Case 21D 221D Wheel Loaders Operator's Manual 6-34101NA - PDF DOWNLOAD

21D 221D Wheel Loaders

Operator’s Manual Revision Date: 05/2004 6-34101NA

THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS AND BE ALERT TO THE POSSIBILITY OF DEATH OR SERIOUS INJURY Safety Decals on this machine use the words Danger, Warning or Caution, which are defined as follows: • DANGER: Indicates an immediate hazardous situation which, if not avoided, will result in death or serious injury.

The color associated with Danger is RED. • WARNING: Indicates a potentially hazardous situation which, if not avoided will result in serious injury. The color associated with Warning is ORANGE. • CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

It may also be used to alert against unsafe practices. The color associated with Caution is YELLOW.

IMPROPER OPERATION OF THIS MACHINE CAN CAUSE DEATH OR SERIOUS INJURY. BEFORE USING THIS MACHINE, MAKE CERTAIN THAT EVERY OPERATOR: • Is instructed in safe and proper use of the machine.

• Reads and understands the Manual(s) pertaining to the machine.

• Reads and understands ALL Safety Decals on the machine.

• Clears the area of other persons.

• Learns and practices safe use of machine controls in a safe, clear area before operating this machine on a job site.

It is your responsibility to observe pertinent laws and regulations and follow Case Corporation instructions on machine operation and maintenance.

Copyright O2004 c CNH America LLC. All rights reserved

Ber 6-34101 May, 2004

Issued May, 2004 • 6-34101NA • Ber Copyright © 2004 CNH America LLC. All Rights Reserved.

OPERATOR’S MANUAL 21D / 221D

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

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 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 21D Wheel Loader .................................................................................................................................. 17 TECHNICAL DATA .................................................................................................................................. 21 221D Wheel Loader ................................................................................................................................ 21 Noise emissions Outside the machine ............................................................................................................................ 25 Inside the machine ................................................................................................................................ 25 Vibration levels Vertical vibration level at the operator’s seat ........................................................................................ 25 Vibration level at hands and arms ........................................................................................................ 25 STABILITY Center of gravity position during transport ............................................................................................ 26 Rated load at stability limit .................................................................................................................... 27 Warning and instruction signs Machine number.................................................................................................................................... 32 Engine number ...................................................................................................................................... 32 Axle number .......................................................................................................................................... 32 Travel pump number ............................................................................................................................ 32 Travel motor number ............................................................................................................................ 32 Attachments .......................................................................................................................................... 32 DRIVER’S CAB Entering and leaving the machine - Safety instructions ........................................................................ 33 Driver’s cab door

Opening the door .................................................................................................................................. 34 Closing the door .................................................................................................................................... 34 Slide-down window ................................................................................................................................ 34 Emergency exit ...................................................................................................................................... 35 Documentation ........................................................................................................................................ 35 Cab interior lighting ................................................................................................................................ 36 Roller blind .............................................................................................................................................. 36 Adjusting the operator’s seat Adjusting the weight-oriented suspension ............................................................................................ 37 Weight adjustment ................................................................................................................................ 37 Height adjustment ................................................................................................................................ 37 Fore-and-aft adjustment ........................................................................................................................ 38 Backrest adjustment .............................................................................................................................. 38 Adjusting the right armrest .................................................................................................................... 39 Height adjustment ................................................................................................................................ 39 Fore-and-aft adjustment ........................................................................................................................ 39 WARNING, MONITORING AND CONTROL ELEMENTS ...................................................................... 40 Driver’s compartment, overall layout .................................................................................................... 41 Warning and control lamps .................................................................................................................... 42 Switches and pushbuttons .................................................................................................................... 46 PUTTING THE MACHINE INTO OPERATION ........................................................................................ 50 Refueling Refueling - Safety instructions .............................................................................................................. 50 Refueling .............................................................................................................................................. 50 Electrical system ON / OFF Battery main switch .............................................................................................................................. 51 Immobilizer .............................................................................................................................................. 51 Electrical system key-switch Starting and stopping the engine .......................................................................................................... 52 Starting .................................................................................................................................................. 52 Engine does not start ............................................................................................................................ 53 Stopping the engine .............................................................................................................................. 53 Ventilation and heating Ventilation.............................................................................................................................................. 54

Heating .................................................................................................................................................. 55 Fan ........................................................................................................................................................ 55 Horn, turn signal, main beam and windscreen wiper / -washer.......................................................... 56 Lighting .................................................................................................................................................... 58 Rear screen wiper / washer .................................................................................................................... 59 Cigarette lighter / Socket outlet ............................................................................................................ 59 DRIVING .................................................................................................................................................. 60 Driving - Safety instructions .................................................................................................................. 60 Adjustment of steering column Steering column - Safety instructions .................................................................................................... 60 Adjusting the steering column .............................................................................................................. 61 Seat belt Seat belt - Safety instructions ................................................................................................................ 61 Control lever - Traveling / Working ...................................................................................................... 62 Driving Warming up the machine ...................................................................................................................... 63 Engine .................................................................................................................................................. 63 Steering and working hydraulics .......................................................................................................... 63 Front and rear axle ................................................................................................................................ 63 Braking and stopping ............................................................................................................................ 63 Start ...................................................................................................................................................... 64 Travel direction and gears .................................................................................................................... 64 Fast-speed variant (optional equipment) Activating fast speed ............................................................................................................................ 65 Disengaging fast speed ........................................................................................................................ 65 Monitoring the indicators Hydraulic oil temperature ...................................................................................................................... 66 Engine oil pressure................................................................................................................................ 67 Alternator .............................................................................................................................................. 67 Air filter .................................................................................................................................................. 67 Coolant temperature.............................................................................................................................. 68 Braking pressure .................................................................................................................................. 68 Driving on public highways .................................................................................................................. 69 Recovering / towing of the machine Recovery and towing, safety instructions .............................................................................................. 71

Towing lug ............................................................................................................................................ 71 Towing .................................................................................................................................................. 72 Transport Transport - Important information .......................................................................................................... 73 Loading by crane .................................................................................................................................. 73 Locking the articulated joint .................................................................................................................. 74 WORKING OPERATION Working operation - Safety instructions ................................................................................................ 75 Driving on the public highway ................................................................................................................ 81 Highway transfer .................................................................................................................................. 81 STANDARD EQUIPMENT ...................................................................................................................... 82 Control lever for bucket equipment Floating position of the bucket equipment ............................................................................................ 83 Combined functions .............................................................................................................................. 83 Control lever - 3rd/4th function .............................................................................................................. 84 Quick-coupler ........................................................................................................................................ 84 Control lever locking .............................................................................................................................. 84 Locking the control levers ...................................................................................................................... 84 Unlocking the control levers .................................................................................................................. 84 OPTIONAL EQUIPMENT Bottom-dump bucket ............................................................................................................................ 85 Sweeper ................................................................................................................................................ 85 After daily operation Securing the machine............................................................................................................................ 86 Cleaning and refueling of machine ........................................................................................................ 86 Carry out visual inspection .................................................................................................................... 86 Wheel chock .......................................................................................................................................... 86 WORKING EQUIPMENT .......................................................................................................................... 87 Assembling working equipment - safety instructions ........................................................................ 87 ATTACHMENTS ...................................................................................................................................... 89 Quick-coupler .......................................................................................................................................... 89 Bucket Attaching the bucket .............................................................................................................................. 89 Checking the bucket locking .................................................................................................................. 90 Detaching the bucket ............................................................................................................................ 90 Four-in-one bucket

Attaching the four-in-one bucket............................................................................................................ 91 Detaching the four-in-one bucket (bottom-dump bucket) ...................................................................... 92 Carriage with lifting forks Attaching the equipment carrier ............................................................................................................ 93 Removing the Carriage ........................................................................................................................ 93 Lifting forks ............................................................................................................................................ 93 Working with lifting forks ........................................................................................................................ 94 Picking up loads .................................................................................................................................... 94 Transporting loads ................................................................................................................................ 94 Setting down loads ................................................................................................................................ 94 Floodlamps, front.................................................................................................................................... 95 Floodlamps, rear .................................................................................................................................... 95 Rotating beacon ...................................................................................................................................... 95 Acoustic reversing signal (Back-up alarm) .......................................................................................... 96 Load holding safety device Without shut-off possibility .................................................................................................................... 97

PART 3 - INSPECTION AND SERVICING INSPECTION AND SERVICING - SAFETY INSTRUCTIONS .............................................................. 101 MAINTENANCE WORK Securing the machine.......................................................................................................................... 105 Opening the engine hood .................................................................................................................... 105 SERVICING Draining hose for oil changes .............................................................................................................. 106 Hourmeter .......................................................................................................................................... 106 Inspection and servicing plans - instructions Intervals .............................................................................................................................................. 107 Change of engine oil .......................................................................................................................... 107 Oil / Grease ........................................................................................................................................ 107 Cleaning jobs ...................................................................................................................................... 107 Servicing material ................................................................................................................................ 107 Plan V - once prior to initial commissioning ........................................................................................ 108 Plan N - After initial commissioning .................................................................................................... 109 Plan T - Every 10 HOURS or each working shift ................................................................................ 110 Plan W - Every 50 HOURS or weekly ................................................................................................ 110 Plan B - after every 500 HOURS ........................................................................................................ 112 Plan C - after every 1000 HOURS ...................................................................................................... 112 Plan D - after every 3000 HOURS ...................................................................................................... 112 LUBRICATING CHART - GREASE Lubricating chart - grease .................................................................................................................... 115 Articulations and hinges ...................................................................................................................... 115 OIL INSPECTION PLAN Oil inspection plan .............................................................................................................................. 117 Refilling quantities - Oil ........................................................................................................................ 117 Refilling quantities - Other .................................................................................................................. 117 LUBRICANTS ........................................................................................................................................ 118 Oils for internal combustion engines.................................................................................................. 118 Oils for hydraulic system, mineral ...................................................................................................... 119 Oils for axles and gearboxes (selection) ............................................................................................ 120 Greases for bearing points and articulations .................................................................................... 121 ENGINE Safety instructions for inspection and servicing .................................................................................. 122

Checking the engine oil level / Adding up oil ...................................................................................... 122 Changing the engine oil ...................................................................................................................... 123 Replacing the engine oil filter .............................................................................................................. 124 Crankcase ventilation .......................................................................................................................... 124 Valve clearance .................................................................................................................................. 125 COOLING SYSTEM Checking the cooling liquid level ........................................................................................................ 126 Changing the cooling liquid ................................................................................................................ 126 AIR-INTAKE SYSTEM Dust-discharge valve .......................................................................................................................... 127 Removing, checking and cleaning the main filter element .................................................................. 128 Cleaning the main filter element .......................................................................................................... 129 Checking / replacing safety filter.......................................................................................................... 129 Checking air-intake lines .................................................................................................................... 130 FUEL SYSTEM Fuel filter.............................................................................................................................................. 131 Water pre-separator ............................................................................................................................ 132 Draining off water ................................................................................................................................ 132 Cleaning the water pre-separator ........................................................................................................ 132 Cleaning the fuel tank .......................................................................................................................... 132 Injection nozzles .................................................................................................................................. 133 ELECTRICAL SYSTEM Safety instructions .............................................................................................................................. 134 Alternator, instructions ........................................................................................................................ 134 Battery main switch .............................................................................................................................. 135 Battery Battery - checking the fluid level .......................................................................................................... 136 Battery - checking the charge .............................................................................................................. 136 Removing and installing the battery .................................................................................................... 137 HYDRAULIC SYSTEM Checking the hydraulic oil level .......................................................................................................... 138 Return-flow filter .................................................................................................................................. 138 Replacing the filter .............................................................................................................................. 138 Breather filter ...................................................................................................................................... 139 Hydraulic reservoir Changing the hydraulic oil .................................................................................................................. 140 Filling the hydraulic reservoir with oil .................................................................................................. 140 Bleeding the hydraulic working and steering systems

