................................................... 35

Changing the hydraulic oil ................................ 142

Axles .................................................................. 16

Chassis .............................................................. 16

AXLES .............................................................. 146

Checking / replacing safety filter ...................... 131 Checking air-intake lines .................................. 132

B Backrest adjustment .......................................... 41 Basic unit ............................................................ 16 Battery .............................................................. 137 Battery - checking the charge .......................... 138 Battery - checking the fluid level ...................... 138

Checking of fork prongs.................................... 181 Checking the accumulator pressure ................ 177 Checking the brake disks ................................ 149 Checking the braking pressure ........................ 176 Checking the bucket locking .............................. 93

Checking the cooling liquid level ...................... 128

Driver’s cab door ................................................ 37

Checking the engine oil level / Topping up oil .. 124

DRIVER’S CAB VENTILATION ........................ 157

Checking the hydraulic oil level ........................ 140

Driver’s stand, overall layout .............................. 44

Checking the preloading pressure .................... 177

DRIVING ............................................................ 63

Checking the tyre pressure - Reinflating the tyre.................................................................... 154

Driving .......................................................... 66, 67

Chock ................................................................ 89 Cigarette lighter / Socket outlet .......................... 62 Cleaning and refuelling of machine .................... 89

Driving - Safety instructions ................................ 63 Driving on public road ........................................ 84 Driving on public roads ...................................... 72 Dust-discharge valve ........................................ 129

Cleaning jobs .................................................... 109 Cleaning the fuel tank ...................................... 134

E

Cleaning the main filter element ...................... 131

Electric energy ...................................................... 8

Cleaning the water pre-separator .................... 134

Electrical system ................................................ 16

Closing the door ................................................ 37

ELECTRICAL SYSTEM............................ 136, 167

Combined functions ............................................ 86

Electrical system key-switch .............................. 55

Combustion engine start / stop ........................ 187

Electrical system ON / OFF ................................ 54

Connecting the jumper cables .......................... 166

Emergency exit .................................................. 38

Control lever - 3rd/4th function .......................... 87

Engine ................................................................ 66

Control lever - Travelling / Working .................... 65

ENGINE .................................................... 124, 164

Control lever for bucket equipment .................... 85

Engine .............................................................. 186

Control lever locking .......................................... 87

Engine - repair instructions .............................. 164

Coolant temperature .......................................... 71

Engine does not start.......................................... 56

COOLING SYSTEM ........................................ 127

Engine number .................................................. 35

Crankcase ventilation ...................................... 126

Engine oil pressure ............................................ 70

D

Entering and leaving the machine - Safety instructions ........................................................ 36

DESCRIPTION OF THE MACHINE .................. 15 Designated use .................................................... 4

Environmentally compatible hydraulic fluid (biodegradability) .............................................. 143

Detaching the bucket .......................................... 93

Environmentally compatible hydraulic fluid, conversion ........................................................ 143

Detaching the four-in-one bucket (bottomdump bucket) ...................................................... 95

Environmentally compatible hydraulic fluid, operating instructions ...................................... 143

Disengaging fast speed ...................................... 68 Documentation .................................................. 38

Environmentally compatible hydraulic fluid, sampling .......................................................... 144

Draining hose for oil changes .......................... 108

Equipment carrier with lifting forks ...................... 96

Draining off water ............................................ 134 Drive unit ............................................................ 16 DRIVER’S CAB .................................................. 36

F

I

Fan .................................................................... 58

Immobilizer ........................................................ 54

Fast-speed variant (optional equipment) ............ 68

Injection nozzles .............................................. 135

Fastening of wheels.......................................... 156

Inside the machine ............................................ 29

Fault.................................................................. 185

INSPECTION AND SERVICING - SAFETY INSTRUCTIONS .............................................. 103

Filling the hydraulic reservoir with oil ................ 142 Filter.................................................................. 157 Floating position of the bucket equipment .......... 86 Floodlamp ........................................................ 171 Floodlamps, front ................................................ 98 Floodlamps, rear ................................................ 98

Inspection and servicing plans - instructions .... 109 Instructions on troubleshooting ........................ 185 Intervals ............................................................ 109

J Joints and hinges.............................................. 117

Fold-down window .............................................. 37 Fore-and-aft adjustment .............................. 41, 42

L

Four-in-one bucket ............................................ 94

Layout of fault table .......................................... 185

Front and rear axle ............................................ 66

Layout of the machine ........................................ 15

Front axle.......................................................... 146

Lifting cylinder - installation .............................. 174

Fuel filter .......................................................... 133

Lifting forks ................................................ 96, 181

FUEL SYSTEM ................................................ 133

Lighting ...................................................... 61, 169

FUNDAMENTAL SAFETY INSTRUCTIONS ........ 4

Loading by crane ................................................ 76

Fuses ................................................................ 167

Locking the control levers .................................. 87 LUBRICANTS .................................................. 120

G Gas, dust, steam and smoke ................................ 8 Greases for bearing points and slewing rings .. 123

H Headlamp ........................................................ 169 Heating .............................................................. 58 Height adjustment ........................................ 40, 42 Horn, travel direction indicator, main beam and windscreen wiper / -washer ........................ 59 Hydraulic and pneumatic equipment .................... 9 Hydraulic oil temperature.................................... 69 Hydraulic reservoir............................................ 142 Hydraulic system ................................................ 16 HYDRAULIC SYSTEM ............................ 140, 174

LUBRICATING CHART - GREASE .................. 116 Lubricating chart - grease ................................ 117 LUBRICATING THE GREASING POINTS ...... 157

M Machine number ................................................ 35 MAINTENANCE WORK .................................. 107 MAINTENANCE, SAFETY INSTRUCTIONS........ 7 Measure............................................................ 185 Monitoring the indicators .................................... 69

N Noise .................................................................... 9 Noise emissions ................................................ 29

O

PREFACE ............................................................ 3

Oil / Greases .................................................... 109

Preserving the engine ...................................... 158

OIL INSPECTION PLAN .................................. 118

Prior to assisted starting .................................. 166

Oil inspection plan ............................................ 119

PUTTING THE LOADER OUT OF OPERATION ................................................................ 158

Oil, grease and other chemical substances .......... 9 PUTTING THE MACHINE INTO OPERATION .. 53 Oils for axles and gearboxes (selection) .......... 122 Oils for hydraulic system, mineral .................... 121

Q

Oils for hydraulic system, synthetic (biodegradability) ............................................................ 145

Quick-change device .................................... 87, 92

Oils for internal combustion engines ................ 120

R

Opening the door ................................................ 37 Opening the engine hood ................................ 107 OPERATING, SAFETY INSTRUCTIONS ............ 6 Operating-hours meter .................................... 108 OPERATION - SAFETY INSTRUCTIONS ........ 13 OPTIONAL EQUIPMENT .......................... 88, 143 Organizational measures...................................... 5 Outside the machine .......................................... 29

P Parking brake .................................................. 149 PART 1 - INTRODUCTION .................................. 1 PART 2 - OPERATION ...................................... 11 PART 3 - INSPECTION AND SERVICING ...... 101 PART 4 - REPAIR WORK ................................ 161 PART 5 - ANNEX ............................................ 183

Rated load at stability limit .................................. 32 Rear axle .......................................................... 147 Rear screen wiper / washer ................................ 62 Rearward tilt position ........................................ 180 RECOMMISSIONING ...................................... 159 Recovering / towing of the machine.................... 74 Recovery and towing, safety instructions .......... 74 Reducing braking pressure .............................. 149 Refilling quantities - Oil .................................... 119 Refilling quantities - Other ................................ 119 Refuelling............................................................ 53 Refuelling - Safety instructions .......................... 53 Removal of engine preserving agents .............. 159 Removing and installing the battery.................. 139 Removing the equipment carrier ........................ 96

Pipe-break safety system ................................ 100

Removing, checking and cleaning the main filter element .................................................... 130