Working hydraulic system .................................................................................................................. 140 Steering hydraulic system .................................................................................................................. 140 OPTIONAL EQUIPMENT ...................................................................................................................... 141 Environmentally compatible hydraulic fluid (biodegradable) Environmentally compatible hydraulic fluid, operating instructions...................................................... 141 Environmentally compatible hydraulic fluid, conversion ...................................................................... 141 Environmentally compatible hydraulic fluid, sampling ........................................................................ 142 Oils for hydraulic system, synthetic (biodegradability) .................................................................... 143 AXLES .................................................................................................................................................... 144 Safety instructions................................................................................................................................ 144 Front axle .............................................................................................................................................. 144 Rear axle ................................................................................................................................................ 145 Transfer gearbox .................................................................................................................................. 145 Planetary gears .................................................................................................................................... 146 BRAKES Working on brakes, safety instructions ................................................................................................ 147 Parking brake ........................................................................................................................................ 147 Reducing braking pressure ................................................................................................................ 147 Checking the brake disks .................................................................................................................... 147 Bleeding the braking system Bleeding .............................................................................................................................................. 149 TIRES AND WHEELS Tires and wheels - Safety instructions ................................................................................................ 150 Tire pressure - Safety instructions ...................................................................................................... 151 Checking tire pressure - Reinflating the tires ...................................................................................... 152 Tire pressure ...................................................................................................................................... 153 Changing a wheel................................................................................................................................ 154 Fastening of wheels ............................................................................................................................ 154 Tire tread direction .............................................................................................................................. 154 LUBRICATING THE GREASING POINTS ............................................................................................ 155 DRIVER’S CAB VENTILATION Filter .................................................................................................................................................... 155

STORING THE LOADER Engine conservation ............................................................................................................................ 156 Battery storage .................................................................................................................................... 156 RECOMMISSIONING Removal of engine conserving agents ................................................................................................ 157

PART 4 - REPAIR WORK REPAIR WORK - SAFETY INSTRUCTIONS ........................................................................................ 161 ENGINE .................................................................................................................................................. 162 Engine - repair instructions Replacing V-belts ................................................................................................................................ 162 Replacing alternator / coolant pump V-belts........................................................................................ 162 Assisted starting (jump-starting) - Safety instructions Assisted starting (jump-starting) .......................................................................................................... 164 Prior to assisted starting ...................................................................................................................... 164 Connecting the jumper cables ............................................................................................................ 164 Starting the engines ............................................................................................................................ 164 ELECTRICAL SYSTEM Fuses .................................................................................................................................................. 165 Replacing fuses .................................................................................................................................. 166 Replacing bulbs .................................................................................................................................. 166 Lighting Headlamp ............................................................................................................................................ 167 Turn signal lamp .................................................................................................................................. 168 Tail/brake signal lamp ........................................................................................................................ 168 Cab interior lamp ................................................................................................................................ 169 Floodlamp............................................................................................................................................ 169 Rotating beacon .................................................................................................................................. 170 Replacing the lamp.............................................................................................................................. 170 WELDING OPERATIONS Welding operations - safety instructions .............................................................................................. 171 HYDRAULIC SYSTEM Replacing hydraulic hoses - Safety instructions .................................................................................. 172 Lifting cylinder - installation ................................................................................................................ 172 BRAKES Safety instructions .............................................................................................................................. 173 Checking the braking pressure ............................................................................................................ 174 Replacing the brake disks .................................................................................................................. 174 Checking the accumulator pressure .................................................................................................... 175 Checking the preloading pressure ...................................................................................................... 175 ACCUMULATORS ................................................................................................................................ 176 Safety instructions................................................................................................................................ 176

WORKING EQUIPMENT Bucket ................................................................................................................................................ 177 Replacing teeth .................................................................................................................................. 177 Bucket limit stops ................................................................................................................................ 178 Upper dumping position ...................................................................................................................... 178 Rearward tilt position .......................................................................................................................... 178 Lifting forks Checking of forks ................................................................................................................................ 179

PART 5 - ANNEX TROUBLESHOOTING .......................................................................................................................... 183 Instructions on troubleshooting .......................................................................................................... 183 Layout of fault table Fault .................................................................................................................................................... 183 Cause .................................................................................................................................................. 183 Remedial acxion .................................................................................................................................. 183 Chapter reference .............................................................................................................................. 183 Engine .................................................................................................................................................... 184 Engine start / stop ................................................................................................................................ 185 Steering system .................................................................................................................................... 186 Working equipment .............................................................................................................................. 187 Transmission ........................................................................................................................................ 188 Brake system ........................................................................................................................................ 190 ABBREVIATIONS .................................................................................................................................. 191

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

Operator’s manual

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS

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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

1

OPERATOR’S MANUAL 21D / 221D

BLANK PAGE

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OPERATOR’S MANUAL 21D / 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 does not set out to give working instructions for carrying out major repairs.

Such work is willingly done for you by our aftersales 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 and to carry out all required specialised repair work in case of unsatisfactory loader 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 is intended for 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 / 221D

Warnings and symbols

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

Imminent danger involving the risk of death or of severe injuries.

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 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.

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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.

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 life-threatening 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 accordance 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 / 221D Organizational measures The operator’s manual must always be to hand at the place of use of the machine, e.g. by stowing it 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 giving notification of special organizational measures, 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 behavior 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 / 221D Selection and qualification of personnel

OPERATING, SAFETY INSTRUCTIONS

Any work on and with the machine must be carried out 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 work 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 from 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 have 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 traveling 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 behavior) 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 traveling 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 traveling 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 / 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 carried out by skilled personnel only.

Always keep at a safe 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 traveling downhill.

On sloping terrain always adapt your traveling 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 starter switch 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 fore-man 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 / 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, a 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.

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.

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, keep at 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 - 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 / 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).

9

OPERATOR’S MANUAL 21D / 221D

BLANK PAGE

10

OPERATOR’S MANUAL 21D / 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

11

OPERATOR’S MANUAL 21D / 221D

BLANK PAGE

12

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

2913001

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

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

Always have inspection and maintenance work carried out on schedule.

Operating personnel

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

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

The 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.

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

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

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

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

13

OPERATOR’S MANUAL 21D / 221D

Entering and leaving the machine

Flagmen

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

The flagman must keep outside the hazard zone.

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.

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

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

Keep in constant contact with the flagman.

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

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

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 / 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-coupler

9

-

Travel pump

15

OPERATOR’S MANUAL 21D / 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-coupler, lifting and tilting cylinders and the bucket.

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

OPERATOR’S MANUAL 21D / 221D TECHNICAL DATA

1946692

21D Wheel Loader

Operating weight 9260 lb Engine output 56.5 hp Standard-bucket 0.92 yd3 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-coupler Wide range of attachments

17

OPERATOR’S MANUAL 21D / 221D 21D Wheel Loader

Hydraulics

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

Model 70430 56.5 hp / 2300 min-1 4 Euro 1 water

Pump flow for working and steering hydraulics 3.21 gal/min Pressure, working hydraulic 3335.9 psi Pressure, steering hydraulic 2538.2 psi 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 • "Inching pedal" reduces travel speed at full engine rpm with more engine output being diverted to working hydraulics • Powershift for all gears.

Integrated quick -coupler Tip bucket capacity* acc. SAE J 742b/CECE 0.92 yd3 Dump bucket capacity* acc. SAE J 742b/CECE 0.85 yd3 Tipload (articulated) 6160 lb Effective lift force at ground level 8992 lbf Effective break-out force acc. SAE J 732C-ISO 8313 10566 lbf 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 - 12.4 mph 0 - 3.72 mph

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.

Tires Diagonal type tires Radial type tires Other tires on request

12.5-20 335/80 R18 365/70 R18

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

Additional brake: wear-free all-wheel brake through retardation in hydrostatic transmission, actuated via inching-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 157 in • 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

23.4 gal 15.6 gal 4.03 gal

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 3.4 hp / 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 / 221D Dimensions 21D

Bottom Dump Bucket 0.85 yd3 bucket 75 in wide, = 1.35 ton/yd3* (with 335/80 - R18 tyres) in in A= 200.0 G= 29.33 B= 193.7 G1 = 22.04 D = 148.03 G2 = 29.92 D1 = 167.51 H= 31.49 E = 119.09 C= 3.93 F= 94.68 Weight approx. 9372 lb with ROPS/FOPS cab * counterweight (440 lb) required

Lifting forks with Quick-Coupler Dimensions: with tires 335/80R18 in F 3.93 F1 67.51 F2 108.85 G 32.87 G1 47.44 G2 20.27 57.08 3.93

Lift height

Width of fork carriage Tine width

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

FEM II, 57.1 in wide 3.93 x 1.77 x 47.24 in 2B standard 335/80 R18 -9039 lb 3858 lb Payload 3086 lb * 2315 lb

Configuration FEM II, 57.1 in wide 3.93 x 1.77 x 47.24 in 2B standard 335/80 R18 441 lb 9392 lb 4134 lb Payload 3307 lb 2480 lb

* not applicable to full lifting height. Max payload over full lifting height: 3417 lb.

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 / 221D Loading bucket 21D 0.85 yd3 bucket, 70.86 in wide, 0.92 yd3 bucket, 74.80 in wide, 1.05 yd3 bucket, 74.80 in wide, * with counterweight

= 1.5* ton/yd3 = 1.35 ton/yd3 = 1.2 ton/yd3

Dimensions: (for tires 335/80R18) in A =198.22 B =193.70 C = 2.75 D =148.22 E =119.09 F = 96.45

bucket 0,85 yd3 in in G = 29.13 T =16.33 H = 104.52 I = 74.01 J = 56.69 K = 12.99 N = 83.46

Dimensions: (for tires 335/80R18) in A= 198.22 B= 193.70 C = 2.75 D= 148.22 E= 119.09 F =96.45

bucket 0.92 yd3 in in G =29.13 T =16.33 H= 104.52 I =74.01 J =56.69 K =12.99 N =83.46

20

Dimensions: (for tires 335/80R18) in A = 201.18 B = 198.42 C= 2.75 D = 148.03 E = 119.09 F = 93.11

bucket 1.05 yd3 in in G = 32.87 T =16.33 H = 104.52 I = 74.01 J = 56.96 K = 12.99 N = 83.46

OPERATOR’S MANUAL 21D / 221D TECHNICAL DATA

1946694

221D Wheel Loader

Operating weight 11440 lb Engine output 62 hp Standard-bucket 1.17 yd3 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-coupler Wide range of attachments

21

OPERATOR’S MANUAL 21D / 221D 221D Wheel Loader

Hydraulics

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

Model 70430 62 hp / 2500 min-1 4 Euro 1 water

Pump flow for working and steering hydraulic 16.6 gal/min Pressure, working hydraulic 3335.9 psi Pressure, steering hydraulic 2538.2 psi 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 • "Inching pedal" reduces travel speed at full engine rpm with more engine output being diverted to working hydraulics • Powershift for all gears.

Integrated quick-coupler Tip bucket capacity* acc. SAE J 742b/CECE 1.17 yd3 Dump bucket capacity* acc. SAE J 742b/CECE 1.11 yd3 Tipload (articulated) 8470 lb Effective lift force at ground level 11015.6 lbf Effective break-out force acc. SAE J 732C-ISO 8313 13488.5 lbf 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 - 12.4 mph 0 - 3.72 mph

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.

Tires Diagonal type tires Radial type tires Other tires on request

14.5 - 20 365/80 R20 405/70 R20

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

Additional brake: wear-free all-wheel brake through retardation in hydrostatic transmission, actuated via inching-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 169.29 in • 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

26 gal 16.9 gal 4.03 gal

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 3.4 hp / 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 / 221D Dimensions 221D

Bottom Dump Bucket 1.11 yd3 bucket 80.70 in wide, = 1.35 ton/yd3 (with 365 / 80R20 tires) in in A = 210.23 F= B = 207.87 G= 30.51 C= 3.34 G1 = 21.65 D = 159.25 G2 = 32.28 D1 = 177.36 H= 108.85 E= Weight approx. 11660 lbs with ROPS/FOPS cab

Lifting forks with Quick-Coupler Dimensions: with tires 365/80R20 in F 3.93 F1 52.75 F2 115.35 G 31.88 G1 47.83 G2 19.09 57.08 3.93

Lift height

Width of fork carriage Tine width

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

FEM II, 20.27 in wide 3.93 x 1.77 x 47.24 in 2B standard 365/80 R20 --11220 lb 4950 lb Payload 3960 lb * 2970 lb

Configuration FEM II, 20.27 in wide 3.93 x 1.77 x 47.24 in 2B standard 365/80 R20 440 lb 11660 lb 6050 lb Payload 4840 lb 3630 lb

* not applicable to full lifting height. Max payload over full lifting height: 4840 lb.

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 / 221D Loading bucket 221D 1.17 yd3 bucket, 80.70 in wide, 1.3 yd3 bucket, 82.67 in wide,

= 1.35 / 1.5* ton/yd3 = 1.35 ton/yd3

* with counterweight

Dimensions: (for tires 365 / 80R20) bucket 1.17 yd3, 80.70 in wide in in in A = 210.23 G = 30.31 T =18.11 B = 206.69 H = 108.85 C= 3.34 I = 76.57 D = 156.88 J = 60.07 E = 124.21 K = 14.96 F = 98.81 N = 88.58

24

Dimensions: (for tires 365 / 80R20) bucket 1.3 yd3, 82.67 in wide in in in A = 210.43 G = 30.31 T =18.11 B = 206.69 H = 108.85 C= 3.54 I = 76.57 D = 159.05 J = 60.07 E = 124.21 K = 14.96 F = 98.81 N = 88.58

OPERATOR’S MANUAL 21D / 221D Noise emissions

2747156

Outside the machine The sound power level LWA during working is: 21D - 100 dB(A) 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 / 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 lengths, 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 lengths, 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).