Plan B - after every 500 HOURS ...................... 114

REPAIR WORK - SAFETY INSTRUCTIONS .. 163

Plan C - after every 1000 HOURS .................... 114

Replacing alternator / coolant pump V-belts .... 164

Plan D - after every 3000 HOURS .................... 114

Replacing bulbs ................................................ 168

Plan N - After initial commissioning .................. 111

Replacing fuses ................................................ 168

Plan T - All 10 HOURS or each working shift .. 112 Plan V - once prior to initial commissioning ...... 110

Replacing hydraulic hoses - Safety instructions .................................................................. 174

Plan W - All 50 HOURS or weekly .................... 112

Replacing of teeth ............................................ 179

Planetary gears ................................................ 148

Replacing the brake disks ................................ 176

Possible causes................................................ 185

Replacing the engine oil filter............................ 126 Replacing the filter ............................................ 140

Replacing the lamp .......................................... 172

T

Replacing V-belts ............................................ 164

Tail/brake signal lamp ...................................... 170

Return flow filter................................................ 140

Taking up loads .................................................. 97

Road transfer ...................................................... 84

TECHNICAL DATA ................................ 17, 21, 25

Roller blind.......................................................... 39

Towing ................................................................ 75

Rotary beacon ............................................ 98, 172

Towing lug .......................................................... 74 Transfer gearbox .............................................. 147

S Safety instructions .................... 136, 146, 175, 178 Safety instructions for inspection and servicing 124 Seat belt ............................................................ 64

Transmission ............................................ 190, 191 Transport ............................................................ 76 Transport - Important information ...................... 76

Seat belt - Safety instructions ............................ 64

TRANSPORTING AND TOWING - RECOMMISSIONING ........................................................ 9

Section.............................................................. 185

Transporting loads .............................................. 97

Securing the machine ................................ 89, 107

Travel direction and gears .................................. 67

Selection and qualification of personnel .............. 6

Travel motor number .......................................... 35

SERVICING ...................................................... 108

Travel pump number .......................................... 35

Servicing material ............................................ 109

TROUBLESHOOTING .................................... 185

Setting down loads ............................................ 97

Turn signal lamp .............................................. 170

STABILITY.......................................................... 31

Tyre pressure .................................................. 155

STANDARD EQUIPMENT ................................ 85

Tyre pressure - Safety instructions .................. 153

Standard operation .............................................. 6

Tyre tread position ............................................ 156

Start .................................................................... 67

TYRES AND WHEELS .................................... 152

Starting .............................................................. 55

Tyres and wheels - Safety instructions ............ 152

Starting and stopping the engine ........................ 55 Starting the engines.......................................... 166 Steering and working hydraulics ........................ 66 Steering column - Safety instructions ................ 63 Steering hydraulic system ................................ 142 Steering system ................................................ 188 Stopping the engine............................................ 56 Sweeper ............................................................ 88 Switches and pushbuttons.................................. 49

U Unlocking the control levers .............................. 87 Upper dumping position.................................... 180

V Valve clearance ................................................ 127 Ventilation .......................................................... 57 Ventilation and heating ...................................... 57 Vertical vibration level at the operator’s seat ...... 29 Vibration level at hands and arms ...................... 29 Vibration levels .................................................. 29

W Warming up the machine .................................... 66 Warning and control lamps ................................ 45 Warning and instruction signs ............................ 33 WARNING OF SPECIAL DANGERS .................. 8 WARNING, MONITORING AND CONTROL ELEMENTS ........................................................ 43 Warnings and symbols ........................................ 4 Water pre-separator ........................................ 134 Weight adjustment .............................................. 40 WELDING OPERATIONS ................................ 173 Welding operations - safety instructions .......... 173 Wheel loader 121D ............................................ 21 Wheel loader 21D .............................................. 17 Wheel loader 221D ............................................ 25 Without shut-off possibility ................................ 100 Working equipment ............................................ 16 WORKING EQUIPMENT............................ 90, 179 Working equipment .......................................... 189 Working hydraulic system ................................ 142 Working on brakes, safety instructions ............ 149 WORKING OPERATION .................................... 78 Working operation - Safety instructions .............. 78 Working with lifting forks .................................... 97