25

OPERATOR’S MANUAL 21D / 221D STABILITY

2747157

Fig. 1

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

221D

x = 50 in

x = 55.51 in

The center of gravity position depends upon the attachment position.

26

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

221D

Tires

Steering angle

max. payload (lb)

Steering angle

max. payload (lb)

STANDARD

0

3305.7

0

4784.8

Bucket

41

2921.6

41

4189.5

OPTIONAL

0

3528.0 *

0

5071.5 *

Lifting forks without additional counterweight

41

3087.0 *

41

4851.0 *

OPTIONAL

0

3748.5 *

-

-

Lifting forks with additional counterweight

41

3307.5 *

-

-

* on level ground

This machine, as approved, is not intended for any other applications, namely is should not be used as a 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 factoryfitted with special equipment and instructions for the specific application.

27

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

Fig. 1

28

1946875

OPERATOR’S MANUAL 21D / 221D 9 Observe the warning and instruction signs attached to the machine.

Keep the signs clean and legible.

Replace the signs immediately if they are no longer legible.

New warning and instructions signs can be obtained from the Spare-parts service.

The Part Numbers for ordering are set out in the spare-parts list of your machine.

Legend of Fig. 1 1

- Operation This sign shows the control levers and the corresponding movements of the working equipment. Observe also the instructions in the Owner’s Manual.

2

- Fire extinguisher Indicates the place where the fire extinguisher is located.

3

- Risk of burning caused by hot coolant.

Open the cap of the radiator only after the coolant has had time to cool down.

4

- Parking brake The parking brake can be applied or released here. Observe the instructions in the Owner’s Manual.

5

- Fuses Indicates the location of the fuses.

6

- Risk of injury from unauthorized starting of the machine. Before working on the machine, shut off the engine and remove the key. Observe the instructions in the Owner’s Manual (see: "Inspection and servicing, safety instructions").

7

8

- Risk of injury from battery acid and gases. Observe the instructions in the Owner’s Manual (see: "Inspection and servicing, safety instructions", "Electrical system, safety instructions" and "Starting aid").

- Battery main switch Never set battery main switch to OFF when the engine is running. Risk of damage to alternator and electronic modules.

Observe the instructions in the Owner’s Manual (see: "Inspection and servicing, safety instructions", "Electrical system, safety instructions").

- Risk of injury from hydraulic fluid under pressure. Depressurize the hydraulic system before working on the system itself, the reservoir or the filters (see Owner’s Manual "Depressurizing the hydraulic system").

10 - Screen-washer Indicates the location of the wash fluid reservoir for the screen-washer.

11 - Risk of injury due to crushing. Put the machine into operation only after all persons have left the hazard area.

12 - Risk of injury due to unprotected articulated joint during inspection, servicing or transport. Observe the instructions in the Owner’s Manual (see: "Inspection and servicing, safety instructions" und "Transport").

13 - Risk of injury due to inadequately locked attachments. Observe the instructions in the Owner’s Manual (see: "Fitting of working equipment, safety instructions" ans "Quick-change device").

14 - Risk of injury from lowering working equipment. Observe the instructions in the Owner’s Manual (see: "Inspection and servicing, safety instructions" and "Fitting of working equipment, safety instructions").

15 - Indicates the place where slings have to be fastened for transporting the machine.

16 - Driving position Bring the attachments to driving position before setting off. Observe the instructions in the Owner’s Manual (see: "Driving on public roads").

17 - Quick-coupler Securing the quick-coupler. Observe the instructions in the Owner’s Manual (see: "Quick-coupler").

18 - Indicates the place where slings have to be fastened for transporting the machine.

19 - Fuel tank Fill with diesel fuel here.

20 - Quick-coupler Locking of quick-coupler. Observe the instructions in the Owner’s Manual (see: "Quick-coupler").

29

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

Fig. 2

30

OPERATOR’S MANUAL 21D / 221D

Observe the warning and instructions signs attached to the machine.

29 - Risk of injury Start the engine only as described in the Owner’s Manual and after all persons have left the hazard area. Observe the instructions in the Owner’s Manual.

Keep the signs clean and legible.

30 - Slow-moving vehicle

Replace the signs immediately if they are no longer legible.

31 - Risk of burning from hot, pressurized coolant. Open the cap of the radiator only after the coolant has had time to cool down. Observe the instructions in the Owner’s Manual (see: "Inspection and servicing, safety instructions" and "Cooling system").

New warning and instructions signs can be obtained from the Spare-parts service.

The Part Numbers for ordering are set out in the spare-parts list of your machine.

Legend of Fig. 2 15 - Indicates the place where slings have to be fastened for transporting the machine.

18 - Indicates the place where slings have to be fastened for transporting the machine.

21 - Control lever ’Travel’ Observe the instructions in the Owner’s Manual (see: "Traveling").

22 - Lever positions F=forward, N=neutral, R=reverse 23 - Do not put the machine into operation before having read and understood the Owner’s Manual(see "Working operations, safety instructions").

24 - Risk of injury from rotating parts in the engine compartment. Open the hood only after the engine is stationary.

25 - Risk of injury Keep at a distance from turning V-belts when the engine is running.

26 - Risk of injury from hot hydraulic oils. Observe the instructions in the Owner’s Manual (see: "Inspection and servicing, safety instructions" and "Hydraulic system").

32 - Risk of injury from hydraulic fluid under high accumulator pressure. Depressurize the hydraulic system before working on the system itself, the reservoir or the filters (see Owner’s Manual "Depressurizing the hydraulic system" and "Pressure accumulator, safety instructions").

33 - Risk of injury Do not jump out of a toppling machine. Use your safety belt.

34 - Do not put the machine into operation before having read and understood the Owner’s Manual.

35 - Risk of injury from falling loads or moving working equipment. Do no stand under raised loads or the working equipment.

36 - The fresh-air filter can be replaced here.

Observe the instructions in the Owner’s Manual (see: "Cab - Ventilation").

37 - The steering column can be adjusted here. Observe the instructions in the Owner’s Manual (see: "Steering column, safety instructions").

27 - Risk of injury from reversing machine. Set the machine in motion only after all persons have left the hazard area.

28 - Towing Observe the instructions in the Owner’s Manual (see: "Recovery and towing, safety instructions").

31

OPERATOR’S MANUAL 21D / 221D Machine number

2905024

The MACHINE NUMBER is engraved on the nameplate (Fig. 3). 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. 6).

Fig. 6 Fig. 3

Engine number The NAMEPLATE with the engine number is attached to the engine (Fig. 4).

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

Fig. 7 Fig. 4

Axle number

Attachments

The axle number can be found on the nameplate on the axle casing (Fig. 5).

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

Fig. 5

Fig. 8

32

OPERATOR’S MANUAL 21D / 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.

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

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

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

33

OPERATOR’S MANUAL 21D / 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.

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

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

Release latches 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 latches lock safely.

34

OPERATOR’S MANUAL 21D / 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.

35

OPERATOR’S MANUAL 21D / 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.

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

36

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.

OPERATOR’S MANUAL 21D / 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.

2905352

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

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

Before adjusting the seat: - stop the machine - set travel direction lever to "0" - apply parking brake.

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

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

Fig. 1

Adjusting the weight-oriented suspension

Height adjustment The height can be adjusted in several stages.

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

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

Fig. 2

37

OPERATOR’S MANUAL 21D / 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

38

OPERATOR’S MANUAL 21D / 221D Adjusting the right armrest

2905354

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.

Fig. 1

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.

39

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

Fig. 1

40

1946862

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

Function

1

Instrument panel

Incorporates warning and monitoring lamps, indicator instruments and switches

2

Steering column

Incorporates travel direction switch and steering wheel

3

Right console

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

4

Left console

Incorporates 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

Lock the parking brake

Symbol

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

Compartment for radio

41

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

Fig. 2

42

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

Page 1 of 2

Function

1

Control lamp

Turn signal, left

Lights up when the left turn signal 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

Turn signal, right

Lights up when the right turn signal 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

Symbol

43

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

Fig. 3

44

OPERATOR’S MANUAL 21D / 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.

Symbol

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)

Shows the travel speed machine.

45

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

Fig. 4

46

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

Pedal

Function Service brake and inching

Symbol

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 quick-coupler 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

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

47

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

Fig. 5

48

OPERATOR’S MANUAL 21D / 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

Preheating

Symbol

Lights up during the preheating process Adjustable

49

OPERATOR’S MANUAL 21D / 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")

2747159

221D

Refueling Refueling - 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.

21D

Fig. 1

50

Fig. 2

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

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

If possible, use a microfilter in the filling line.

OPERATOR’S MANUAL 21D / 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

Immobilizer (option)

2904964

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.

In OFF position, the battery main switch (1) prevents • unauthorized starting of the engine • inadvertent discharge of the battery.

Fig. 1

Fig. 1

Fig. 2

51

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

1946873

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

Fig. 2

Starting and stopping the engine

Fig. 1

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

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.

The automatic glow time control is switched on.

• Deactivate the immobilizer.

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

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

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.

52

Starting

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.

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.

OPERATOR’S MANUAL 21D / 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 while under 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 attempts 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.

• 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.

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.

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.

• Remove key.

• Secure wheeled loader against inadvertent movements and unauthorized starting.

53

OPERATOR’S MANUAL 21D / 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 right-hand 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

54

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

OPERATOR’S MANUAL 21D / 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

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

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.

55

OPERATOR’S MANUAL 21D / 221D Horn, turn signal, main beam and windscreen wiper / -washer

2913079

Fig. 2

Fig. 1

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

Position Function

56

Symbol

Remarks

1

Horn

Depress lever knob towards position 1

2

Turn signal, right

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

3

Turn signal, 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.

OPERATOR’S MANUAL 21D / 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.

Remove the cap and add water if necessary.

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. 4

Fig. 3

57

OPERATOR’S MANUAL 21D / 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.

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.

58

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

OPERATOR’S MANUAL 21D / 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.

• Switching off

Fig. 2

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

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

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

- Press toggle switch onto symbol-free area.

Using the socket with the engine stationary discharges the battery.

59

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

2905157

Adjustment of steering column 2905627

Steering column - Safety instructions When raising working equipment make sure 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.

Warn persons in the surrounding area by sounding 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 around 2 to 3 minutes before setting off.

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

60

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

Before adjusting the steering column: - Stop the machine.

- Lower working equipment to the ground.

- Set the travel direction to "0".

- Apply the parking brake.

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

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.

Seat belt

2905416

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

Seat belt - Safety instructions

• Pull steering column into desired position.

• Release lever to lock steering column.

Always belt up before driving.

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

This may result in injury.

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

The buckle opening must not be blocked, 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

61

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

1946867

The wheeled loader is equipped with a control lever (25, Fig. 1) with which the traveling 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 used as 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).

• 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.

62

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.

OPERATOR’S MANUAL 21D / 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 travel 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 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.

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

Fig. 1

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.

Extend and retract all hydraulic cylinders several times.

Do not warm up the steering and working hydraulic systems by keeping 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.

63

OPERATOR’S MANUAL 21D / 221D Driving Start

Observe the travel function indicator symbols (12 - 15, Fig. 1) before driving.

1946868

Travel direction and gears The functions can be engaged "under load", i.e. the machine does not have to 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.

• Sound the horn.

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

Fig. 3

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.

This feature offers the possibility of performing controlled driving operations such as precision driving, soft starting, sensitive maneuvring and controlled braking independent of 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).

64

OPERATOR’S MANUAL 21D / 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.

Disengaging fast speed Activating fast speed

Fig. 2 Fig. 1

• Switch on or start up the machine

• Machine running, fast speed is activated.

• The machine must be stationary!

• Engine running, working or creep speed activated.

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

• Preselect the fast speed with rocker switch (36, Fig. 1). Switch in 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 lamps (12 or 15, Fig.2) ON.

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

• Release brake pedal - pilot lamp(36, Fig.1) OFF.

• Release brake pedal - pilot lamp (36) OFF.

• Set rocker switch (36) to OFF.

• Set rocker switch (36) to OFF. Fast-speed remains activated.

• Fast speed is deactivated when the machine is stopped (engine off) and the working speed is activated.

• Set off slowly.

• Pilot lamp (35a) OFF.

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

65

OPERATOR’S MANUAL 21D / 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.

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

66

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

OPERATOR’S MANUAL 21D / 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

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.

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

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 is not due.

Fig. 5

67

OPERATOR’S MANUAL 21D / 221D Coolant temperature

Braking pressure

The coolant circuit is controlled by a thermostat.

The max. admissible temperature is about 221 F. The coolant temperature is monitored by indicator (19, Fig. 6).

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

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.

Fig. 7

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

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.

68

OPERATOR’S MANUAL 21D / 221D Driving on public highways

2747160

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

221D

When the vehicle is being driven on public highways, it must be equipped with a firstaid 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.

Before driving on public roads • Empty the bucket and bring into the marked position for transport (indicator on left side of lifting frame) with the bucket cutting edge pointing upwards (Fig. 1 and Fig. 2).

21D

Fig. 2

• Cover up the bucket cutting edge with a guard strip.

• Check brakes, steering, tires and lighting system.

• 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.

69

OPERATOR’S MANUAL 21D / 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

70

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

2747193

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 = 11025 lb.

221D = 12789 lb.

Fig. 1

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

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

Nobody must stand near the towing rod or rope.

Tow away only if the brakes and the steering of the machine are functional and if the machine cannot be transported by 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.

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

Towing lug

Fig. 2

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 pin (1); catch (2) is automatically locked.

71

OPERATOR’S MANUAL 21D / 221D Towing

2800967

Towing must be carried out only at low travel speed (about 3.1 mph) and over a max. distance of 540 yd 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.

Fig. 4

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.

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 the 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 the articulated joint.

72

OPERATOR’S MANUAL 21D / 221D Transport

2913078

Transport - Important information

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

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

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

Loading by crane

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

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

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

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

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

Fig. 2

Lock the articulated joint.

Never actuate the steering when the articulated joint is locked.

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

73

OPERATOR’S MANUAL 21D / 221D Locking 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 stop limit.

Fig. 3

Fig. 4

74

OPERATOR’S MANUAL 21D / 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 horn to warn persons in the surrounding area 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.

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 the "Lubricants" section.

Lower the working equipment immediately and shut off the engine if 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.

Always use and operate the wheel-mounted 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.

75

OPERATOR’S MANUAL 21D / 221D 2800542

Before starting work with the loader, the Operator should know the operating procedures included in the safety standards and those which are forbiden, otherwise he could be a cause of accidents 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 in a figure highlights a practice which is forbidden or dangerous.

Figures show wheel loaders of the small-high range.

Never accelerate hard or move off in a jerk. This causes waste of fuel and release of harmful smoke in the atmosphere.

Always drive the loader so 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 using the controls practice in a safe area. 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. Lower the bucket to the ground, block the wheels and remove the starter switch key.

76

OPERATOR’S MANUAL 21D / 221D • Do not park the loader where the exhaust silencer 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 (1.5 -2 in).

• It is recommended to apply the brakes and bring the machine to a complete stop prior to engaging reverse gear.

• 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 you may drop the load or overturn the loader.

Fig. 2

• Never use matches, a lighter or a naked flame to check fluid levels or for leaks. Never smoke while handling 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 80.

Fig. 4

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

Fig. 5 Fig. 3

77

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

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

It is good practice to have a flagman assisting you.

• When driving up or down a slope, the loader center 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 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. If possible 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 excessive 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

78

OPERATOR’S MANUAL 21D / 221D • Do not turn on a slope or move, 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 machine movements always under control.

Sound the horn when approaching people. Accidents frequently occur immediately after startup.

Fig. 12

• In case of loader faulty operation, drive it out of the transit area and then report it 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.

Fig. 13

79

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

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

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

Fig. 14

Fig. 15

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

80

OPERATOR’S MANUAL 21D / 221D Driving on the public highway

2800543

Highway transfer

2913063

Never drive the machine on public highways 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 tire inflating pressure.

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

Check all signal lights for correct operation.

Some tire types and tread patterns are not suitable for highway transfer. Consult the tire manufacturer.

Keep in mind braking distances and adjust speed consequently.

Fig. 1

1 - Bucket lock lever and lifting frame lock lever 3 - Headlights 4 - Rotating beacon

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

5 - Tail lights

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

7 - Toothed bucket cutting edge guard

6 - License plate light

Watch the gauges closely to assess correct operation. Be escorted by a vehicle to warn other highway users appropriate warning means (flashing lights, signs, etc) that a loader is traveling on the road.

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

Attention - During highway transfers carefully observe Highway Regulations. 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 highway regulations in force in the different countries.

81

OPERATOR’S MANUAL 21D / 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 about 2/3) and with the parking brake applied - to bleed any air from in the cylinders.

Control lever for bucket equipment

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

82

2913064

OPERATOR’S MANUAL 21D / 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 equipment would otherwise drop too fast.

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

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

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

For leveling, 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, held down 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 useful 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 performed one after another.

Fig. 2

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.

83

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

Control lever locking

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

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

Fig. 4

Fig. 5

Locking the control levers

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

84

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.

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

1946642

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

Control lever (26) is used to initiate the following working movements:

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.

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.

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

85

OPERATOR’S MANUAL 21D / 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 refueling of machine Remove any debris 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, tires and the working equipment.

Wheel 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 any debris dirt from the machine. Visual inspection: check hydraulic system for leaks. Visual inspection: check condition of machine, tires and equipment. Protect the machine against unauthorized starting.

Withdraw starter switch key. Close windows. Lock cab door and engine hood.

Fig. 1

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

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

86

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

2913013

Personnel

Tools and auxiliary equipment

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.

Securing working equipment Personal protective gear 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 and gloves.

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

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

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

87

OPERATOR’S MANUAL 21D / 221D 2905636

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

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.

If the wheel-mounted loader is equipped with a bucket for light-weight material with a bulk density of less than to 1.5 ton/yd3, the driver’s field of vision can be obstructed. In this case, work must either be carried out with the assistance of flagmen or with the working range of the wheel-mounted loader limited.

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

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

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

See 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 the attachment manufacturer are to hand.

88

1946672

The maximum operating pressure for the quick-coupler and the hydraulic ports for attachments is: 2902 + _72 psi

OPERATOR’S MANUAL 21D / 221D ATTACHMENTS

1946701

Quick-coupler 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 quickcoupler.

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.

Fig. 1

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 quick-coupler.

Set bucket on the ground.

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

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-coupler control lever (1, Fig. 1) must be in position "I".

Fig. 2

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

Fig. 3

89

OPERATOR’S MANUAL 21D / 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

Fig. 6

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

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-coupler. 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 lugs hook by reversing the loader.

Fig. 7

90

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

2747161

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 = 221D

Fig. 4

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

Fig. 2

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

91

OPERATOR’S MANUAL 21D / 221D

The eyelet (3, Fig. 5) provided on the fourin-one bucket (bottom-dump 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-coupler 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). Seal off the hydraulic lines and connections with the pertaining plugs.

Proceed as described under "Detaching the bucket".

Fig. 5

92

OPERATOR’S MANUAL 21D / 221D Carriage with lifting forks

2913067

Attaching the equipment carrier

Removing the Carriage

Stand the carriage (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.

Fig. 1

Loads placed at a distance of more than 19.68 in from the loader’s center of gravity reduce the payload.

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 forks including its packing. Pallets, cases and means of suspension are part of the payload.

Fig. 2

Fig. 3

93

OPERATOR’S MANUAL 21D / 221D Working with lifting forks

Lock control lever (26) with locking device (7, Fig. 4).

Setting down loads During unloading, the loader must be in horizontal position. The place of unloading must be sloping neither 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 cycle, always set lifting forks down on the ground.

Always make sure the forks are inclined backwards when transporting loads. Always approach the place of unloading with the load in raised position.

Fig. 4

Picking up loads To pick up a 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.

Transporting loads During transport, the fork carriage 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

94

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

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

1946869

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

Rotating beacon (option)

2747182

The rotating beacon (1, Fig. 1) is mounted by means of a magnetic base 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.

95

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

1946872

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

Fig. 3

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

Fig. 4

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

The rotating 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.

96

OPERATOR’S MANUAL 21D / 221D Load holding safety device (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.

• Seal off the area of the working equipment in such a way that nobody can stand below the equipment and the load or near 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 load holding safety systems. These systems prevent the working equipment from uncontrolled lowering if 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.

• 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 work be resumed.

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 work be resumed.

97

OPERATOR’S MANUAL 21D / 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

99

OPERATOR’S MANUAL 21D / 221D

BLANK PAGE

100

OPERATOR’S MANUAL 21D / 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, lock the joints. Remove the blocks on finishing work.

The operator’s manual lists all jobs to be performed. 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 shifted, 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.

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

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

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.

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.

101

OPERATOR’S MANUAL 21D / 221D

Cleaning jobs

Fastening and securing elements

Clean the units within the working range before starting work.

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

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

Replace any damaged parts.

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

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

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

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

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

Wear gloves.

Observe the instructions on the packaging.

Handling flammable liquids

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.

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

Visible loss of oil

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

Have any visible leakage repaired immediately.

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

Escaping oil is an environmental hazard.

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 house.

102

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 / 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 drive 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 an evacuation system and ventilate the premises well.

If oil has penetrated 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.

103

OPERATOR’S MANUAL 21D / 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 vapors.

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.

Disconnect first the negative pole, then the positive pole.

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 grease point, then lubricate as scheduled.

After servicing

After work:

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

Connect first the positive pole, then the negative pole.

On completing work, reinstall all protective devices.

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

Carry out a performance test with the machine.

104

OPERATOR’S MANUAL 21D / 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).

• Lock articulated joint.

• Shut off engine.

• Apply the parking brake.

• Withdraw key from the starter 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. (see "Welding operations - safety instructions" section and "Electrical system - safety instructions" section).

Fig. 1

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

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

105

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

2411336

Hourmeter

2905175

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

Collect escaping oil and evacuate it without polluting the environment.

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 make it possible to perform oil changes in a clean and non-polluting way.

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.

106

Fig. 1

The hourmeter shows the total machine operating time.

OPERATOR’S MANUAL 21D / 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 14 F.

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

In case of higher sulphur content and/or a permanent ambient temperature of below 14 F, 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.

Carry out all jobs...

Oil / Grease

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 D 1)

I

Oils for combustion engines and compressors

... every 1000 HOURS

II

Oils for hydraulic systems

... every 3000 HOURS

III

Oils for gearboxes and axles

V

Grease for bearings and pivoted connections

whichever comes first.

HOURS = Operating hours

Cleaning jobs Cleaning jobs, especially on cooling systems, must be carried out 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.

107

OPERATOR’S MANUAL 21D / 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

Brakes

Check functioning

Wheel Tires 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-coupler 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

108

Oil / Quantity/ Grease Number

OPERATOR’S MANUAL 21D / 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

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

Hydraulic system

1

1

1

109

OPERATOR’S MANUAL 21D / 221D Plan T - Every 10 HOURS or each working shift (whichever occurs first) Plan W - Every 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 Intake 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

110

1

1

• • • •

• • • • • • • •

OPERATOR’S MANUAL 21D / 221D Plan T - Every 10 HOURS or each working shift (whichever occurs first) Plan W - Every 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-coupler 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

• • • • •

111

OPERATOR’S MANUAL 21D / 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

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

Air intake system Filter element

Replace

1

•

•

•

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

1 1

• •

• •

• • • •

• • •

• • •

Cooling system

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)

112

1

2

OPERATOR’S MANUAL 21D / 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

113

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

Fig. 1

114

= Operating hours

2913071

OPERATOR’S MANUAL 21D / 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-coupler 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"

Articulations and hinges

2411970

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

115

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

Fig. 2

116

= Operating hours

2747163

OPERATOR’S MANUAL 21D / 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. 2.25

ca. 2.25

Hydraulic system

ca. 15.87

ca. 17.20

ca. 1.0 ca. 1.0 ca. 0.3 ca. 4 x 0.13

ca. 1.0 ca. 1.0 ca. 0.3 ca. 4 x 0.13

Axles front axle rear axle transfer gearbox planetary gearbox 1)

Refilling quantity1) (gal) 21D 221D

The consumable 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

Refilling quantity1) (gal) 21D 221D

Fuel tank

ca. 23.85

ca. 26.52

Cooling system

ca. 4.10

ca. 4.10

117

OPERATOR’S MANUAL 21D / 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 in upper range. Follow with a warming-up phase. When warming-up, increase engine speed and load 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.

118

OPERATOR’S MANUAL 21D / 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 function operation.

119

OPERATOR’S MANUAL 21D / 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

120

2905902

OPERATOR’S MANUAL 21D / 221D

V.

Greases for bearing points and articulations

2732723

for centralized lubricating systems and tensioning systems, e.g. drive 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

121

OPERATOR’S MANUAL 21D / 221D ENGINE

2800440

Safety instructions for inspection and servicing

Checking the engine oil level / Adding 2913020 up oil Bring engine oil to operating temperature.

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.

• Park the 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, add engine oil through filler pipe (3, Fig. 2).

Fig. 2

122

OPERATOR’S MANUAL 21D / 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 the machine on a horizontal surface and protect against inadvertent movement.

Fig. 4

• Shut off engine.

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 the grating backwards, then swing it downwards and remove it.

Fig. 5

When the engine oil has drained off: • replace the engine oil filter • unscrew draining hose (19) and screw cap back in place Fig. 3

• fill in engine oil through the filler pipe (3, Fig. 2) until the oil level reaches the "max" mark

Place a collecting receptacle under the drain plug. Capacity: see "Filling quantities" table.

• start up and run the engine at idling speed for about 2 minutes

Unscrew cap (5, Fig. 4), screw on supplied hose (19, Fig. 5) and drain off the engine oil.

• check the oil level and add oil to "max" mark if necessary.

Installation of the draining hose is described under "Draining hose for oil change".

• On completion of engine servicing work, refit cover (14, Fig. 3) on rear frame with hex screws (13).

123

OPERATOR’S MANUAL 21D / 221D Replacing the engine oil filter

Risk of scalding through hot engine oil.

Crankcase ventilation Unscrew screws (8, Fig. 7) and remove cap (9).

Remove membranes (10), washer (11) and spring (12).

Collect escaping oil and discard in accordance with local environmental regulations.

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).

• Apply clean engine oil to the seal of filter cartridge (6).

• 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 the oil level and add more oil if necessary.

Fig. 8

• Clean the 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).

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.

124

OPERATOR’S MANUAL 21D / 221D Valve clearance 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 0.013 in for intake valves and 0.013 in for exhaust valves.

COOLING SYSTEM

1946673

Cooling agent specification 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 made of aluminium. Therefore, only use ethylene glycol based agent as anti-corrosive. This agent must be mixed with water which is as 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 -22˚F to -31˚F. 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".

125

OPERATOR’S MANUAL 21D / 221D Checking the cooling liquid level

Changing the cooling liquid

Check the cooling liquid 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.

Fig. 1

For this purpose, a drain plug (3, Fig. 2) is located under the radiator (2).

• 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, add more 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 add more coolant, if necessary.

126

OPERATOR’S MANUAL 21D / 221D AIR-INTAKE SYSTEM

Read and observe: "Inspection and Servicing - Safety instructions".

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 is not yet due.

Risk of injury through hot engine components.

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.

Fig. 2

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.

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

127

OPERATOR’S MANUAL 21D / 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 the filter paper, using a bulb (Fig. 6).

Damaged areas can be seen where the light shines through the element. Replace the 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 good condition. Use only screw-type hose clamps.

Fig. 5

The safety element remains in place. Clean or replace the 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 the dust collector, respect the "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.

128

OPERATOR’S MANUAL 21D / 221D Cleaning the main filter element

Checking / replacing safety filter

Dry-cleaning

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 72.5 psi.

Start by applying compressed air to the filter surface diagonally from outside (Fig. 8).

Never start up the engine when the safety filter element has been removed.

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.

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.

129

OPERATOR’S MANUAL 21D / 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.

130

OPERATOR’S MANUAL 21D / 221D FUEL SYSTEM

2905439

• Clean the outer sides of the fuel filter (5, Fig. 1) carefully.

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.

Discard used filter cartridges without polluting the environment.

Diesel fuel may cause skin injury. Wear protective gloves or use a barrier cream.

• Tighten screw (14).

• Hold the filter bottom (15, Fig. 2) and slacken screw (14).

• Pull filter bottom (15) down.

• Withdraw filter cartridge (5) and discard without polluting the envoiroment.

• Clean the filter head and filter bottom (15).

• Replace seals (6 and 7) and O-ring (9, Fig. 2) and smear slightly with clean fuel.

Read and observe the "Safety Instructions".

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 to the injection pump.

Fig. 2

• Hold filter bottom (15) under the new filter cartridge (5) and attach it to the filter head. Make sure filter cartridge (5) sits properly on sealing ring (7).

• Vent the fuel system.

Fig. 1

131

OPERATOR’S MANUAL 21D / 221D Water pre-separator

Cleaning the fuel tank

Draining off water Drain off the water from the water pre-separator (1, Fig. 3) every day.

Risk of explosion 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 the tank with diesel fuel.

Fig. 3

Screw plug (8) back in place and fill with fuel through the filter sieve in the filler opening.

To do so, open plug (2,Fig.3) and allow any 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

Bleed the fuel system in accordance with the Engine Operating Instructions.

132

OPERATOR’S MANUAL 21D / 221D Injection nozzles

If your skin comes into contact with highpressure fuel seek medical assistance immediately.

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 nozzles 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 misfiring or running erratically.

High fuel consumption.

Black exhaust smoke.

Engine knocking or vibrating.

Engine overheating.

To identify 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 union nut of the defective nozzle is slackened, the engine speed will change only slightly or not at all.

133

OPERATOR’S MANUAL 21D / 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".

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 invert 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 "tap 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 (pre-excited) 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.

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.

Correct alternator functioning is indicated by a LED on the control console (charging control). This LED must light up when the key-switch 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 to prevent further damage.

Contact our local dealer for assistance.

134

OPERATOR’S MANUAL 21D / 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 right-hand side of the wheeled loader in the rear frame (Fig. 2).

Opening the engine hood 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 Fig. 2

In OFF position, the battery main switch (1) prevents • unauthorized starting of the engine • inadvertent discharge of the battery.

Fig. 1

135

OPERATOR’S MANUAL 21D / 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 68 F.

• 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 0.4 in.

• 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, add distilled water only.

Fig. 1

Acid density in kg / dm3

136

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 / 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.

Turn mainswitch for electrical system to "0" and withdraw key.

Detach and attach the pole terminals in the given sequence.

Failure to observe this sequence may result in short-circuits.

• Disconnect the pole terminal at the negative pole of battery.

• Disconnect the pole terminal at the positive pole of battery.

• Insulate the pole terminals.

2905177

Before installing the new battery, polish the contact surfaces of the battery terminals and of the pole terminals.

• Install the new battery.

• Screw battery holder (1) in place.

• Connect the pole terminal to the positive pole of battery.

Tighten the clamping screws of the pole terminals without using force, as this would cause damage.

• Connect the pole terminal to the negative pole of battery.

• Grease the 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 the battery out of the battery box.

Fig. 1

137

OPERATOR’S MANUAL 21D / 221D HYDRAULIC SYSTEM

2747471

Return-flow filter Position the wheeled loader on a horizontal surface and set the working equipment down on the ground.

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) from the 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 is not yet due.

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

138

OPERATOR’S MANUAL 21D / 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 replaced.

• 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).

• 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).

Fig. 7

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.

139

OPERATOR’S MANUAL 21D / 221D Hydraulic reservoir Changing the hydraulic oil • Set the working equipment down on the ground.

• Shut off the engine and apply parking brake.

Risk of scalding from hot hydraulic oil.

Collect escaping hydraulic oil and discard in accordance with local environmental regulations.

Read and observe "Inspection and servicing - Safety instructions".

Never start up the engine when the hydraulic reservoir is empty.

Secure the machine against unauthorized starting.

To empty the reservoir, unscrew the plug on the combi-radiator.

Place a waste-oil receptacle below the hydraulic reservoir. Receptacle capacity: see "Refilling quantities" table.

Unscrew cap (2, Fig. 2) on the 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 the plug back in place.

Filling the hydraulic reservoir with oil Unscrew the breather filter. Fill with new hydraulic oil using a hand pump or an oil can, along with 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.

140

Bleeding the hydraulic working and steering systems Bleeding of the system is required after each oil change, after hydraulic system malfunctions or after protracted downtimes.

Working hydraulic system Check oil level in the hydraulic reservoir and add oil if necessary. Start the engine and run at idling speed for a few minutes. Extend and retract the piston rods of all hydraulic cylinders several times.

Steering hydraulic system 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 / 221D OPTIONAL EQUIPMENT Environmentally compatible hydraulic fluid (biodegradable) 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.

2913022

Environmentally compatible hydraulic fluid, conversion

Read and note: "Inspection and Servicing, Safety Instructions".

For the initial filling, use only: PANOLIN HLP SYNTH 46

- Bring the hydraulic system to operating temperature.

A change from mineral hydraulic oil to this synthetic hydraulic fluid can, however, be made at a later date.

- Retract all hydraulic cylinders.

Environmentally compatible hydraulic fluid, too, must not be simply poured away but disposed of in the same way as used oil.

- Fill the hydraulic oil tank with HLP SYNTH 46 up to halfway mark.

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.

- Drain off the hydraulic oil (see operator’s manual, section 3 "Inspection and Servicing").

- Activate all hydraulic functions including travel 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 adding the hydraulic fluid.

The hydraulic fluid must not be mixed with hydraulic oils or hydraulic fluids from 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.

141

OPERATOR’S MANUAL 21D / 221D - Start up the machine. Check the level in the 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 the servicing plan.

- Take a sample of the hydraulic fluid after 30 50 operating hours and send in for analysis.

(See section: "Environmentally compatible hydraulic fluid, sampling").

Environmentally compatible hydraulic fluid, sampling Complete sets are available 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 taking 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.

142

OPERATOR’S MANUAL 21D / 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.

143

OPERATOR’S MANUAL 21D / 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.

Secure the machine against unauthorized starting.

Risk of scalding caused by hot oil.

Collect escaping oil and evacuate it without polluting the environment.

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 oil level • Unscrew checking and filling plug (1, Fig. 1).

The oil level must come up to the opening. If this is not the case, add in oil until it emerges from the opening.

• Screw checking and filling plug (1, Fig. 1) back in place.

Read and observe the "Inspection and servicing - Safety instructions" section.

Secure the machine as described in the "Securing the machine" section.

Fig. 1

Changing 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 with oil as described under "Checking of oil level".

Renew damaged sealing rings.

144

OPERATOR’S MANUAL 21D / 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 oil level

Checking oil level

• Unscrew checking and filling plug (3, Fig. 2).

The oil level must come up to the opening. If this is not the case, add oil until it emerges from the opening.

• Unscrew checking and filling plug (5, Fig. 3).

The oil level must come up to the opening. If this is not the case, add oil until it emerges from the opening.

• Screw checking and filling plug (3) back in place.

Fig. 3

Fig. 2

Changing 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 the 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 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 with oil as described under "Checking of oil level".

• Now fill with oil as described under "Checking of oil level".

Renew damaged sealing rings.

145

OPERATOR’S MANUAL 21D / 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 oil level • Park the machine on level ground. To allow for oil level balancing in the axles, wait ten minutes before checking.

• 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 come up to the lower edge of the opening. If this is not the case, add oil until it emerges from the opening. Screw plug (7) back in place.

Changing 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 with oil as described under "Checking of oil level".

• Repeat checking after about 10 minutes and add oil again, if needed.

Fig. 5

Fig. 4

146

OPERATOR’S MANUAL 21D / 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 the machine as detailed in the "Securing the machine" section.

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 the parking brake.

If in doubt, have the work done by our Dealer.

Read and take note of the "Inspection and servicing, safety instructions" section.

Securing the machine Never do inspection and servicing work on brakes unless the machine is secured as detailed in the "Securing the Machine" section.

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 linings must be replaced if they are worn down to a minimum (see Fig. 2) of 0.177 in.

Consult our dealer.

2800793

The braking pressure must be reduced prior to any work on the braking system.

• Set the working equipment down on ground.

• Switch off the engine.

• Apply the parking brake.

• Depress the brake pedal 10-15 times.

The braking system is depressurized when the pedal can be depressed without marked resistance.

Fig. 2

147

OPERATOR’S MANUAL 21D / 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.

2747164

• 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 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

148

OPERATOR’S MANUAL 21D / 221D Bleeding For bleeding, a hose (2) must be attached to the respective bleeding valve and the other end plunged 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.

149

OPERATOR’S MANUAL 21D / 221D TIRES AND WHEELS

1946824

Tires and wheels - Safety instructions

Risk of injury

Tire pressure

Heat-induced combustion of gas inside the tire may lead to explosions in airinflated tires. 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 tire explosion is more violent than that occuring during normal bursting of tires. Such an explosion can eject parts of the tire and the rim over several 110 yards. Exploding and/or bursting tires and ejected parts of tires and rims may cause severe or sometimes even fatal injuries.

-

Therefore: - If a tire is suspected to be too hot, secure the machine and wait some distance away until the tire has cooled down.

- Before inflating the tire, check the tire itself, the rims and rim components for damage, penetrated foreign objects and perfect fit.

- Always have detected faults rectified immediately by specialized workshops.

- If you are in doubt about the safe condition of the tire, the rims or rim components, do nothing yourself but have the complete wheel removed by a special workshop.

Changing of tires, 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 tires unless you are qualified to do so.

150

-

-

-

-

-

Check the tire pressure only when the tire is cold; the pressures indicated are higher when the tire is warm.

Use a tire inflator with a long filling hose, snap-on valve and pressure gauge (Fig. 1).

Use only compressed ambient air for inflating the tires. Never use flammable gases: risk of explosion.

When inflating the tire, keep at some distance from the wheel facing in the direction of travel.

Watch the tire and the gauge of the filling gear permanently during inflation and never exceed the specified tire pressures.

Place a safety cage around dismantled wheels.

When pumping up, make sure all persons are well clear of the tire.

Always pump up the tire to the specified air pressure: - Excessive tire pressure makes for poor off-the-road handling with a risk of bursting tires.

- Insufficient tire pressure causes greater tire wear and affects the stability of the machine.

OPERATOR’S MANUAL 21D / 221D Tire pressure - Safety instructions

Bursting tires and parts splintering away from the rims or from the tire itself may cause severe injury.

The following instructions must therefore be strictly observed: - Before inflating the tire, check the tires, rims and rim parts for damage, penetrated foreign objects and proper fitting.

- Have all damage detected repaired by a qualified workshop.

- Check the tire inflation pressure only when the tires 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 tires with compressed ambient air only. Never use inflammable gases: Risk of explosion.

- Keep away from the tire during inflation and always stand besides the tire tread.

- Keep an eye on the tire and and on the pressure gauge of the filling equipment when inflating the tire. Never exceed the prescribed tire inflation pressures.

- Place a safety cage around dismantled wheels.

- Make sure nobody is standing near the tire when it is being inflated.

1946841

Always inflate the tires to the prescribed pressure: - Excessive pressures result in poor offroad handling properties and tires may burst.

- Insufficient tire pressures lead to increased tire 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 tires have the prescribed minimum tread and the correct air pressure.

Always make sure that both axles are equipped with tires of the same size and same degree of wear.

Tires with different diameters may cause damage to the differentials.

To avoid excessive tire wear: - inflate to the correct air pressure, - do not start or brake abruptly, - take corners slowly.

Clean the tires and the gaps between the tires 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.

151

OPERATOR’S MANUAL 21D / 221D Checking tire pressure - Reinflating the 1946825 tires

Read and observe: "Tire 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 tire valve (Fig. 1).

• Inflate all tires with the prescribed pressure (see: "Table of tire inflation pressures")

Fig. 1

152

OPERATOR’S MANUAL 21D / 221D Tire pressure

2747194

The machine can be equipped with various tires.

The following tire pressures are valid for the 21D loader: Tire size

Front axle Working operation Lifting fork Tipping and and other loading equipment bucket

The following tire pressures are valid for the 221D loader:

Rear axle

Tire size

10.5-18MPT TL 12PR 122E

X*

44 psi

25 psi

12.5 R20MPT 10PR 132G

12.5-18MPT TL 8PR 125E

X*

36 psi

25 psi

12.5-20MPT TL 10PR 129E

51 psi

44 psi

12.5-R20MPT TL 12PR 132G

44 psi

15.5/55 R18 MPT TL 14PR 134E

Front axle Working operation Lifting fork Tipping and and other loading equipment bucket

Rear axle

X*

51 psi

36 psi

14.5-20MPT 10PR 132G

51 psi

44 psi

22 psi

22 psi

14.5 R20 MPT 10PR 132G

51 psi

44 psi

29 psi

36 psi

22 psi

335/80 R20 EM147 A2136B

X*

51 psi

29 psi

58 psi

51 psi

25 psi

335/80 R20xMPT 134G Michelin

X*

47 psi

32 psi

335/80 R18 XM 27 MPT TL 132G

51 psi

44 psi

20 psi

365/80 R20 EM157 A2141B

51 psi

44 psi

29 psi

335/80 R18 EM TL 134B 145A2

51 psi

44 psi

25 psi

375/75 R20xMPT 136G Michelin

51 psi

37 psi

20 psi

335/80 R20 MPT TL 139G 153A2

44 psi

36 psi

22 psi

405/70 R20xMPT 136G Michelin

51 psi

37 psi

20 psi

335/80 R20 EM TL 147A2 136B

44 psi

36 psi

22 psi

16/70-20MPT 10PR 137G

36 psi

29 psi

22 psi

335/80 R20 XM27 MPT TL 134G

45 psi

37 psi

20 psi

16/70-20EM 10PR 157 A2141B

36 psi

29 psi

22 psi

365/70 R18 EM TL 135B 146A2

47 psi

40 psi

22 psi

405/70 R20 EM155 A2143B

44 psi

36 psi

22 psi

* Unsuitable for use with lifting forks

* Unsuitable for use with lifting forks.

Before undertaking longer trips on the road, the tire pressure of the front wheels must be adapted to the pressure of the rear wheels to increase the driving comfort.

153

OPERATOR’S MANUAL 21D / 221D Changing a wheel

2913028

Fit the new wheel: - Inflate the tire to a pressure of ca. 14.5 psi.

Read and observe the section on: "Wheels and tires - Safety instructions".

"Tire 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).

- Observe the instructions set out in the "Wheels - Tire 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, see "Fastening of wheels" Inflate the tires to their correct pressure. See "Tire pressures" and "Tire 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 332 lbf ft.

Tire tread direction Pay attention to the tread direction when fitting the wheels (Fig. 2). Fig 2 shows the normal tread direction for best traction results during froward travel.

Fig. 1

• Secure the machine as described in the "Securing the machine" section.

• Deflate the tire.

• 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.

154

Fig. 2

In some special cases, another tread position may prove more favorable. In these cases, please contact our service.

OPERATOR’S MANUAL 21D / 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 the 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 the knurled screws (1, Fig. 1).

• First turn cover (2) down (arrow I) until the filter element is free, then withdraw forwards (arrow II) • Remove the filter element and discard it in accordance with local environmental regulations.

Fig. 1

The greasing points on the working equipment and the machine are lubricated with a hand-operated grease-gun.

• Insert the new filter element.

• Push in cover (2) as far as the stop limit and tighten screws.

• Withdraw the protective cap from the 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 the protective cap on the greasing nipple.

155

OPERATOR’S MANUAL 21D / 221D STORING THE LOADER

2905158

If the loader is to be put out of operation for longer periods, the following measures are recommended: • Lock articulated joint.

• Place the machine on supports to lift the tires clear of the ground.

• Release the parking brake.

• Set the working equipment down on the ground, retracting the piston rods of hydraulic cylinders as far as possible.

• Set the control lever to position "0".

• Apply grease to the bright-metal parts of the machine.

• Carry out engine conservation procedures.

• Carry out preservation of the engine in accordance with the engine operating instructions.

• Set the battery main switch to OFF.

Engine conservation (see engine operator’s manual) • Clean the engine with high-pressure equipment.

• Run the engine up to operating temperature, then switch off.

• Drain off the engine oil and fill with anti-corrosion oil (see engine operator’s manual).

• Drain the fuel from the tank.

• Prepare the fuel mixture from 90 % diesel and 10 % anti-corrosion oil and fill up the tank.

• Run the engine for about 10 minutes.

• Switch off the engine.

• Rotate the engine repeatedly by hand for cylinder and combustion chamber preservation.

• Dismantle the V-belts and store in packaged form.

• Spray the V-belt pulley grooves with anti-corrosion agent.

• Close the intake and exhaust openings.

156

Battery storage

2411346

For extended outage periods, remove battery / batteries and store in dry, well ventilated premises at about 68 F. Observe the following maintenance points: • Clean the battery/batteries.

• Check the acid density and battery fluid level once a fortnight.

• Charge the batteries when acid density has fallen to 1.23 kg/dm3 or earlier.

• Keep the battery / batteries clean and dry externally.

OPERATOR’S MANUAL 21D / 221D RECOMMISSIONING

2747203

Before recommissioning the machine after a longer downtime observe the following points:

Removal of engine conserving agents

• Remove the engine conservation measures. Fill with new engine oil.

• Remove the anti-corrosion agent from the grooves of the V-belt pulley.

• Check oil level in the hydraulic reservoir.

• Mount the V-belts and adjust the tension after a brief operating period.

• Check oil level in the frontaxle and the rearaxle.

(see engine operator’s manual)

• Check oil level in the transfer gearbox.

• Remove the covers from the intake and exhaust openings.

• Check oil level in the planetary gears.

• Start up the engine.

• Check the battery charge condition.

• Install the battery and reconnect it to the electrical system.

• Set the battery main switch to ON. • Check tire pressure.

• Degrease the piston rods of hydraulic cylinders.

• Put the loader back on its wheels.

• Check for correct operation of the electrical system.

• Remove the articulated joint locking mechanism.

• Check for correct operation of the braking and steering systems.

• Bring the machine into driving position and apply the parking brake.

• Bleed the hydraulic system.

157

OPERATOR’S MANUAL 21D / 221D

BLANK PAGE

158

OPERATOR’S MANUAL 21D / 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

159

OPERATOR’S MANUAL 21D / 221D

BLANK PAGE

160

OPERATOR’S MANUAL 21D / 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 the complete assembly.

Pay special attention to: "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.

In exceptional cases, open only when the system and the operating sequence are precisely known and any special tools required are available.

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.

Repair personnel

Leave time for the machine to cool down.

Repair personnel must have know-how and experience relevant to repairing this or comparable machines.

Before starting work, depressurize piping and hoses, cylinders, radiator, hydraulic tank, air-brake reservoir and other systems or units.

In the absence of such know-how, meticulous training must be given by experienced repair personnel.

Replace defective components in good time to prevent major damage.

Clean the defective component carefully before dismantling it.

Locking the articulated joint When carrying out repair work in the pivoting range, lock the articulated joint.

Remove the lock on completing work.

Mark the dismantled parts in the correct sequence to facilitate assembly.

When dismantling the component, seal off exposed hose and piping connections, exposed bores and housing carefully to prevent any dust from penetrating.

Never remove lead seals Never change the rated pressure for pressure relief.

Never remove lead seals from pressure relief valves and accumulators.

161

OPERATOR’S MANUAL 21D / 221D ENGINE Engine - repair instructions

2913030

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 soundand vibration-insulation material.

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

Check the repaired components and all machine functions with a trial run.

Never release the machine for recommissioning until it is fully functional.

Read and observe: "Repair, safety instructions" and operator’s manual for the engine before working on the engine.

Risk of injury from rotating or hot engine parts!

Switch off the engine and leave it to cool down.

Do repair work only if machine is secured as described in the "Securing the machine" section of this operator’s manual.

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.

162

OPERATOR’S MANUAL 21D / 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 jumpstarting 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 short-circuiting.

Never use jumper cables with overvoltage, e.g. two or three batteries or booster units connected in series and generating voltages in excess of 12V. Never use welding generators or welding transformers as a source of current.

Position jumper cables in such a way that they cannot be caught by rotating engine components.

Read and observe: "Inspection and servicing - Safety instructions", paying special attention to the "Handling batteries" section.

163

OPERATOR’S MANUAL 21D / 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 all electrical appliances (headlamps, fan).

- Turn the key-switch to "ON". The engine monitoring lamps must light up.

- If the monitoring lamps do not light up, the battery is defective (exhaustive discharge or internal short-circuit).

In this case the machine must not be started, as the alternator would then be damaged.

Install a functional battery before jump-starting.

• Switch off all electrical appliances in the receiving machine and turn the key-switch to 0 .

• Switch off all appliances in the supplying machine (booster battery) and shut off the 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).

164

Fig. 1

Starting the engines • Start the engine of the supplying machine and run it with stepped-up revolutions.

• Start the engine of the receiving machine. If the engine does not start up after 15 seconds, wait one minute before re-starting.

• 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 appliances, 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 the high-consumption appliances.

- 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 / 221D ELECTRICAL SYSTEM

2905038

The fuses are housed in the rear wall of the cab, to the left of the driver’s seat.

Fuses

Top fuse assembly (Fig. 2) F1 A 7,5A left high beam light B 7,5A right low beam light fuse C 15A horn 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.

Fuses in cab The fuses are accessible after removal of the cover (1, Fig. 1).

F2 A

5A

solenoid Y42 & S42.1 switch fuse

B 7,5A hand brake & indicator lamp fuse C 15A rear working light fuse F3 A 10A wiper motor & radio fuse B 10A brake lights & direction light fuse C 7,5A reversing light & 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 C 10A immobilizer Fig. 1

F6 A 7,5A right high beam light B

5A

F/R switch & creep speed fuse

C 7,5A left low beam light fuse F7 A 10A driver seat fuse B 15A blower motor fuse C 10A radio & cigarette lighter fuse, cab interior lamp F8 A 10A warning lights Fig. 2

B

5A

front left & rear right tail light fuse

C

5A

front right, rear left tail light

F9 A 15A front working lights fuse B 10A rotary beacon fuse C 10A reserve fuse

165

OPERATOR’S MANUAL 21D / 221D Replacing fuses

Replacing bulbs

2905444

Remove screws (2, Fig. 1) and cover (1).

Withdraw the defective fuse and insert a new one with the same current rating.

Put on the cover and tighten screws.

Fuses in engine compartment (Fig. 3) 2 fuses for the preheating control are located close to the air filter.

Shut off the engine and set the 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

166

OPERATOR’S MANUAL 21D / 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.

167

OPERATOR’S MANUAL 21D / 221D Turn signal lamp

Tail/brake signal lamp

Remove screws (Fig. 2) and take off lens (9, Fig. 5).

Unscrew caps (Fig. 6) from the lamps. The bulbs are then accessible.

Fig. 5

Fig. 6

Replace the defective bulb. Re-assembly in reverse sequence.

11 - Reflector, red 12 - Rear lamp, Braking lamp 13 - Turn signal lamp 14 - Reversing lamp

Fig. 7

168

OPERATOR’S MANUAL 21D / 221D Cab interior lamp

Floodlamp

Withdraw cover (Fig. 8) and replace the 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 the new bulb. Re-assembly in reverse sequence.

Fig. 11

169

OPERATOR’S MANUAL 21D / 221D Rotating beacon (option)

1946970

Replacing the lamp Hold rotating 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 direction of 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

170

OPERATOR’S MANUAL 21D / 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 cause 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 at 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.

171

OPERATOR’S MANUAL 21D / 221D HYDRAULIC SYSTEM

2913032

Replacing hydraulic hoses - Safety instructions

Lifting cylinder - installation

• During the installation of a new lifting cylinder (2, Fig. 1) take care that the retaining screws (1) of lifting cylinder (2) face inside.

Before unscrewing hydraulic hoses: Depressurize the hydraulic system!

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.

172

2904150

Fig. 1

OPERATOR’S MANUAL 21D / 221D BRAKES

2800627

Safety instructions

Personnel Never do repair work on brakes unless you are qualified to work on brake systems.

Securing the machine Never do repair work on brakes unless the machine is secured as described in the "Securing the machine" section.

Block the articulated joint when carrying out work on the brake system.

Health protection Always store hydraulic oil in the original containers.

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.

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.

Swallowing hydraulic oil is a severe health hazard.

If hydraulic oil is swallowed, 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.

173

OPERATOR’S MANUAL 21D / 221D Checking the braking pressure

2913083

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

• Reduce braking pressure by pressing down the brake pedal 10-15 times. The braking system is depressurized when the pedal can be applied with no great resistance.

• Connect a pressure gauge (measuring range up to 2902 psi) 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

If - the Central Warning lamp does not go out, - the acoustic warning goes on sounding, - the braking pressure is less than 653 psi, there is a fault in the braking system.

In this case, contact our local dealer.

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 the parking brake is applied and gear-change lever in neutral position.

• Start up the engine and wait until the 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 653 psi.

Fig. 3

Fig. 2

174

OPERATOR’S MANUAL 21D / 221D Checking the accumulator pressure

Checking the preloading pressure

2913084

2913085

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

Secure the 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 a 2902 psi pressure gauge.

• Start up the 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 the pressure gauge.

• Start up the 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 2176 psi.

• On reaching braking pressure: engine OFF.

• If accumulator pressure is below this value, check the preloading pressure of the accumulator.

• 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 725 psi has been reached.

• If the pressure is below 725 psi, replace the accumulator.

175

OPERATOR’S MANUAL 21D / 221D On finishing work, • reduce braking pressure,

ACCUMULATORS Safety instructions

2800629

• unscrew the pressure gauge, • screw the closing cap onto the measuring connection.

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 the 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.

176

OPERATOR’S MANUAL 21D / 221D WORKING EQUIPMENT

2904067

Bucket Replacing 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 tie and tooth.

The safety tie 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 the 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 tie (1, Fig. 1) using a chisel (2) or a piece of flat iron.

Fig. 3

Fig. 1

• Drive the new safety tie (1, Fig. 4) into opening (5) of housing (4). The tie can be fitted from either side of the tooth.

• Drive the tooth out of its housing (3, Fig. 2) using a chisel.

Fig. 4

177

OPERATOR’S MANUAL 21D / 221D Bucket limit stops

2913034

The space between the toggle link and lifting frame limit stop can be compensated by plates.

Make sure nobody is standing under the lifting frame.

Raise the lifting frame and bring into dumping position so that toggle link (2, Fig. 3) rests on the limit stop (7) on crossmember (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 it into dumping position (Fig. 1).

Fig. 3

Any existing play can be compensated for by shimming.

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+0.06 in (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 0.12 in.

Any greater deviation can otherwise be compensated for by shimming.

Fig. 2

178

OPERATOR’S MANUAL 21D / 221D Lifting forks

2747195

Checking of forks

Forks must be repaired in specialized repair shops only.

The forks must be checked: • at regular intervals at least, however, once a year; • if persisting distortions are detected.

Continuing to use a fork with a lower carrying capacity than indicated is admissible on condition that:

Each fork is identified in the upper part of the fork guide with the admissible carrying capacity and the pertaining center-of-gravity distance.

• the mark indicating the old carrying capacity has been replaced clearly and distinctly by the new carrying capacity.

Checking of carrying capacity and checking for the presence of cracks:

• the fork successfully passes a load test with the new carrying capacity without persisting distortion.

• Measure the distance L2 between check marks 1 and 2 (Fig. 1).

• Test each fork independently by applying the highest admissible load (max. carrying capacity) at the pertaining center-of gravity distance.

Checking of wear The table below gives the most important fork dimensions (width B and thickness H) for wheelmounted loaders.

Loader Type

BxH in x in

Hmin in

21D / 221D

3.94 x 1.77

1.61

• Measure width B and thickness H of each fork (Fig. 2).

• Compare the measured values with the B x H values in the above table.

• Renew the fork immediately if thickness H is less than the admissible minimum value Hmin.

Fig. 1

• Remove the load.

Also check the fork locking system at regular intervals for perfect functioning.

• Measure distance L2 again.

• Renew the fork if measured distance L2 (see table) exceeds the admissible max. value L2 max.

L2 max. = 102 % of L2.

L

L2

L2 max.

< 39.37 in > 39.37 in

19.69 + _ 0.08 in 39.37 + _ 0.08 in

20.08 in 40.16 in

After successful testing check each fork with suitable means (e.g. dye-penetration test) for the presence of cracks. Renew cracked forks immediately.

Fig. 2

179

OPERATOR’S MANUAL 21D / 221D

BLANK PAGE

180

OPERATOR’S MANUAL 21D / 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

181

OPERATOR’S MANUAL 21D / 221D

BLANK PAGE

182

OPERATOR’S MANUAL 21D / 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, contact your 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 will ensure 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 reported 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 signs 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?

Cause The possible causes of the observed fault are outlined in this group. They are arranged in order of probability, i.e. the possible cause in most cases heads the list.

Remedial acxion This describes the troubleshooting procedure.

Chapter reference This specifies where information useful for troubleshooting is given in the operator’s manual.

If there is no entry, the Dealer after-sales service should be consulted.

183

OPERATOR’S MANUAL 21D / 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 Add 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

•

•

• • •• •• ••• • • •• • • •• • •• • • • • • • • •• • • • •• ••••• •• •

184

Chapter reference

Temperature below starting limit 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

Fuel quality does not correspond to operator’s manual specification Air filter contaminated/turbocharger defective

W Air-intake system

Air filter maintenance switch / indicator defective Oil cooler / cooling fins dirty

W W 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 / 221D Engine start / stop

2913037

Fault Engine does not turn over 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

• • • • • •

•

Remedial action Check Adjust Replace Add Lubricate Clean Contact Service

Cause

Chapter reference

Gearshift / travel direction lever not in neutral position

Travel

P E W A S R SE

P

See troubleshooting section of engine operating instruc- Electrical tions system

P

Fuse blown

P

Shut-off solenoid jamming

SE

Engine internally siezed

SE

Combustion engine siezed on power output side

SE

185

OPERATOR’S MANUAL 21D / 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 erratic, 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 Add Lubricate

P E W A S

Clean Contact Service

R SE

Steering wheel continues to turn after being released Cause

• • • •

186

• • • • • • •

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 / 221D Working equipment

2913039

Fault Lifting, tipping and steering functions not available Lifting and tipping functions not available; engine audibly under load Lifting and tipping functions not available, engine not under load Control lever for bucket equipment does not remain latched in floating position Tipping and lifting times too long

Remedial action Check Adjust Replace Add 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 distorted), limit stop incorrect

SE

Operating kinematics of control 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 valve or in cylinders

SE

Insufficient control valve spool travel

SE

Zero positioning of control valve spool(s) defective

SE

Pump flow rate insufficient

SE

Control valve spool locking defective

SE

Pump drive coupling defective

SE

Primary pressure setting too high

SE

187

OPERATOR’S MANUAL 21D / 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 Add 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. travel speed cannot be reached Max. travel speed cannot be reached, abrupt deceleration at fast speed reduction of combustion engine Abrupt deceleration at fast speed reduction of 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

• •

•••• • ••• • • •

• • •

188

• •

•

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 tire pressure

Tires

Oil has wrong viscosity

Lubricants

Cooler dirty

Hydraulic oil cooler

Oil temperature too high

Travel drive malfunction

P

Tires have considerably differing diameters

Wheels and tires

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 / 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; engine runs without load No forward travel, no reversing, central warning lamp illuminated No forward travel, no reversing, stop light illuminated No forward travel, no reversing, engine under load

Remedial action

Check Adjust Replace Add 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 Engine speed dropping off heavily during acceleration or pushing Max. travel speed cannot be reached Max. travel speed cannot be reached, abrupt deceleration at fast speed reduction of engine Abrupt deceleration at fast speed reduction of 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

189

OPERATOR’S MANUAL 21D / 221D Brake system

2913042

Fault No braking or insufficient braking action of loader Loader braking action too strong Sensitive braking by means of inching function not possible Max. accumulator pressure not reached Noise during braking Cause

• • • • • • • • • • • • • •

190

Remedial action Check Adkust Replace Add 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 / 221D ABBREVIATIONS Ampere (SI base unit of electric current) Ampere hours (SI base unit of quantity of electricity) API American Petroleum Institute approx. approximately A Ah

bar

unit of pressure measurement (1 bar = 14.5 psi)

Communaute Européenne = European Community CECE Committee for European Construction Equipment (Defines a measure for bucket, grab, or scoop filling) CEN European Standardization Committee cm centimeter (= 1/100 m) 3 cm /rev Cubic centimeters per revolution CV / Ch metric horsepower CE

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)

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 N N, kN NLGI

191

OPERATOR’S MANUAL 21D / 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

192

B 2

Backrest adjustment .......................................... 38

21D Wheel Loader.............................................. 17

Basic unit ............................................................ 16

221D Wheel Loader............................................ 21

Battery .............................................................. 135 Battery - checking the charge .......................... 136

A ABBREVIATIONS .................................... 191, 192 ACCUMULATORS .......................................... 176 Acoustic reversing signal (Back-up alarm) ........ 96 Activating fast speed .......................................... 65 Adjusting the operator’s seat .............................. 37

Battery - checking the fluid level ...................... 136 Battery main switch .................................... 51, 135 Battery storage ................................................ 156 Bleeding............................................................ 149 Bleeding the braking system ............................ 148

Adjusting the right armrest .................................. 39

Bleeding the hydraulic working and steering systems ............................................................ 140

Adjusting the steering column ............................ 61

Bottom-dump bucket .......................................... 85

Adjusting the weight-oriented suspension .......... 37

Brake system .................................................... 190

Adjustment of steering column .......................... 60

Brakes ................................................................ 16

After daily operation............................................ 86

BRAKES .................................................. 147, 173

After-Sales-Service .............................................. 3

Braking and stopping .......................................... 63

Air filter .............................................................. 67

Braking pressure ................................................ 68

AIR-INTAKE SYSTEM...................................... 127

Breather filter .................................................... 139

Alternator ............................................................ 67

Bucket ........................................................ 89, 177

Alternator, instructions ...................................... 134

Bucket limit stops.............................................. 178

Articulations and hinges .................................. 115 Assembling working equipment - safety instructions ............................................................ 87

C Cab interior lamp .............................................. 169

Assisted starting (jump-starting) ...................... 164

Cab interior lighting ............................................ 36

Assisted starting (jump-starting) - Safety instructions .......................................................... 163

Carriage with lifting forks .................................... 93

Attaching the bucket .......................................... 89 Attaching the equipment carrier .......................... 93 Attaching the four-in-one bucket ........................ 91 Attachments........................................................ 32 ATTACHMENTS ................................................ 89 Axle number ...................................................... 32 Axles .................................................................. 16 AXLES .............................................................. 144

Carry out visual inspection ................................ 86 Cause .............................................................. 183 Center of gravity position during transport .......... 26 Change of engine oil ........................................ 107 Changing a wheel ............................................ 154 Changing the cooling liquid .............................. 126 Changing the engine oil .................................... 123 Changing the hydraulic oil ................................ 140 Chapter reference ............................................ 183 Chassis .............................................................. 16

Checking / replacing safety filter ...................... 129

Documentation .................................................. 35

Checking air-intake lines .................................. 130

Draining hose for oil changes .......................... 106

Checking of forks .............................................. 179

Draining off water ............................................ 132

Checking the accumulator pressure ................ 175

Drive unit ............................................................ 16

Checking the brake disks ................................ 147

DRIVER’S CAB .................................................. 33

Checking the braking pressure ........................ 174

Driver’s cab door ................................................ 34

Checking the bucket locking .............................. 90

DRIVER’S CAB VENTILATION ........................ 155

Checking the cooling liquid level ...................... 126

Driver’s compartment, overall layout .................. 41

Checking the engine oil level / Adding up oil .... 122

DRIVING ............................................................ 60

Checking the hydraulic oil level ........................ 138

Driving .......................................................... 63, 64

Checking the preloading pressure .................... 175

Driving - Safety instructions ................................ 60

Checking tire pressure - Reinflating the tires .... 152

Driving on public highways ................................ 69

Cigarette lighter / Socket outlet .......................... 59

Driving on the public highway ............................ 81

Cleaning and refueling of machine .................... 86

Dust-discharge valve ........................................ 127

Cleaning jobs .................................................... 107 Cleaning the fuel tank ...................................... 132 Cleaning the main filter element ...................... 129 Cleaning the water pre-separator .................... 132 Closing the door ................................................ 34 Combined functions ............................................ 83 Connecting the jumper cables .......................... 164 Control lever - 3rd/4th function .......................... 84 Control lever - Traveling / Working .................... 62 Control lever for bucket equipment .................... 82 Control lever locking .......................................... 84 Coolant temperature .......................................... 68 COOLING SYSTEM ........................................ 125 Crankcase ventilation ...................................... 124

E Electric energy ...................................................... 8 Electrical system ................................................ 16 ELECTRICAL SYSTEM............................ 134, 165 Electrical system key-switch .............................. 52 Electrical system ON / OFF ................................ 51 Emergency exit .................................................. 35 Engine ................................................................ 63 ENGINE .................................................... 122, 162 Engine .............................................................. 184 Engine - repair instructions .............................. 162 Engine conservation ........................................ 156 Engine does not start.......................................... 53 Engine number .................................................. 32

D

Engine oil pressure ............................................ 67

DESCRIPTION OF THE MACHINE .................. 15

Engine start / stop ............................................ 185

Designated use .................................................... 4

Entering and leaving the machine - Safety instructions ........................................................ 33

Detaching the bucket .......................................... 90 Detaching the four-in-one bucket (bottomdump bucket) ...................................................... 92 Disengaging fast speed ...................................... 65

Environmentally compatible hydraulic fluid (biodegradable) ................................................ 141 Environmentally compatible hydraulic fluid, conversion ........................................................ 141

Environmentally compatible hydraulic fluid, operating instructions ...................................... 141

Hydraulic reservoir............................................ 140 Hydraulic system ................................................ 16

Environmentally compatible hydraulic fluid, sampling .......................................................... 142

HYDRAULIC SYSTEM ............................ 138, 172

F

I

Fan .................................................................... 55

Immobilizer ........................................................ 51

Fast-speed variant (optional equipment) ............ 65

Injection nozzles .............................................. 133

Fastening of wheels.......................................... 154

Inside the machine ............................................ 25

Fault.................................................................. 183

INSPECTION AND SERVICING - SAFETY INSTRUCTIONS .............................................. 101

Filling the hydraulic reservoir with oil ................ 140 Filter.................................................................. 155 Floating position of the bucket equipment .......... 83

Inspection and servicing plans - instructions .... 107 Instructions on troubleshooting ........................ 183 Intervals ............................................................ 107

Floodlamp ........................................................ 169 Floodlamps, front ................................................ 95

L

Floodlamps, rear ................................................ 95

Layout of fault table .......................................... 183

Fore-and-aft adjustment .............................. 38, 39

Layout of the machine ........................................ 15

Four-in-one bucket ............................................ 91

Lifting cylinder - installation .............................. 172

Front and rear axle ............................................ 63

Lifting forks ................................................ 93, 179

Front axle.......................................................... 144

Lighting ...................................................... 58, 167

Fuel filter .......................................................... 131

Load holding safety device ................................ 97

FUEL SYSTEM ................................................ 131

Loading by crane ................................................ 73

Fuses ................................................................ 165

Locking the articulated joint ................................ 74 Locking the control levers .................................. 84

G Gas, dust, steam and smoke ................................ 8 Greases for bearing points and articulations .... 121

H Headlamp ........................................................ 167 Heating .............................................................. 55 Height adjustment ........................................ 37, 39 Highway transfer ................................................ 81 Horn, turn signal, main beam and windscreen wiper / -washer .................................................. 56 Hourmeter ........................................................ 106 Hydraulic and pneumatic equipment .................... 9 Hydraulic oil temperature.................................... 66

LUBRICANTS .................................................. 118 LUBRICATING CHART - GREASE .................. 114 Lubricating chart - grease ................................ 115 LUBRICATING THE GREASING POINTS ...... 155

M Machine number ................................................ 32 MAINTENANCE WORK .................................. 105 MAINTENANCE, SAFETY INSTRUCTIONS........ 7 Monitoring the indicators .................................... 66

N

Plan W - Every 50 HOURS or weekly .............. 110

Noise .................................................................... 9

Planetary gears ................................................ 146

Noise emissions ................................................ 25

PREFACE ............................................................ 3 Prior to assisted starting .................................. 164

O

PUTTING THE MACHINE INTO OPERATION .. 50

Oil / Grease ...................................................... 107 OIL INSPECTION PLAN .................................. 116

Q

Oil inspection plan ............................................ 117

Quick-coupler .............................................. 84, 89

Oil, grease and other chemical substances .......... 9 Oils for axles and gearboxes (selection) .......... 120 Oils for hydraulic system, mineral .................... 119 Oils for hydraulic system, synthetic (biodegradability) ............................................................ 143

R Rated load at stability limit .................................. 27 Rear axle .......................................................... 145 Rear screen wiper / washer ................................ 59

Oils for internal combustion engines ................ 118

Rearward tilt position ........................................ 178

Opening the door ................................................ 34

RECOMMISSIONING ...................................... 157

Opening the engine hood ................................ 105

Recovering / towing of the machine.................... 71

OPERATING, SAFETY INSTRUCTIONS ............ 6

Recovery and towing, safety instructions .......... 71

OPERATION - SAFETY INSTRUCTIONS ........ 13

Reducing braking pressure .............................. 147

OPTIONAL EQUIPMENT .......................... 85, 141

Refilling quantities - Oil .................................... 117

Organizational measures...................................... 5

Refilling quantities - Other ................................ 117

Outside the machine .......................................... 25

Refueling ............................................................ 50 Refueling - Safety instructions ............................ 50

P Parking brake .................................................. 147 PART 1 - INTRODUCTION .................................. 1 PART 2 - OPERATION ...................................... 11 PART 3 - INSPECTION AND SERVICING ........ 99

Remedial acxion .............................................. 183 Removal of engine conserving agents ............ 157 Removing and installing the battery.................. 137 Removing the Carriage ...................................... 93

PART 4 - REPAIR WORK ................................ 159

Removing, checking and cleaning the main filter element .................................................... 128

PART 5 - ANNEX ............................................ 181

REPAIR WORK - SAFETY INSTRUCTIONS .. 161

Picking up loads ................................................ 94

Replacing alternator / coolant pump V-belts .... 162

Plan B - after every 500 HOURS ...................... 112

Replacing bulbs ................................................ 166

Plan C - after every 1000 HOURS .................... 112

Replacing fuses ................................................ 166

Plan D - after every 3000 HOURS .................... 112

Replacing hydraulic hoses - Safety instructions .................................................................. 172

Plan N - After initial commissioning .................. 109 Plan T - Every 10 HOURS or each working shift .................................................................. 110 Plan V - once prior to initial commissioning ...... 108

Replacing teeth ................................................ 177 Replacing the brake disks ................................ 174 Replacing the engine oil filter............................ 124

Replacing the filter ............................................ 138

T

Replacing the lamp .......................................... 170

Tail/brake signal lamp ...................................... 168

Replacing V-belts ............................................ 162

TECHNICAL DATA ...................................... 17, 21

Return-flow filter .............................................. 138

Tire pressure .................................................... 153

Roller blind.......................................................... 36

Tire pressure - Safety instructions .................... 151

Rotating beacon ........................................ 95, 170

Tire tread direction............................................ 154 TIRES AND WHEELS ...................................... 150

S Safety instructions .................... 134, 144, 173, 176 Safety instructions for inspection and servicing 122 Seat belt ............................................................ 61 Seat belt - Safety instructions ............................ 61 Securing the machine ................................ 86, 105 Selection and qualification of personnel .............. 6 SERVICING ...................................................... 106

Tires and wheels - Safety instructions .............. 150 Towing ................................................................ 72 Towing lug .......................................................... 71 Transfer gearbox .............................................. 145 Transmission ............................................ 188, 189 Transport ............................................................ 73 Transport - Important information ...................... 73

Servicing material ............................................ 107

TRANSPORTING AND TOWING - RECOMMISSIONING ........................................................ 9

Setting down loads ............................................ 94

Transporting loads .............................................. 94

Slide-down window ............................................ 34

Travel direction and gears .................................. 64

STABILITY.......................................................... 26

Travel motor number .......................................... 32

STANDARD EQUIPMENT ................................ 82

Travel pump number .......................................... 32

Standard operation .............................................. 6

TROUBLESHOOTING .................................... 183

Start .................................................................... 64

Turn signal lamp .............................................. 168

Starting .............................................................. 52 Starting and stopping the engine ........................ 52 Starting the engines.......................................... 164 Steering and working hydraulics ........................ 63 Steering column - Safety instructions ................ 60 Steering hydraulic system ................................ 140 Steering system ................................................ 186 Stopping the engine............................................ 53 STORING THE LOADER ................................ 156 Sweeper ............................................................ 85 Switches and pushbuttons.................................. 46

U Unlocking the control levers .............................. 84 Upper dumping position.................................... 178

V Valve clearance ................................................ 125 Ventilation .......................................................... 54 Ventilation and heating ...................................... 54 Vertical vibration level at the operator’s seat ...... 25 Vibration level at hands and arms ...................... 25 Vibration levels .................................................. 25

W Warming up the machine .................................... 63 Warning and control lamps ................................ 42 Warning and instruction signs ............................ 28 WARNING OF SPECIAL DANGERS .................. 8 WARNING, MONITORING AND CONTROL ELEMENTS ........................................................ 40 Warnings and symbols ........................................ 4 Water pre-separator ........................................ 132 Weight adjustment .............................................. 37 WELDING OPERATIONS ................................ 171 Welding operations - safety instructions .......... 171 Wheel chock ...................................................... 86 Without shut-off possibility .................................. 97 Working equipment ............................................ 16 WORKING EQUIPMENT............................ 87, 177 Working equipment .......................................... 187 Working hydraulic system ................................ 140 Working on brakes, safety instructions ............ 147 WORKING OPERATION .................................... 75 Working operation - Safety instructions .............. 75 Working with lifting forks .................................... 94

CNH America LLC 700 STATE STREET RACINE, WI 53404 U.S.A.

Part Number North American English Printed in U.S.A.

6-34101NA August 04 Ber